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CHANCADOR TRAYLOR
MANUAL DE INSTALACION, OPERACION Y MANTENIMIENTO
MANUAL DE INSTALACION,
OPERACION Y MANTENIMIENTO DE
1525mm x 2870mm (60x113)
TIPO NT
CHANCADOR GIRATORIO TRAYLOR
VOLUMEN 2 of 3 (SUMINISTRADORES)
SOCIEDAD MINERA
CLIENTE:
CERRO VERDE S.A.A.
UBICACION PLANTA : AREQUIPA, PERU
ORDEN DE COMPRA NO.: A1WF-59-001-PO
FFEM CONTRATO NO.: 04-31645-720
EQUIPO NO.: C-3110-CR-001
COPYRIGHT FFE Minerals USA Inc. 2004
COVER PAGE - VOLUME 2

Manual Volume 2 Manual Section Preface ai Contract No. 04-31645-720
Prep. by SRH Date 11/21/2005 FFEM DWG. No. 5.401475
App by MDS Date 11/21/2005 Rev. 0 Page 1 of 1
CHANCADOR TRAYLOR
FFE MINERALS USA., INC.

HOJA DE REGISTRO DE DISTRIBUCION y REVISION
PARA
1525 X 2870 (60x113) TIPO NT
CHANCADOR GIRATORIO TRAYLOR
MANUAL DE INSTALACION,
OPERACION Y MANTENIMIENTO
CLIENTE: SOCIEDAD MINERA
CERRO VERDE S.A.A.
Volumen COMENTARIOS REV. POR FECHA

Manual No. TRANSMISION
2 MANUAL - CERTIFICADO 0 S.R. HARRIS 12/16/2005
2 MANUAL ELECTRONICO - CERTIFICADO 0 S.R. HARRIS 12/16/2005
Distribucion: Cliente : 6 Copias & 3 Copias Electronica

FFEM Ingeniera CHQ : 1 Copias & 3 Copias Electronica
FFEM Chile : 3 Copias & 3 Copias Electronica
DISTRIBUTION AND REVISION RECORD

Manual Volume 2 Manual Section Preface aii Contract No. 04-31645-720
App. by MDS Date 12/12/2005 Rev 1 Page 1 of 1
CHANCADOR TRAYLOR
RENUNCIA
El presente manual es un servicio de FFE Minerals U.S.A. Inc. A pesar de

nuestros mejores esfuerzos, cierta informacin en este manual puede quedar
obsoleta con l. FFE Minerals U.S.A. Inc. no acepta responsabilidad por la
exactitud, la integridad o el uso de, ni ninguna otra responsabilidad en la puesta
al da de la informacin contenida en el presente manual. Estos materiales se
entregan TAL COMO SON, SIN GARANTA DE NINGN TIPO, NI EXPRESA
NI IMPLCITA, INCLUYENDO, AUNQUE NO LIMITADO A, LAS GARANTAS
INVOLUCRADAS RELATIVAS AL COMERCIO, OPORTUNIDAD PARA UN
PROPSITO PARTICULAR O DE NO TRANSGRESIN, UD. ASUME LA
COMPLETA RESPONSABILIDAD Y RIESGO POR EL USO DE ESTE
MATERIAL. Algunas jurisdicciones no permiten la exclusin de las garantas
implicadas, por lo que las exclusiones establecidas anteriormente, podran no
aplicarse a Ud.
FFE MINERALS U.S.A. INC., SUS AGENTES, REPRESENTANTES Y

EMPLEADOS, NO SON RESPONSABLES NI IMPUTABLES POR CUALQUIER
DAO DIRECTO, INDIRECTO, INCIDENTAL, CONSECUENCIAL, ESPECIAL,
EJEMPLAR, PUNITIVO U OTROS, QUE SURGIERAN DE O SE RELACIONEN
DE ALGUNA MANERA CON EL PRESENTE MANUAL Y/O SU CONTENIDO,
TRADUCCIN, NI LA INFORMACIN DENTRO DEL MANUAL. SU NICO
ACTO DE INSATISFACCIN RESPECTO DE ESTE MANUAL ES DEJAR DE
UTILIZARLO.
Todos los contenidos dentro de este manual, incluyendo, aunque no limitado a,

su texto, logos e imgenes, son de propiedad de FFE Minerals U.S.A. Inc.
Ninguna porcin de los materiales de estas pginas puede ser reimpreso o
republicado de ninguna forma sin la expresa autorizacin por escrito de FFE
Minerals U.S.A. Inc.
AL USAR ESTE MANUAL UD RECONOCE HABER LEIDO, COMPRENDIDO Y

EST DE ACUERDO CON LOS TRMINOS PARA SU USO.
DISCLAIMER
Manual Volume all Manual Section preface Contract ALL
Orig. by J. Anthony Date 1/22/2003 FFEM DWG. No. 7.500267
Rev. by M. Solomon Date 5/14/2004 Rev. 1 Page 1 of 1
CHANCADOR TRAYLOR
SEGURIDA
SE ESTABLECEN EN EL PRESENTE MANUAL REGLAS

BSICAS RELATIVAS A LA SEGURIDAD DENTRO Y
CERCA DE UNA PLANTA CHANCADORA EN LA SECCIN
1.2, PROCEDIMIENTO DE TRABAJO SEGURO.
LA SEGURIDAD DE UN OPERADOR Y LA DE LOS DEMS
DEPENDE DEL CUIDADO Y JUICIO RAZONABLES EN LA
OPERACIN DE ESTE CHANCADOR. UN OPERADOR CUIDADOSO
ES UN BUEN SEGURO CONTRA ACCIDENTES.
LA MAYORA DE LOS ACCIDENTES, SIN IMPORTAR
DONDE OCURREN, SON CAUSADOS POR FALLAS AL
OBSERVAR Y RESPETAR REGLAS O PRECAUCIONES
SIMPLES Y FUNDAMENTALES. POR TAL RAZN, LA
MAYORA DE LOS ACCIDENTES PUEDEN PREVENIRSE
RECONOCIENDO PELIGROS Y SIGUIENDO PASOS PARA
EVITARLOS ANTES QUE OCURRA UN ACCIDENTE.
SIN DESMEDRO DEL CUIDADO QUE SE HA TENIDO EN
EL DISEO Y CONSTRUCCIN DE ESTE TIPO DE
EQUIPOS, EXISTEN CONDICIONES QUE NO PUEDEN SER
COMPLETAMENTE SALVAGUARDADAS, SIN INTERFERIR
CON UN ACCESO RAZONABLE Y UNA OPERACIN
EFICIENTE. SE INCLUYEN ADVERTENCIAS EN EL
PRESENTE MANUAL DE INSTRUCCIONES PARA
RESALTAR DICHAS CONDICIONES.
SAFETY STATEMENT
Manual Volume all Manual Section prefac Contract ALL
Orig. by J. Anthony Date 1/22/2003 FFEM DWG. No. 7.500268
Rev. by M. Solomon Date 5/14/2004 Rev. 1 Page 1 of 1
TRAYLOR CRUSHER
CHANCADOR TRAYLOR
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
A Spanish translation of this Installation, Maintenance and

Operation manual has been provided. The Spanish translation was
prepared by an outside service. FFE Minerals USA, Inc. cannot
guarantee or warrant the accuracy of the translation, and therefore
the English version of this manual shall be the official manual for all
purposes.
In the event of any inconsistency or conflict between the English and

Spanish version, or in the event that the Spanish version omits or
fails to accurately state in Spanish what is stated in English, the
English version shall prevail.
*******************************************************
Se ha hecho llegar una versin en Espaol para el Manual de

Instalatcin, Mantencin y Operacin. Esta versin fue realizada
por servicios externos a nuestra compaia. Aunque fue FFE
Minerals USA, Inc. No se hace responsable ni garantiza su exacto
traduccin, este manual se considerar como el documanto oficial
para cualquier propsito.
En la eventualidad de existir alguna disconformidad o mala

interpretacin de la traduccin Ingls al Espaol, o que su versin
omita o no corresponda con lo indicado en Ingls, prevalecer e
trmino en Ingls
TRANSLATION WARNING
Manual Volume all Manual Section prefac Contract ALL
Orig. by SRH Date 08/19/2004 FFEM DWG. No. 7.500433
Rev. by MDS Date 08/19/2004 Rev. 0 Page 1 of 1
CHANCADOR TRAYLOR
INFORMACION ACERCA ESTE MANUAL
ESTE MANUAL CONSTA DE 3 VOLUMENES.
CADA VOLUMEN CONTIENE ESTA DESCRIPCIN & UNA TABLA

DE CONTENIDOS DEL VOLUMEN.
EL CONTENIDO DE LOS VOLUMENES ES:
VOLUMEN 1: INSTRUCCIONES DE INSTALACIN, OPERACIN

& MANTENCIN MECANICAS & PLANOS FFEM
MECANICOS
VOLUMEN 2: PLANOS E INSTRUCCIONES DE

SUMINISTRADORES
VOLUMEN 3: ELECTRICIDAD
ABOUT THIS MANUAL

Manual Volume all Manual Section preface Contract 04-31645-720
No.
App by MDS Date 11/21/2005 Rev. No. 0 Page 1 of 1
CHANCADOR TRAYLOR
MANUAL DE INSTALACION, OPERACION Y MANTENCION
TABLA DE CONTENIDOS
VOLUMEN 2
SEC MPL TITULO Plano No. Rev.
(o pgina No.) No.
ai Cubierta 5.401475 0
aii Registro de Distribucin y Revisin 5.401476 0
aiii Exencin de Responsabilidad 7.500267 1
aiv Declaracin de Seguridad 7.500268 1
````
av Aviso Sobre la Traduccion 7.500433 0
avi Acerca de este Manual 5.401468 0
INDICE TABLA DE CONTENIDOS 5.401477 0
1 RODAMIENTOS CONTRA-EJE, TIMKEN
Manual de Mantencin de Cojinetes 7313
Manual de Mantencin de Cojinetes Espaol 7313S
2 COJINETE CONTRA-EJE RTD DE MINCO
RTD de Minco S56
Soporte de Minco FG110-1

Cabeza de Conexin de Minco CH103
3 UNIDAD HIDRAULICA Y DE LUBRICACION
1 Listado de Materiales 6.507158 0

2 Arreglo General 6.506776 1
3 Dibujos Esquemticos 6.506777 0
4 Diagrama de Cableado 6.506779-01 0
6.506779-02 0
TABLA DE CONTENIDOS
Vol. Manual 2 Seccin INDICE Contrato No. 04-31645-720
Prep. por SRH Fecha 12/12/2005 PLANO FFEM No. 5.401477
Aprobado MDS Fecha 12/12/2005 Rev. 0 Pag. 1 de 6
por No.
CHANCADOR TRAYLOR
5 Informacin de Vendedores
4 ENFIRADOR DE AIRE, YOUNG
Catlogo de Enfriador OCS 10-2000
Plano Enfriador OCS 6.506996 0
Enfriador OCS - Recomendaciones &
Form 2952-1
Instrucciones de Instalacin
Enfriador OCS Instrucciones de Mantencin y Form 2952
Garanta
Instrucciones Enfriador OCS Espaol Form 2952-1
Motor 10HP, Toshiba Hojas Tcnicas
- Hoja Tecnica, Motor MDSL0001-04
- Instrucciones de IOM, Motor
- Instrucciones de Lubricacion MDS-O-0001
- Almacenaje, Motor
5 VALVULA DE ALIVIO DE LUBRICACIN,

FULFLO
Vlvula de Alivio, Fulflo Vlvula Serie V
INTERRUPTOR DE FLUJO, UNIVERSAL FLOW
6 MONITOR
Manual de Instalacion y Mantenimiento, Monitor de GENMAN-200.5M
Flujo
Instrucciones de Instalacion, Monitores de Flujo SPGENMAN-200.1
Contador de Flujo, Plano Serie MN 6.507816 3

Contador de Flujo, Catalago Serie MN
Contador de Flujo, Plano Serie SN 6.507815 2
TABLA DE CONTENIDOS
por No.
CHANCADOR TRAYLOR
Contador de Flujo, Catalago Serie SN
7 VALVULA DE BOLAS CON MOTOR,

JAMESBURY
Vlvula de bolas, Jamesbury, Catlogo B101-2 6/05
Vlvula de bolas, Jamesbury, Manual de

IMO-213EN 7/05
Instalacin, Operacin y Mantencin
Actuador Elctrico, Jamesbury, Catlogo A120-3 12/03
Actuador, Jamesbury, Instrucciones de IMO-516 7065 12/01

Instalacin, Operacin y Mantencin
Instrucciones de Montaje Vlvula/Actuador AMI-388 12/01
Actuador Elctrico, Limitadores adicionales de IMO-505 01/02

fin de carrera
Limitadores adicionales de fin de carrera
(disyuntores de seguridad), Jamesbury, EK-5120 A
Instrucciones
Limitadores adicionales de fin de carrera
(disyuntores de seguridad), Valvcon, 1080 D
Instrucciones
8 RTD & THERMOWELL
Sensores de temperatura y accesorios Rosemount 00813-0100-2654
Instrucciones de Alambraje del Sensor y Planos aprobados 00813-0400-2654
ENSAMBLE VALVULA ALIVIO &

9
ACUMULADOR
Plano FFE Arreglo General 1.512208 3
Diagrama Esquemtico de Distribuidor HS43-A37-3026-A 1
Acumulador, Distribuidor y Base, Ensamble y 43AS-13074-0-C 2
Arreglo General
Acumulador & Distribuidor, Arreglo General de AGA-14591-0-C 0
Ensamble
Acumulador & Distribuidor, Ensamble y Listado
R978933506
de Materiales
TABLA DE CONTENIDOS
por No.
CHANCADOR TRAYLOR
Lquidos a base de petrleo para ser usados en

motores y bombas de paleta, de engranajes, de RA 07 075/03.96
pistones y radiales.
Ensamble, Puesta en Marcha y Mantencin de

RA 07 300/06.98
Vlvulas Industriales Ingls
Ensamble, Puesta en Marcha y Mantencin de
RA 07 300/12.02
Vlvulas Industriales Espaol
Ensamble, Puesta en Marcha & Servicio de
Unidades y Sistemas Hidrulicos Ingls RA 07 900/06.98
Ensamble, Puesta en Marcha & Servicio de

RA 07 900/12.02
Unidades y Sistemas Hidrulicos Espaol
Vlvula de Aguja PU-A21-16-00 5
Manmetro PU-A31-11-00 1
Elemento Lgico 971 55 08 4 272182 b
Vlvulas de Cartucho de 2 vas Ingls RA 21 050/06.98
Vlvulas de Cartucho de 2 vas Espaol RS 21 050/02.03
Acumulador 9 535 233 184/01.04
Instrumento de Carga & Prueba de Acumulador 1 539 929 009

i
Documento de Reparacin de Acumulador
Estndar
Gua de Repuestos Recomendados
10 SISTEMA DE LUBRICACIN DE LA ARAA
Bomba Electrica Rotatoria tipo FloMaster 422823
Interruptor Limitador Serie D 402877

Vlvulas Dividoras 9505A
Controlador de Lubricacin Serie A 402671
TABLA DE CONTENIDOS
por No.
CHANCADOR TRAYLOR
11 SISTEMA INDICADOR DE POSICION DEL EJE

PRINCIPAL
Caja de Ensamble de Indicador de Barras 6.507184 0
Transductor Lineal, Balluff 814511U
Conjunto de cuerdas, Balluff
Caja, Hoffman CHQR
Kit de Ventana de Caja, Hoffman
Suministro de Energa, AstroDyne, Serie PS, PD-
25
Indicador de barra, Sistema M, Modelo 49AV2 ES-9333 Rev 6
Transmisor de Seal, Sistema M, Modelo W2VS ES-5518 Rev 3
Bloque terminal montado sobre riel, 020000000

Mdulos de Interfase de Cables, Riel DIN
12 ACOPLAMIENTO DE ENGRANAJE &

ENSAMBLE DE EJE, FALK
Plano de acoplamiento de engranaje y ensamble 6.507057 1
de eje
Instalacin & Mantencin - Ingls 458-110
Instalacin & Mantencin - Espaol 458-110S
13 POTENCIA HIDRAULICA PACK, SIMPLEX
Instrucciones de Operacin & Mantencin #54393
Listado de Partes del Cilindro, Simplex #86183
Instrucciones de Operacin del Cilindro, Simplex #86183
Detalles de Manguera
14 SOPLADOR DEL SELLO DE POLVO, GAST
Especificaciones y dimensiones del soplador
Manual de Operacin y Mantencin del Soplador 70-6000 F2-200 G
Instrucciones de Operacin de la Vlvula de
70-6300 F2-105 F
Alivio
TABLA DE CONTENIDOS
por No.
CHANCADOR TRAYLOR
Instrucciones de Operacin del Soplador Ingls UK10103 D
Instrucciones de Operacin del Soplador
UK10103 D
Espaol
15 PLATAFORMA DE SERVICIO Y CARRO DE LA
EXCENTRICA
LATER
TABLA DE CONTENIDOS
por No.
WHEN ORDERING SPECIFY SENSING ELEMENT, CASE LENGTH, NUMBER
OF LEADS, AND LEAD LENGTH.
S56PA124Z24 EXAMPLE OF MODEL NUMBER
S56 SPECIFICATIONS DRAWING NUMBER.
PA SENSING ELEMENT:
CC = COPPER;
NA = NICKEL;
PA = 100 OHM, .00392 PLATINUM.
124 CASE LENGTH A IN .1O INCREMENTS (124 = 12.4O).

MINIMUM A = 40 (4.0O) [102];
MAXIMUM A = 480 (48.0O) [1219].
Z NUMBER OF LEADS:
Y = 2 LEADS PER ELEMENT (NOT AVAILABLE WITH CC
ELEMENT MODELS);
Z = 3 LEADS PER ELEMENT.
24 LEAD LENGTH B IN INCHES.
1. ELEMENTS (2): COPPER, NICKEL, OR PLATINUM.

2. RESISTANCE (EACH ELEMENT):
COPPER: 10.00 OHMS .50% (10.05/9.95) AT 25C (77F), R/T TABLES
#16-9 (C) AND #17-9 (F);
NICKEL: 120.0 OHMS .5% (120.6/119.4) AT 0C (32F), R/T TABLES
COMPANY CONFIDENTIAL
#7-120 (C) AND #8-120 (F); PROPRIETARY INFORMATION
PLATINUM: 100.0 OHMS .5% (100.5/99.5) AT 0C (32F), R/T TABLES
#1-100 (C) AND #2-100 (F).
OF MINCO PRODUCTS, INC.
RESISTANCE IS EXCLUDING ALL LEADWIRE RESISTANCE.
3. TEMPERATURE RANGE: -50C TO 260C (-58F TO 500F).
DO NOT DUPLICATE
4. INSULATION RESISTANCE: 100 MEGOHMS MINIMUM AT 100 VOLTS DC,
BETWEEN ELEMENTS AND LEADS TO PROBE CASE.
5. LEADS: AWG #22, STRANDED, TFE INSULATED.
6 TOLERANCE ON LEAD LENGTH:
71O [1803] AND UNDER: +2/-0O [+51/-0];
72O TO 119O [1829 TO 3023]: +4/-0O [+102/-0];
120O [3048] AND OVER: +6/-0O [+152/-0].
7. CASE: STAINLESS STEEL, COPPER ALLOY TIP.
8 CASE MAY BE CUT TO SHORTER LENGTH. USE CARE NOT TO DAMAGE
LEADWIRE INSULATION. LOCATE THE SLIP-FIT TFE SLEEVE IN END OF
CUT-OFF CASE TO PROTECT LEADWIRE INSULATION AT POINT OF
EMERGENCE. MINIMUM A FOR CUT-OFF CASE IS 40 (4.0) [102].
Print Date: 05/20/2010 16:32

MODEL USED WITH O-RING BODY
NUMBER MINCO PROBE A MATERIAL MATERIAL
FG114-1 .188 .190 VITON
FG114-2 .188 .190 BUNA N
FG110-1 .215 .218 VITON TYPE 303
FG110-2 .215 .218 BUNA N STAINLESS STEEL
FG113-1 .250 .253 VITON
FG113-2 .250 .253 BUNA N
FG914 .188 .190 VITON
TYPE 316
FG912 .215 .218 VITON
STAINLESS STEEL
FG911 .250 .253 VITON
FG314 .188 .190 VITON
FG310 .215 .218 VITON
NYLON
FG315 .236 .242 VITON
FG313 .250 .253 VITON
1. HOLDER IS EQUIPPED WITH AN O-RING TO SEAL AROUND PROBE.

2. PRESSURE RATING: 50 PSI (3.4 BAR).
3. TEMPERATURE LIMITS:
VITON O-RING: -40C TO 260C (-40F TO 500F);
BUNA N O-RING: -53C TO 149C (-65F TO 300F);
NYLON HOLDER: -40C TO 120C (-40F TO 248F).
4 NYLON HOLDER TO HAVE 1.0" WRENCH FLATS.
Print Date: 05/20/2010 16:32

WHEN ORDERING SPECIFY PIPE THREAD CODE AND TYPE OF CONNECTION
POINTS.
CH103P4T6 EXAMPLE OF MODEL NUMBER
CH103 SPECIFICATIONS DRAWING NUMBER.
P4 PIPE THREAD CODE:

CODE THREAD A THREAD B
P1 3/4 14 NPT 1/2 14 NPT 3
P2 3/4 14 NPT 3/4 14 NPT
P3 1/2 14 NPT 1/2 14 NPT 3
P4 1/2 14 NPT 3/4 14 NPT
T6 TYPE OF CONNECTION POINTS: 2

T0 = MOUNTING PACKAGE FOR TEMPTRAN MOUNTING;
T6 = TERMINAL BLOCK WITH 6 CONNECTION POINTS;
T8 = TERMINAL BLOCK WITH 8 CONNECTION POINTS;
W0 = EMPTY ENCLOSURE (NO CONNECTION POINTS);
W4 = 4 WIRE NUTS;
W6 = 6 WIRE NUTS.
1. CONNECTION HEAD PROVIDES A WEATHERPROOF ENCLOSURE IN

WHICH LEADWIRE FROM PROBE TYPE RESISTANCE THERMOMETERS OR
THERMOCOUPLES CAN BE CONNECTED TO EXTENSION WIRES LEADING
TO REMOTELY LOCATED READOUT OR CONTROL INSTRUMENTATION.
2 CONNECTION HEAD CAN BE SUPPLIED WITH TEMPTRAN MOUNTING
PACKAGE OR A TERMINAL BLOCK FOR MAKING CONNECTIONS
BETWEEN PROBE LEADWIRES AND EXTENSION LEADWIRES.
3 ONE 3/4 x 1/2 NPT REDUCER BUSHING SUPPLIED WITH EACH HEAD.
4. T6 (EPOXY GLASS) OR T8 (PHENOLIC) TERMINAL BLOCK: SCREW
CONNECTIONS ARE SUITABLE FOR CONNECTING PROBE LEADWIRES TO
EXTENSION WIRES RANGING IN SIZE UP TO AWG #16.
5. WIRE NUTS: PORCELAIN, SUITABLE FOR CONNECTING PROBE WIRES TO
EXTENSION WIRES RANGING IN SIZE UP TO AWG #14.
6. TEMPERATURE LIMIT: 600F MAXIMUM, WHEN USED WITH WIRE NUTS.
7 INSTALLATION: THE MOUNTING FITTING FOR THE PROBE NORMALLY
ATTACHES TO THREAD A. CONDUIT ADAPTER OR PIPE FOR EXTENSION
WIRES NORMALLY ATTACHES TO THREAD B.
8. SUITABLE FOR USE IN ENVIRONMENTS AS DEFINED IN
NEMA TYPE 3 AND 4.
9. APPROXIMATE WEIGHT: 2.05 LBS.
Print Date: 05/20/2010 16:32

MANUAL
TROLA-DYNE, INC.
2951
Lube and Hydraulic Unit
For
FFE Minerals USA Inc.
Project: Fluor/Cerro Verde/Phelps Dodge
FFE Contract Number: 0431645
FFE Purchase Order Number: 003338
FFE Line Item Number: 1
FFE Inventory ID Number: F005122

www.Imo-Pump.com
Performance Shown at 150 PSID (10 BAR),
200 SSU (43 CST)
1 The reliable pump people

www.Imo-Pump.com
IMO Series 3G Pump
AXIAL OR RADIAL
HYDRAULICALLY
(ELBOW) INLET VARIETY OF PORT
BALANCED
PUMP SCREWS STYLES AVAILABLE
(SEE TABLE)
CHOICE OF
SHAFT SEALING
FOOT OR
FLANGE MOUNT
Shown Above: 3G-095, Flange Mount Iron Cased Axial Inlet, Built-In Relief Valve
Shown Above: Tamper Resistant Optional Built-In Pressure Relief Valve

for sizes 162 and smaller
The reliable pump people 2

www.Imo-Pump.com
Applications
The 3G series pump is intended for use in lubrication, hydraulic and control oil services such as those
found on rotating machinery or other equipment needing forced lubrication, circulation, fluid transfer,
distillate fuel burner or similar systems. This series is available in seventeen displacements fitted into five
casing sizes. Pump casings are produced from cast iron with the option of cast steel.
All pumps are fitted with mechanical shaft seals. Inlet porting can be either radial (elbow), rotatable in 90o
increments, or axial. An internal tamper resistant relief valve is available as an option. Porting on the 95
through 162 rotor size pumps can be either SAE straight thread or SAE 4-bolt, Code 61, flange pad.
Porting on the 187 through 250 pumps is SAE 4-bolt, Code 61, flange pad.
Steel case pumps are equipped with SAE 4-bolt flange pads. An optional in-line relief valve is also
available. All SAE flange pads accept 4-bolt, O-ring sealed, Code 61 mating flanges of either socket weld
or FNPT style.
Both iron and steel pumps are designed for flange mounting and can be provided with mating foot brack-
ets or pump to motor (C-face) brackets. Flange or foot mounting on rotor sizes 95 through 162 and flange
mounting on rotor sizes 187 through 250 allows the pump outlet port to be directed radially in 90
increments. Port options allow almost any global standard connection type. Units can also be supplied for
vertical tank mounting.
3G095 with radial SAE pad inlet port
3G095 mounted to a C face electric motor on lube oil service

www.Imo-Pump.com
2-210 GPM (7-795 L/M) Pressure
to 250 PSIG (17 Bar)
E BOLT CIRCLE 2 HOLES
A B C D E H L M N R U W WEIGHT*
PUMP
SIZE INCH MM INCH MM INCH MM INCH MM INCH MM INCH MM INCH MM INCH MM INCH MM INCH MM INCH MM INCH MM LBS. KG
95 1 25.4 3/4 19 4.66 118.4 3.249 82.52 4.19 106.4 4.57 116.1 10.83 275.1 2.25 57.2 1.88 47.8 5.02 127.5 .5 12.7 5.25 133.4 18 8.0
118 1-1/2 38.1 1 25.4 6 152.4 5 127 6.38 162 5.76 146.3 13.91 353.3 4 101.6 2.80 71.1 6.19 157.2 .625 15.875 9 228.6 34 15.4
143/162 2 50.8 1-1/2 38.1 7.67 194.8 5 127 6.38 162 7.57 192.3 16.26 413.1 4 101.6 2.76 70.1 6.65 168.9 .75 19.05 7.75 196.9 44 20.0
A B C D E H L M N R U W WEIGHT*
PUMP
SIZE INCH MM INCH MM INCH MM INCH MM INCH MM INCH MM INCH MM INCH MM INCH MM INCH MM INCH MM INCH MM LBS. KG
187/200 3 76.2 2 50.8 10.06 255.5 6 152.37 9 228.6 9.44 239.8 22.52 572 4.94 125.5 3.31 84.1 9.84 249.9 1.250 31.75 5.62 142.7 117 53
250 4 101.6 2-1/2 63.5 12.61 320.3 6 152.37 9 228.6 10.19 258.8 25.84 656.3 4.94 125.5 3.31 84.1 10.21 259.3 1.250 31.75 5.62 142.7 131 59.4
* Inlet and Outlet are SAE 4-bolt 3000 PSI flange pads.
* Flange mounted version. Weights exclude port adapters and mounting foot bracket / plate.
For a more detailed view of the above referenced outline drawings, please refer to our website at
http://www.imo-pump.com
www.Imo-Pump.com
Specifications
Casing Cast iron or cast steel.
Rotors Power rotor is ductile (nodular) iron. Idler rotors are gray iron.
Shaft Seal Type V: Fluoroelastomer bellows mechanical seal with carbon on ni-resist faces,
fluoroelastomer O-rings, recommended for viscosities below 3000 SSU (650 CST) and
distillate fuel oils.
Type H: Metal bellows balanced, positive drive mechanical seal with carbon on silicon carbide faces,
fluoroelastomer O-rings, recommended for viscosities above 3000 SSU (650 CST) or for
closer compliance with API.
Type J: Balanced, positive drive mechanical seal with neoprene O-rings for high inlet pressure /
low differential pressure applications.
Type N: No shaft seal (must use mounting option I).
Bearing Internal, ball type.
Relief Valve Optional internal, tamper resistant, built-in pressure relief valve for viscosities not exceeding 1500
SSU (324 CST). Specify differential set pressure in 15 PSI (1.03 BAR) increments, i.e. 60, 75210.
(This relief valve is intended for momentary protection for the pump against overpressure. It
is not intended to be a system pressure control device). Minimum set pressure is 60 PSID (4.1
BAR). Maximum set pressure is 210 PSID (14.5 BAR). An optional in-line relief valve with external
return-to-tank connection is also available.
Viscosity Range 32 to 3000 SSU (2 to 650 CST) type V seal.
32 to 15,000 SSU (2 to 3200 CST) type H seal.
Inlet Pressure 50 PSIG (3.4 BAR) normal maximum.
300 PSIG (20.7 BAR) optional maximum (Contact factory).
Outlet Pressure 250 PSIG (17 BAR) maximum [(to 300 PSIG (20.7 BAR) with inlet at 50 PSIG (3.4 BAR)]. Operation
at differential pressures below 40 PSI (2.8 BAR) may require pump modification- consult Imo Pump
with full operating range data.
Temperature 0 to 225F (-18 to 107C)
Drive/Rotation Direct only. Clockwise facing pump shaft standard. Counterclockwise optional.
Speed Size 95: 5000 rpm maximum. Sizes 118 - 200: 4000 rpm maximum. Size 250 1.3D & 1.6D leads:
4000 rpm maximum. Size 250 2D lead: 3250 rpm maximum.
Mounting May be foot or flange mounted in any orientation. Vertical tank mounts available.
Connections Port Type Availability
Inlet Port Type Iron Case Steel Case
Axial SAE Straight Thread Yes No
Axial SAE 4-Bolt Pad, Code 61 Yes Yes
Radial SAE Straight Thread Yes No
Radial SAE 4-Bolt Pad, Code 61 Yes Yes
Outlet Port Type Iron Case Steel Case
Radial SAE Straight Thread Yes No
Radial SAE 4-Bolt Pad, Code 61 Yes Yes
Straight thread for use with O-ring fittings. SAE pad is for use with mating SAE 4-bolt 3000 PSI flanges.
Filtration Inlet strainers are required to keep contaminants and abrasives out of the pump and must be
selected in consultation with the strainer vendor to prevent pump starvation. Normally, 60 mesh
(0.01 inch- 238 micron) for light and 1/8-3/16 inch (3-5mm) openings for heavy oils are
recommended. Return line filters for closed loop systems also recommended.
Accessories Completely mounted pump/driver assemblies with baseplates or NEMA C face motor adapters are
available.

www.Imo-Pump.com
Model Code Nomenclature
Model No. Code Example A A 3 G / N V I J F B 1 1 8 S P 0 0 0
Design Sequence Designator for Special Modifications

Pump Series Size/Lead/Rotation
095AE = 1.2D, CW 162SP = 1.6D, CW
Separator
095AF = 1.2D, CCW 162SR = 1.6D, CCW
Fixed Designator 095SP = 1.6D, CW 162SC = 2.0D, CW
095SR = 1.6D, CCW 162SD = 2.0D, CCW
Seals 095SC = 2.0D, CW
095SD = 2.0D, CCW 187SY = 1.45D, CW
V = Fluorocarbon Bellows mechanical seal, 187SZ = 1.45D, CCW
carbon on Ni-resist, Fluorocarbon O-rings 118SP = 1.6D, CW 187SM = 1.75D, CW
H = Metal bellows balanced mechanical seal, 118SR = 1.6D, CCW 187SN = 1.75D, CCW
carbon on silicon carbide, Fluorocarbon 118SC = 2.0D, CW 187SC = 2.0D, CW
O-rings 118SD = 2.0D, CCW 187SD = 2.0D, CCW
N = No shaft seal (must use mounting I), 143SJ = 1.5D, CW 200SC = 2.0D, CW
Fluorocarbon O-rings 143SK = 1.5D, CCW 200SD = 2.0D, CCW
J = Metal Bellows balanced mechanical seal, 143SE = 1.7D, CW
143SF = 1.7D, CCW 250AL = 1.3D, CW
carbon on silicon carbide, Neoprene O-rings
143SC = 2.0D, CW 250AM = 1.3D, CCW
Case Material and Outlet Port 143SD = 2.0D, CCW 250SP = 1.6D, CW
250SR = 1.6D, CCW
I = Iron case, SAE straight thread port** 250SC = 2.0D, CW
P = Iron case, SAE 4-bolt port pad 250SD = 2.0D, CCW
S = Steel case, SAE 4-bolt port pad
Relief Valve Set Range (Limit 1500 ssu)
X = Special
**Not available on Rotor Sizes 187 thru 250 A = No relief valve
B = 60/75 psi differential
Inlet Port C = 90/105/120 psi differential
J = Axial inlet, SAE straight thread port** D = 135/150/165 psi differential
No Weep Hole
STANDARD
K = Axial inlet, SAE 4-bolt port pad E = 180/195/210 psi differential

L = Radial inlet, SAE straight thread port** Iron Pump only
M = Radial inlet, SAE 4-bolt pad In-line relief valve option available
Mounting
N = Axial inlet, SAE straight thread port**
C = SAE flange mount
WEEP HOLE
Front Cover
P = Axial inlet 4-bolt port pad F = Foot mount

R = Radial inlet, straight thread port** I = Integral flange mount
(note: must specify N for Seals)
S = Radial inlet 4-bolt port pad
**Not Available on Rotor Sizes 187 thru 250

Imo Pump is proud to be a member of the Colfax
Pump Group associated with Allweiler Pump of
Radolfzell, Germany, Houttuin Pump of Utrech,
The Netherlands, Warren Pump of Warren, Mas-
sachusetts, USA, providing World-Class fluid
handling equipment and services to a global
market.
Imo Pump means in a word, Performance. Imo
Pumps Performance Over Time provides the
best overall value by providing low maintenance or
lengthy service intervals and efficient product
operation or low energy costs, which results in the
lowest Total Cost of Ownership.
All of Imo Pumps products are designed to be of
Heavy Duty - Industrial Grade construction and
certain models are designed specifically for
Severe Duty services such as Marine, Power
Generation or Process Applications.
Imo Pump is fully qualified to respond on all of the
imposed quality and design standards provided,
such as Military Standards, ABS, ANSI, ASME,
SAE, ISO-9000, CE, UL, CSA, NEMA and ISO,
among others.
Imo Pump maintains a fully qualified staff of
experienced Application Engineers, Technical
Sales Engineers, Product Engineers, Service
Engineers and Draftsmen capable of handling the
most demanding applications.
We are responding to our customer needs with
efficient, reliable products capable of handing a
wide range of fluids over a long service life.
Our QuickServe Department processes

internet and credit card orders. Most repair kits
can be shipped same or next business day
delivery saving valuable down time. Visit out
our E-Commerce site on the web or call our
customer service department to place your
order today!
Quality Management System

Bulletin 3G-00
Bulletin 3G-00 2000 Imo Pump All rights reserved.
TM
GENERAL INSTALLATION, OPERATION,

MAINTENANCE AND TROUBLESHOOTING
MANUAL
FOR
THREE SCREW AND CIG SERIES PUMPS
WARNING
This manual, and the specific INSTRUCTION MANUAL, should be
read thoroughly prior to pump installation, operation, maintenance
or troubleshooting.
This manual now is

identified as part no.
SRM00046
Manual No. CA-1 Rev. 4 September 1997

READ THIS ENTIRE PAGE BEFORE PROCEEDING
FOR THE SAFETY OF PERSONNEL AND TO PREVENT DAMAGE TO THE EQUIP-

MENT, THE FOLLOWING NOMENCLATURE HAS BEEN USED IN THIS MANUAL:
DANGER
Failure to observe the precautions noted in this box can result in severe
bodily injury or loss of life.
WARNING
Failure to observe the precautions noted in this box can cause injury to
personnel by accidental contact with the equipment or liquids. Protection
should be provided by the user to prevent accidental contact.
CAUTION ATTENTION
Failure to observe the precautions noted in this box can cause damage or
failure of the equipment.
Non-compliance of safety instructions Safety instructions Safety instructions which shall be con-
identified by the following symbol could where electrical safety sidered for reasons of safe operation
affect safety for persons: is involved are identi- of the pump and/or protection of the
fied by: pump itself are marked by the sign:
ATTENTION
CONTENTS
SAFETY AND TABLE OF CONTENTS .................................................................................. A

A - GENERAL ......................................................................................................................... 1
B - TRANSPORTATION AND STORAGE ............................................................................... 1
C - DESCRIPTION OF THE PUMP ........................................................................................ 1
D - INSTALLATION/ASSEMBLY .............................................................................................. 1
E - STARTUP, OPERATION AND SHUTDOWN ................................................................... 10
F - MAINTENANCE .............................................................................................................. 14
G - FIELD AND FACTORY SERVICE ................................................................................... 15
H - TROUBLESHOOTING .................................................................................................... 16
A
APPLICATIONS MANUAL FOR IMO PUMPS
A. GENERAL
The instructions found herein cover the general installation, operation, maintenance and trouble-
shooting of subject equipment. NOTE: Individual contracts may have specific provisions that vary
from this manual. Should any questions arise which may not be answered by these instructions, refer
to the specific pump instruction manual provided with your order. For further detailed information and
technical assistance to questions not answered by these manuals, please refer to Imo Pump, Techni-
cal/Customer Service Department, at (704) 289-6511.
This manual cannot possibly cover every situation connected with the installation, operation, mainte-
nance and troubleshooting of the equipment supplied. Every effort was made to prepare the text of
the manual so that engineering and design data was transformed into easily understood wording.
Imo Pump must assume the personnel assigned to operate and maintain the supplied equipment and
apply this instruction manual have sufficient technical knowledge and experience to use sound safety
and operational practices which may not be otherwise covered by this manual.
In applications where equipment furnished by Imo Pump is to become part of a process or other
machinery, these instructions should be thoroughly reviewed to determine proper fit of the equipment
into overall plant operational procedures.
WARNING
If installation, operation, and maintenance instructions are not correctly and strictly fol-
lowed and observed, injury to personnel or serious damage to pump could result. Imo
Pump cannot accept responsibility for unsatisfactory performance or damage resulting
from failure to comply with instructions.
B. TRANSPORTATION AND STORAGE

Always protect the pump against taking in water and other contaminants. Store the pump in a clean,
dry and relatively warm environment. Pumps are delivered with their internals oiled (unless specified
otherwise by the customer order) and with protective covers in or over all openings. These covers
should remain in place during the mounting and alignment procedures. The covers must be removed
just prior to attaching system piping to pump. If pumps are to be stored in other than a clean, warm,
or dry environment, or if they are to be stored for more than six months, contact Imo for appropriate
storage procedures.
C. DESCRIPTION OF THE PUMP
See specific pump instruction manual provided with your order.
D. INSTALLATION / ASSEMBLY
WARNING
On critical or dangerous equipment, provide safety and emergency systems to protect
personnel and property from injury due to pump malfunction. If pumped liquids are flam-
mable, toxic, corrosive, explosive or otherwise hazardous, provide for safety in the event of
leakage or malfunction. BEFORE working on equipment, make sure all power to equip-
ment is disconnected and locked-out.
D.1 TOOLS
The procedures described in this manual require common mechanics hand tools, dial indicators
for alignment and suitable lifting devices such as slings, straps, spreader bars, etc.
D.2 LIFTING OF PUMP AND PUMP/DRIVER ASSEMBLIES
All pumps and pump/driver assemblies should be lifted with appropriate devices securely at-
tached to the whole unit. Ensure units center-of-gravity is located between lifting points. See
Figure 1. This will avoid tipping of pump or pump/driver assembly. Spreader bars should be
used as necessary to insure load is properly distributed and lifting straps do not damage equip-
ment.
Some pumps and pump/driver assemblies have designated lifting points that are shown on their
outline drawings.
DANGER ATTENTION
Lifting a vertical pump/driver using straps or hooks attached to the pump or pump-to-
driver bracket may be dangerous since the center-of-gravity of the assembly may be higher
than the points of attachment. Take precautions to prevent slippage of slings and hooks.
Always use properly rated lifting devices.
Max 90
Min 60
Max 90 Max 90
Min 60
Figure 1 Lifting Pumps and Pump/Driver Assemblies
D.3 INSTALLATION OF PUMP ASSEMBLY

To insure adequate flow of liquid to pumps inlet port, place pump near liquid source and prefer-
ably place pump centerline below liquid surface. Use short, straight inlet lines.
A dry, clean, well-lit and well-ventilated site should be selected for installing the pump assembly.
Sufficient open space should be provided around pump rotor and/or gear housing to permit
routine visual inspection, on-site service and maintenance, and pump replacement. For instal-
lation and servicing of large pump units, ample overhead clearance should be provided to allow
for lifting device maneuvering.
D.4 FOUNDATIONS AND BASEPLATES
Foundations and baseplates must be designed and installed so pump and driver alignment can
be maintained at all times. Be sure baseplates are level and rest on smooth flat surfaces. Small
pumps may be mounted on baseplates or directly to existing floors that meet the criteria of
foundations. Larger pumps and/or drivers must be mounted to baseplates and foundations. It is
recommended that pumps and their drivers be mounted on common baseplates.
D.5 MOUNTING OF FOOT MOUNTED PUMPS AND DRIVERS
Some pumps are shipped on baseplates without drivers. For these units, install and tighten
each coupling half on driver and pump shafts. Place driver on baseplate and set proper dis-
tance between shafts and coupling hubs (See Figure 2). Locate driver so pump and driver
shafts are in axial alignment. See Section D.6 on Alignment.
Coupling Installation
Gap Length
Figure 2 Coupling Gap Measurement
For pumps driven through a separate gearbox or other device, first align device relative to pump,
and then align driver relative to device.
See Section D.6.5 for belt-driven pumps. On horizontal pump/driver assemblies, shaft couplings
are often shipped disassembled to prevent coupling damage during shipping and handling.
When not supplied by the manufacturer, coupling, shaft and/or belt guards conforming to ANSI
B15.1 should be installed for personnel protection during pump operation.
Final alignment of pump and driver should take place after unit is secured to foundation. If
baseplate is to be grouted, this should be completed before final alignment.
NOTE: Grouting is recommended to prevent lateral shifting of baseplate, not to take up irregu-
larities in the foundation. For installations requiring grouting, a baseplate designed
specifically for this purpose is needed.
WARNING
Install guards over couplings and shafts to protect personnel from accidental contact with
rotating couplings, belts, sheaves, chains, shafts and/or keyways.
D.6 ALIGNMENT
D.6.1 General
All pump and driver assemblies must be aligned after site installation and at regular
maintenance intervals. This applies to factory-mounted units (new or rebuilt) because
factory alignment is often disturbed during shipping and handling. Flexible couplings
shall be used to connect pump to its driver (unless otherwise specified by Imo Pump).
The objective of any aligning procedure is to align shafts (not align coupling hubs) by
using methods that cancel out any surface irregularities, shaft-end float, and eccentricity.
At operating temperatures above 175o F (65o C), pumps require hot alignment after
pump and driver reach normal operating temperatures. Also, re-check final alignment
after all piping is connected to pump.
D.6.2 Flexible Shaft Couplings
Flexible couplings are intended to provide a mechanically flexible connection for two
aligned shaft-ends. Flexible couplings are not intended to compensate for major angular
or parallel shaft misalignment. The allowable misalignment varies with the type of cou-
pling. Any improvement in alignment beyond coupling manufacturers minimum specifi-
cation will extend pump, mechanical seal or packing, coupling, and driver service life by
reducing bearing loads and wear.
CAUTION ATTENTION
Flexible couplings are NOT intended to permit significant shaft misalignment. Proper
alignment must be established/maintained to obtain proper operation and maximum life.
Pump alignment requirements are nearly always more strict than coupling alignment
requirements. Regardless of coupling manufacturers stated limits, pump-to-driver shaft
alignment must be per pumps alignment requirement.
Be sure all coupling set-screws and bolts are tight and coupling gap is properly set.
D.6.3 Aligning Foot Mounted Pumps - See Figure 3
Feet
Figure 3 Foot Mounted Pump
To install foot mounted pumps, perform the following:

Install pump and driver onto baseplate after installing appropriate coupling halves on
pump and driver shafts.
Perform alignment of pump and driver shafts using dial indicators. Acceptable align-
ment has been attained when FIM (Full Indicator Movement) is less than or equal to
0.005 inch (0.13 mm) for face (angularity) and rim (parallelism) readings at or near
coupling outer diameter while rotating both shafts together one full turn (360). See
Figure 4.
Foot Mounted Pumps
Dial Indicator Dial Indicator
X1
X2
A. Face check (Angularity) B. Rim Check (Parallelism)

Rotating both shafts together for one full Rotating both shafts together for one full
turn, align pump and driver until shaft turn, align pump and driver until shaft
centerlines are parallel ( = 0, X1 = X 2) centerlines coincide (Y = 0) within 0.005
inch (0.13 mm) FIM.
within 0.005 inch (0.13 mm) FIM.
Figure 4 Coupling and Hub Alignment

D.6.4 Aligning Flange Mounted Pumps and Drivers - See Figure 5
Mounting Flange
Figure 5 Flange Mounted Pump
Shaft alignment requirements for flange mounted pumps are the same as for foot mounted
pumps. That is, shafts must be aligned within 0.005 inch (0.13 mm) FIM (Full Indicator
Movement) for face (angularity) and rim (parallelism) at or near coupling outer diameter
while rotating both shafts together one full turn (360).
When a pump and driver are both flange mounted to a bracket, DO NOT assume bracket
will automatically align shafts to the above requirements. Brackets must be designed to
obtain/maintain required alignment as well as to support pump weight plus any (small)
residual piping forces without distorting. If at all possible, bracket design should include
adequate room to check shaft alignment with dial indicators with both pump and motor
mounted onto bracket. See Figure 4. If this is not possible, align bracket to driver shaft
(see Figure 6), then attach pump to bracket (assumes pump fits snugly into its mounting
bore in the bracket).
After pump-bracket-driver is installed into system and after piping is connected to pump,
shaft alignment should be re-checked and adjusted, if necessary,
When a right-angle foot bracket is used, mount pump onto bracket and tighten pump-to-
bracket mounting bolts. At this point, bracket base, in effect, becomes pump feet. Con-
tinue with aligning procedure as if pump were foot mounted. See Section D.6.3.
Driver
Flange Mounted Pumps
Mounting Bracket
Dial Indicator
A
Locating bore (A) must be concentric to driver shaft
centerline within 0.002 inch FIM. Mounting surface
(B) must be perpendicular to driver shaft centerline
within 0.002 inch (0.05 mm) FIM.
Figure 6 Alignment of Flange Mounted Pumps

CAUTION ATTENTION
Be sure all coupling set screws and bolts are tight and coupling gap is properly set.
Install safety shield(s) or plate(s) over bracket opening(s).
D.6.5 Belts and Sheaves

It is only acceptable to belt drive Imo pumps that are specifically designed for this pur-
pose. It is generally not acceptable to belt drive pumps with ratings in excess of 600 psi
differential pressure. Contact Imo if not sure a particular pump can be belt driven.
Belts and sheaves must be properly selected aligned and tensioned to minimize belt
wear, eliminate possibility of belt turnover in sheave grooves, and avoid excessive side
load on pump shaft. Adjustable slide rails mounted under driver are recommended for
proper belt tensioning.
Check belt tension frequently during first 24 to 48 hours of run-in operation. Follow belt
drive manufacturers recommendations for alignment of sheaves and belt-tension set-
tings.
CAUTION ATTENTION
Loose, slipping belts will squeal and cause overheating of sheaves leading to reduced belt
life. Excessively tightened belts will result in reduced belt and bearing life and possible
bearing or shaft failure.
D.7 PIPING AND VALVES

D7.1 General
Piping connected to pump MUST be independently supported and not allowed to
impose strains on pump casing including allowing for expansion and contraction
due to pressure and temperature changes.
To prevent foaming and air entrainment, all return lines in recirculating systems should
end well below liquid surface in reservoir. Bypass liquid from relief pressure and flow
control valves should be returned to source (tank, reservoir, etc.), NOT to pump inlet
line.
Shut-off valves should be installed in both the suction and discharge lines so pump can
be hydraulically isolated for service or removal. All new piping should be flushed clean
before connecting to pump.
CAUTION ATTENTION
Pipe strain will distort a pump. This could lead to pump and piping malfunction or failure.
Return lines piped back to pump can cause excessive temperature rise at pump which
could result in catastrophic pump failure.
D.7.2 Relief Valve

Use relief valves to protect pumps from overpressure. They need to be connected to
pump discharge lines as close to pumps as possible and with no other valving between
pumps and relief valves. Relief valve settings should be set as low as practical.
DO NOT set relief valve higher than maximum pressure rating of pump, including pres-
sure accumulation at 100% bypass. Relief valve return lines should NOT be piped into
pump inlet lines because they can produce a loop that will overheat pump. See Figure 7.
DANGER
The Imo pump is a positive displacement type. It will deliver (or attempt to deliver) flow
regardless of back-pressure on unit. Failure to provide pump overpressure protection can
cause pump or driver malfunction and/or rupture of pump and/or piping.
Relief Valve
Figure 7 Proper Relief Valve Return Line Arrangement

Some low pressure pump models include built-in safety relief valves. They are intended
only for emergency operation, NOT for system control. Extended operation of relief
valves in these pumps could lead to pump damage or failure.
D.7.3 Suction Line
The suction line should be designed so pump inlet pressure, measured at pump inlet
flange, is greater than or equal to the minimum required pump inlet pressure (also re-
ferred to as Net Positive Inlet Pressure Required or NPIPR). Suction line length should
be as short as possible and equal to or larger than pumps inlet size. All joints in suction
line must be tight and sealed. If pump cannot be located below liquid level in reservoir,
position suction line or install a foot valve so liquid cannot drain from pump while it is shut
down. See Figure 8. When pump is mounted vertically with drive shaft upward, or
mounted horizontally with inlet port opening other than facing upward, a foot valve or
liquid trap should be installed in suction line to prevent draining. The suction line should
be filled before pump start-up.
CAUTION ATTENTION
DO NOT operating pump without liquid or under severe cavitation.
Filling
Port
Filling
Port
Foot Liquid Trap

Valve
Figure 8 Fluid Trap and Foot Valve Arrangements for Vertical Pumps
D.7.4 Suction Strainer /Filter
Pump life is related to liquid cleanliness. Suction strainers or filters should be installed in
all systems to prevent entry of large contaminants into pump. See Figure 9.
The purpose of a suction strainer or filter is for basic protection of internal pumping
elements. It should be installed immediately ahead of inlet port. This location should
provide for easy cleaning or replacement of strainer element. Appropriate gages or
instrumentation should be provided to monitor pump pressure. Pressure drop across a
dirty strainer must not allow inlet pressure to fall below NPIPR. General guidelines for
strainer sizing are as follows:
When pumping relatively clean viscous liquids (over 5000 SSU), use 10 to 12 mesh
screens or those with about 1/16 inch (about 1 12 mm) openings.
When pumping relatively clean light liquids such as distillate fuels, hydraulic oil and light
lube oils, use suction strainers of 100 to 200 mesh.
When pumping heavy crude oils, use 5 to 6 mesh strainer screens or those with or about
1/8 inch (3 mm) openings.
When pumping relatively clean distillate fuels in high pressure fuel supply systems, use
25 micron absolute filters for three screw pumps and 10 micron absolute filters for
gear pumps.
Make sure size/capacity of strainer or filter is adequate to prevent having to clean or
replace elements too frequently.
CAUTION ATTENTION
Before connecting pump to system, all system piping must be thoroughly flushed to re-
move debris which accumulates during fabrication, storage, and installation. Imo pumps
should not be used for flushing. One large, hard particle may cause internal damage,
possibly requiring a pump overhaul. Pay particular attention to suction line between suc-
tion strainer and pump to be sure it is clean.
Valves
Pressure Gage Pressure Gage
Strainer
Figure 9 - Ideal Strainer Arrangement
D.7.5 System Filtration

In systems that recirculate the pumped liquid, downstream (pressure and/or return side)
filtration should be installed. Downstream filters may also be required to protect compo-
nents such as servo valves in hydraulic systems or high-pressure fuel nozzles and flow
dividers in fuel oil supply systems for gas turbines.
The systems most contamination-sensitive component determines its liquid cleanliness
requirement. For optimum Imo pump life when running on fuel oil, light lube oil, hydraulic
oil and other relatively low viscosity (thin) liquids, a high efficiency 10 micron absolute
or finer filter is recommended. This same filter rating is recommended for pumps run-
ning at extreme operating conditions and/or in harsh environments. For pumps running
on relatively clean, more viscous (thicker) liquids, filter ratings as high as 25 micron
nominal may be acceptable as long as operating conditions and the operating environ-
ment are moderate. Imo should be contacted for filtration requirements for pumps
running on very low viscosity (water thin) and low lubricity as well as for those
with an unusually large quantity of contaminants.
The system builder determines filter size (dirt holding capacity) by the amount and size
of contamination expected to be produced by system and other external contamination
sources, by allowable pressure drop across filter and by acceptable frequency for clean-
ing/replacing filter elements.
D.7.6 Outlet Piping

In general, outlet piping should be sized to accommodate the pumps flow rate while
minimizing pipe friction losses. It should also be designed to prevent gas and air pock-
ets. Piping downstream of pump should include a vent at highest point in system to allow
air to escape during priming.
D.8 SHAFT PACKING AND SEAL LEAKAGE
The pump should be installed so any leakage from shaft packing or shaft seal does not become
a hazard. Packing leakage should be about 8 to 10 drops per minute. A small amount of liquid
may also leak from mechanical or lip seals (usually less then or equal to 10 drops per hour).
Provisions should be made to collect leakage from packing or shaft seals.
WARNING DANGER
If not appropriately collected, packing leakage may make floor slippery or expose person-
nel to hazardous fluids.
D.9 QUENCHED SHAFT SEALS

Some pumps include quenched mechanical shaft seals. For these pumps, a low pressure
stream of steam, nitrogen, or clean water is supplied from an external source to atmospheric
side of seal faces.
Quenching is used in selected seal applications to:
Heat or cool seal area.
Prevent build up of coke formations by excluding oxygen.
Flush away undesirable material build-up around dynamic seal components.
When quenched mechanical seals are part of pump assembly, an appropriate quenching
stream must be supplied by user.
NOTE: Refer to pump or pump/driver outline drawing and/or specific pumps instruction manual
for quench connection size and port locations.
D.10 GAGES
Pressure and temperature gages are recommended for monitoring the pumps operating condi-
tions. These gages should be easily readable and placed as close as possible to pumps inlet
and outlet flanges. See Figure 10a.
D.11 IDEALIZED INSTALLATION FOR PUMPS LOCATED ABOVE LIQUID LEVEL
Figures 10a and 10b are compilations of Figures 7, 8 and 9 showing good-practice installation
schemes for pumps located above the liquid reservoir in systems that recirculate the pumped
liquid.
Valves
SYSTEM
Temperature Relief Valve
Filter
Gage
Filling Pressure Gages

Port
Pressure Gages
Valves
Outlet
Suction
Strainer
Temperature
Inlet Trap Gage
Reservoir
Figure 10a Vertical Mounted Pump
Filling Port
Outlet
Inlet
Same as Figure 10a
Same as Figure 10a
Seal or Package Leakage Drain Line
Figure 10b - Horizontal Mounted Pump
E. Startup, Operation and Shutdown
CAUTION ATTENTION
Operation conditions, such as speed, liquid viscosity, temperature, inlet pressure, dis-
charge pressure, filtration, duty cycle, drive type, mounting, etc., are interrelated. Due to
these variable conditions, specific application limits may be different from pumps operat-
ing and structural limits. This equipment must not be operated without verifying systems
operating requirements are within the pumps capabilities.
DANGER
Make sure all power equipment is disconnected and locked-out before proceeding.
E.1 ELECTRICAL CONNECTIONS

Verify electrical requirements for driver match electrical supply with respect to voltage, number
of phases and terminal connections. Also, check that driver has been wired to rotate in correct
direction.
E.2 ROTATION
Before connecting couplings, check pump rotation to be sure it matches rotation of driver. When
coupling is connected and shafts are correctly aligned, pump should turn freely by hand. Rota-
tion direction is indicated by an arrow cast on casing or by an attached plate showing a rotation
direction arrow. See Figure 11.
CAUTION ATTENTION
Operating pump in the reverse direction may cause pump damage. Make sure rotation
direction is not confused with inlet or outlet flow direction arrows.
Outlet
Arrow
Inlet
Arrow
Rotation
Arrow
Figure 11 Rotation Arrow
E.3 HYDROSTATIC TESTING THE SYSTEM

Before any system is hydrostatically tested, pump must be removed or isolated.
CAUTION ATTENTION
To prevent damage to pump, it is necessary to remove or isolate it from the system prior to
starting hydrostatic testing.
E.4 PROTECTIVE DEVICES

E.4.1 General
Automatic shutdowns, emergency switches, and similar controls should be part of pumping
system. They are generally supplied by system supplier or user.
E.4.2 Covers and Guards
Before start-up, insure all protective-covers and guards are in place.
WARNING DANGER
To protect personnel from accidental contact with rotating couplings, sheaves, belts,
shafts,keys, keyways, etc., install the following covers or guards over:
Bracket openings on flange mounted pumps.
Couplings and shafts on foot mounted pumps.
Sheaves, gears, chains, belts or other type drives.
E.4.3 Valves
Check all valves, especially those that are manually operated, to be sure they are in the
proper position. Check that there is no possibility of starting pump with a blocked suction
or discharge line.
WARNING
Starting a pump with discharge line blocked and without adequate relief protection will
cause catastrophic pump failure and possible injury to personnel.
E.5 INTERMEDIATE DRIVE LUBRICATION
Some Imo pump units include intermediate gearboxes or other devices between pump and
driver. When these devices are present, lubrication is required. Add lubricant to specified level
per device manufacturers recommendations before start-up.
E.6 HEATING JACKETS
Some pumps require heating before start-up. See Section E.12 on Thermal Shock and Operat-
ing Temperature Limits. This is usually done with steam, hot water, heat transfer fluid or electric
heat strips. Some pumps are fitted with heating jackets (sometimes called steam jackets).
Where electric heating is used, fill jacket with appropriate heat transfer fluid prior to start-up.
Unless specified otherwise, maximum permissible pressure in a heating jacket is 150 psi gage.
WARNING
Provide safeguards to prevent personnel from coming in contact with hot liquid or other
heated equipment surfaces.
E.7 QUENCHED SHAFT SEALS

When quenching fluid is hot water or steam, apply to seal at least 30 minutes prior to pump
start-up to insure seal area is thoroughly heated. When steam is used, it should be saturated at
about 4 to 7 psi gage. When quench fluid is ambient temperature nitrogen, it can be applied just
prior to pump start-up.
E.8 PUMPED LIQUIDS
NEVER operate a pump with water. The pump is designed for liquids having general character-
istics of oil. In closed or recirculating systems, check liquid level in tank before and after start-up
to be sure it is within operating limits. If initial liquid level is low, or if it drops as system fills during
start-up or pumping operations, add sufficient clean liquid to tank to bring liquid to its normal
operating level. Only use liquid recommended or approved for use with the equipment. Regular
checks should be made on the condition of the liquid. In closed systems, follow suppliers
recommendations for maintaining liquid and establishing when liquid is to be changed. Be sure
temperature is controlled so liquid can not fall below its minimum allowable viscosity which
occurs at its maximum operating temperature. Also, insure that maximum viscosity at cold
start-up does not cause pump inlet pressure to fall below its minimum required value.
CAUTION ATTENTION
NEVER operate a pump without liquid in it!
Operate only on liquids approved for use with pump.
WARNING
If not appropriately collected, packing or seal leakage may make floor slippery and/or
expose personnel to hazardous fluids.
E.9 PRIMING
Prime pump before initial start-up by pouring some of liquid to be pumped into fill point in system
or directly into pump suction port. Rotate pump slowly by hand until rotors or gears (pumping
elements) are wet and suction line is as full of liquid as possible. See Figure 12. Also, fill
mechanical seal chamber with liquid to insure seal does not start dry.
CAUTION
Dry-starting a pump is likely to cause damage to pumping elements and shaft seal.
Priming
Point
Figure 12 Priming Point

E.10 START-UP
It is suggested that the driver be started and immediately stopped (jogged) three or four times in
order to verify proper pump rotation and to insure pump is filled with liquid. Open bleed port at
high point in system and vent trapped air until a solid stream of liquid emerges (where practical).
When pump is running, check for unusual noise or vibration. Investigate any abnormalities.
Check inlet and outlet gages to see if pump is operating within its ratings. Generally, differential
pressure across pump should be at least 25 psi to insure proper pump operation.
WARNING
Precautions must be taken when venting air in system using hazardous liquids.
Provide hearing protection whenever high noise levels are expected from system com-
ponents and/or environment.
If operating temperatures exceed 140 F (60 C), measures should be taken to avoid
skin contact.
E.11 SHAFT PACKING (STUFFING BOX) LEAKAGE
Pumps with packing-type seals must be checked to insure packing gland is not too tight. Exces-
sive gland pressure on packing will cause a scored shaft, overheating and rapid breakdown of
packing. Keep gland nuts only finger tight. After new packing has been installed, gland nuts
should be tightened evenly but only tight enough to seat packing rings properly. Then, loosen
gland nuts and re-tighten finger tight. The final adjustment should allow a leakage of approxi-
mately ten drops per minute while pump is operating. This leakage is necessary to lubricate the
packing. Provide a place for safe draining and disposal of this leakage.
WARNING
If not appropriately collected, packing leakage may make floor slippery and/or expose
personnel to hazardous fluids.
E.12 THERMAL SHOCK AND OPERATING TEMPERATURE LIMITS

During pump start-up, as well as during pump operation, pump must not see a thermal shock
greater than 50 F (28 C) from liquid entering the pump. Rapid temperature changes beyond
this limit must be avoided. Unless approved by Imo, liquids entering pump inlet must not be
hotter than 225 F (107 C) nor colder than 0 F (-18 C). Most pumps also have temperature
limits of 225 F to 0 F. The maximum rate of temperature change during pump heating or
cooling should be about 1.5 F/minute (0.8 C/minute). A heated or cooled pump should be held
at its start-up temperature for at least an hour prior to start-up. This will insure uniform tempera-
ture distribution throughout pump assembly.
CAUTION ATTENTION
Never exceed minimum or maximum allowable pump or liquid temperature. Do not expose
equipment to thermal shock. Differences in metallurgy and their respective coefficients of
expansion could cause distortion of pump parts resulting in a breakdown condition. Use of
insulation and heating jacket or heat tracing to maintain pump at liquid temperature is
recommended in high temperature applications.
E.13 SHUTDOWN
If system is to be shut down for a short period, do not drain pump as this would require re-
priming at start-up. If pump is to be stored, apply a rust-inhibiting agent (one compatible with all
pump materials) to all internal and external surfaces, especially those that are machined.
F. MAINTENANCE
DANGER
BEFORE starting any maintenance procedure, do the following:
Shut off all power switches and circuit breakers.
Remove any electrical service fuses.
Lock electrical service panel supplying power to driver.
Shut, wire or chain, and lock all valves in pump inlet/outlet piping.
If applicable, shut off any steam or other fluid supply lines to pump.
F.1 FILTERS AND STRAINERS
All filter and strainer elements should be periodically checked for cleanliness and cleaned or
replaced as necessary. This will protect equipment from damage due to pressure-drop across
clogged or dirty elements.
F.2 FOUNDATION
Foundation and hold-down bolts should be checked for tightness at least every six months.
F.3 ALIGNMENT
Alignment of pump and its driver should be checked and corrected, if necessary, at least every
six months. If system experiences an unusual amount of vibrations or large variations in operat-
ing temperatures, this should be done often. Well-maintained alignment will help insure maxi-
mum equipment life.
WARNING
Rotating parts, such as couplings, pulleys, external fans, or unused shaft extensions should
be permanently guarded against accidental contact with personnel or clothing. This is
particularly important where parts have surface irregularities such as keys or setscrews.
F.4 LUBRICATION
F.4.1 Bearings
Pump environment, operating conditions and intervals between bearing checks all effect
bearing life. Bearings have a finite life and should be checked often for increase in
temperature and/or rough operation. If either condition is noted, stop equipment and
replace bearing. When grease or oil fittings are provided, lubricate bearings as specified
in applicable pump instruction manual.
CAUTION ATTENTION
Continued running with a rough or worn bearing can lead to catastrophic bearing failure
which could cause seal and/or pump failure.
F.5 PACKING
A pump should be repacked when all packing gland travel is exhausted or when packing is
damaged. Follow packing replacement instructions in applicable pump instruction manual.
F.6 SHAFT SEALS AND LEAKAGE
Visually check equipment frequently for signs of damage/leakage from shaft seals, gaskets or
O-rings. Be sure all connections are tight. If seal leakage is more than about 10 drops per hour
per seal, shut down equipment and repair or replace necessary parts. Shaft seals have a finite
life which is affected by operating conditions and environment. Expect them to wear and even-
tually fail. When leakage becomes unacceptable, replace seal unit with one compatible with
pumps operating conditions. Dirty liquids will reduce seal life.
NOTE: A very small amount of leakage (10 drops per hour per seal) is normal, even when
shaft seals are new.
NOTE: Make sure any seal leakage is disposed of properly.
WARNING
Since leakage or seal failure can be expected to eventually occur, be sure installation can
withstand this situation. Take appropriate measures if liquid is hazardous.
F.7 SPARE PARTS

Where pump out-of-service time is of vital concern, and this down time must be minimized, a set
of spare parts or repair kits should be retained on-site.
F.8 DISASSEMBLY AND REASSEMBLY
Various procedures for disassembly and reassembly apply to different pumps. Refer to the
specific pump instruction manual on how to perform these procedures.
G. FIELD AND FACTORY SERVICE AND PARTS

Imo Pump maintains a staff of trained service personnel that can provide pump installation, pump
start-up, maintenance/overhaul and troubleshooting supervision as well as installation and mainte-
nance training.
Our factories provide maintenance as well as overhaul and test facilities in the event the user prefers
to return pumps for inspection or overhaul. Pumps that have been factory-overhauled are normally
tested and warranted as-new for a period of one year from date of shipment.
For either field service or factory overhaul assistance, contact your local Imo Sales Office or repre-
sentative at the Technical/Customer Service Department in Monroe, NC, USA.
Most pumps have repair kits available. Minor Repair Kits are used to repair leaking seals, bad bear-
ings and/or for re-assembly after pump tear-down. They include (as applicable) pump shaft seals,
packing, all gaskets/O-rings and bearings. Major Repair Kits are sufficient to rebuild completely
worn-out pumps to as-new condition. They include all parts found in Minor Repair Kits plus all major
internal parts subject to wear. Since kits have all the necessary parts, it is preferred that they be
purchased rather than selecting individual parts. When parts are individually selected from the Parts
List, some needed components are often overlooked. In addition, mixing worn or used parts with new
parts risks rapid wear and shortened service life from the new parts.
H. TROUBLESHOOTING
MALFUNCTION POSSIBLE CAUSE REMEDY

System component malfunction Inspect all system components.
Correct any malfunctions. Insure that
suction and discharge lines are open
and all valves are in proper positions.
Pump not primed or vented Check reservoir oil level and fill as
required. Vent air from pump.
Low pump speed Insure driver is not overloaded. For
belt drives, insure belt not slipping. For
variable speed drivers or variable
speed intermediate devices, insure
Loss of Flow proper speed is set.
or Low Capacity Incorrect pump rotation Correct directioon of driver rotation.
Obstruction in piping Inspect all system piping and valves.
Remove any obstructions.
Wear of rotors and/or housings Replace worn rotors, gears, and/or
housing(s).
System bypass Check all system bypass valves,
including relief valve. Repair or replace
as required.
Insufficient inlet pressure Remove obstruction. Clean suction
strainer or filter element.
Suction line closed, blocked Verify suction line valve is locked open.
or leaking Inspect suction line, especially joints.
Remove any obstruction and repair any
leaks. Clean strainer or replace filter.
Loss of Suction Excessive viscosity Reduce viscosity by heating pump

and/or system liquids.
Dirty suction strainer Clean or replace strainer or filter
element.
Wrong direction of rotation Correct direection of driver rotation.
Low liquid level in reservoir Check liquid level in reservoir. Fill as
necessary.
Air in system Insure pump is vented and suction
lines are full of liquid.
Worn rotors, gears, and/or Replace worn rotors, gears, and/or
housing(s) housing(s).
Low Discharge
Pressure Obstruction in piping Inspect inlet piping and suction
valve(s). Remove any obstruction(s).
Dirty suction strainer Clean/replace suction strainer or filter
element.
System bypass problem Check all system bypass valves for
leakage, including relief valves. Repair
or replace as as required.
H. TROUBLESHOOTING (Continued)
MALFUNCTION POSSIBLE CAUSE REMEDY
Misalignment Check pump and driver alignment and
correct as required.
Restricted suction line Check suction line and remove any
obstructions.
Air in system Insure pump is vented and suction
lines are full of liquid. Check reservoir
level. Fill as necessary. Check all
lines, flanges, joints and connections
Excessive for leakage. Repair as necessary.
or
Dirty suction strainer Clean suction strainer or filter element.
Unusual Noise
or Relief valve chatter or leakage Check discharge relief valve pressure
Vibration setting. Re-adjust, repair or replace
relief valve.
Heavy internal rubbing of pump parts Verify pump and driver alignment.
Inspect pump wearing parts. Replace
as required.
Mechanical problem Check for loose or mis-positioned
coupling, bent or broken shafts, or
worn bearing. Repair or replace as
required.
Fluid contains abrasive foreign Collect samples of liquid and test for
matter foreign matter. Reduce downstream
filter ratings in re-circulating systems
(do not exceed NPIPR). If necessary,
replace liquid in re-circulating systems.
Fluid contains water Remove any water from reservoir.
Find source and prevent further
Rapid Pump Wear ingestion.
Misalignment Check pump and driver alignment.
Correct as required.
Insufficient liquid Check liquid level in reservoir and
correct as required. Remove any
suction line obstructions.
Clean/replace strainer or filter element.
Fluid more viscous than specified Heat fluid to proper viscosity and/or
design temperature.
Pump suction and/or discharge lines Insure suction and discharge lines are
closed or blocked open, and remove obstructions if
present.
Excessive Heavy internal rubbing of pump parts Verify pump and driver alignment.
Power Inspect pump wearing parts. Replace
Usage as required.
Excessive pump speed Reduce pump speed to design limits.
Mechanical problems Check for bent shaft, tight shaft
parking, or pipe strain. Repair or
replace as required.
Use QuickServe TM
for fast shipment of

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Pump
Now, many of our most popular pumps, repair kits and spare parts are available from this Imo Pump
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on the web at www.Imo-Pump.com
Imo Pump
1710 Airport Road
PO Box 5020
TM Monroe, NC USA
28111.5020
Pump tel 704.289.6511
fax 704.289.9273
Quality Management System email IMO.PUMP@COLFAXCORP.COM
1997 Imo Pump All rights reserved.

TM
INSTRUCTION MANUAL
AND
PARTS LIST
FOR
3G SERIES PUMPS
SIZES 187 THROUGH 250
(Iron Version Only)
WARNING
This Special Instruction Manual and General Instructions Manual, CA-1,
should be read thoroughly prior to pump installation, operation or
maintenance.
SRM00074 Rev. 0 (01-0228) May 02, 2001

READ THIS ENTIRE PAGE BEFORE PROCEEDING
FOR THE SAFETY OF PERSONNEL AND TO PREVENT DAMAGE TO THE EQUIPMENT,
THE FOLLOWING NOMENCLATURE HAS BEEN USED IN THIS MANUAL:
DANGER
Failure to observe the precautions noted in this box can result in severe bodily
injury or loss of life.
WARNING
Failure to observe the precautions noted in this box can cause injury to personnel
by accidental contact with the equipment or liquids. Protection should be provided
by the user to prevent accidental contact.
CAUTION ATTENTION
Failure to observe the precautions noted in this box can cause damage or failure
of the equipment.
Non compliance of safety Safety instructions where Safety instructions which

instructions identified by electrical safety is shall be considered for
the following symbol involved are identified by: reasons of safe operation
could affect safety for of the pump and/or
persons: protection of the pump
itself are marked by the
sign:
ATTENTION
CONTENTS
Safety and Table of Contents..................................................................................................... A
General Instructions ....................................................................................................................1
Pump Model Identification ...........................................................................................................1
Description of the Equipment ......................................................................................................2
Ordering Instructions...................................................................................................................2
Operation ....................................................................................................................................2
Spare Parts and Kits ...................................................................................................................3
Inspection of Parts ......................................................................................................................4
Pump Maintenance .....................................................................................................................4
Pump Disassembly Instructions ..................................................................................................4
Pump Assembly Instructions .......................................................................................................7
Troubleshooting ..........................................................................................................................7
Pump Assembly Drawings .................................................................................................. 8 - 12
ATTENTION
If operation of this pump is critical to your business, we strongly
recommend you keep a spare pump or major repair kit in stock at all times.
As a minimum, a minor repair kit (o-rings, gaskets, shaft seal and bearings)
should be kept in stock so pump refurbishment after internal inspection can
be accomplished.
A
A. GENERAL INSTRUCTIONS
The instructions found herein cover the disassembly, assembly and parts identification of the 3G-187
through 250 Series, Imo pumps.
NOTE: Individual contracts may have specific provision that vary from this manual. Should any
questions arise which may not be answered by these instructions, refer to the General
Instructions Manual, CA-1, provided with your order. For further detailed information and
technical assistance please refer to Imo Pump, Technical Service Department at (704) 289-6511.
This manual cannot possibly cover every situation connected with the installation, operation, inspection
and maintenance of the equipment supplied. Every effort was made to prepare the text of the manual so
that engineering and design data is transformed into the most easily understood wording. Imo Pump must
assume the personnel assigned to operate and maintain the supplied equipment and apply this instruction
manual have sufficient technical knowledge and are experienced to apply sound safety and operational
practices which may not be otherwise covered by this manual.
WARNING
If installation, operation and maintenance instructions are not correctly and strictly followed and
observed, injury to personnel or serious damage to pump could result. Imo Pump cannot accept
responsibility for unsatisfactory performance or damage resulting from failure to comply with instructions.
B. INTRODUCTION
This instruction manual covers series 3G Imo Pumps. This series of pumps has been designed for general
use in lubricating, seal and distillate fuel oil applications. The size and construction of each pump is
identified in the model number on the pump nameplate. Definitions of model designators are identified in
Figure 1.
Figure 1 Model Designator Definitions

1
C. DESCRIPTION OF EQUIPMENT
The 3G Series pumps are positive displacement, rotary screw pumps consisting of a precision bored
housing that encloses a drive screw (power rotor) and two intermeshing driven screws (idler rotors).
These screws, when rotating, form a succession of closures or cavities. As they rotate, the fluid is moved
axially from the inlet to the outlet port in a continuous, uniform flow with minimum fluid pulsation and
pump noise.
D. ORDERING INSTRUCTIONS
To order replacement pump or parts, contact an Imo sales office or representative with pump model
number, serial number and part IDP number. This information can be found on pump nameplate and in
this manual.
E. OPERATION
LIQUID LIMITATIONS
Never operate with water. The pump is designed for liquids having the general characteristics of
lubricating oil or distillate fuel oils
OPERATING LIMITS
CAUTION ATTENTION
Operating conditions, such as speed, fluid viscosity, temperature inlet pressure,
discharge pressure, filtration, duty cycle, drive type, mounting, etc., are
interrelated. Due to these variable conditions, the specific application limits may
be different from that of the operational limitations. This equipment must not be
operated without verifying the systems operating requirements are within the
pumps capabilities.
Under no circumstances are operating and structural limits (specified in Table 1) to be exceeded
without specific approval from Imo Pump.
Table 1 Pump Operating and Structural Limits

Maximum Speed .................................... 4000 RPM for 187/200 models and 3600 RPM for 250 models.
Viscosity....................... 15000 SSU (3200 cSt) Max./ 1500 SSU (325 cst) Max. for Relief Valve models.
2.0 cst Minimum for all models
NOTE: Consult factory for allowable operating viscosity at specific speeds and pressures.
DO NOT alter design viscosity without prior consultation with Imo Pump.
Temperature ..................................................................................................0 to 225F (-18 to 107C)
Inlet Pressure........................................................................................................ 50 psig (3.4 Bar) Max.
Differential Pressure......................................................................................... 250 psig ( 17.2 Bar) Max.
Discharge Pressure............................................................................................. 300 psi (20.7 Bar) Max.
Drive ............................................................................................................................. Direct Drive Only
Filtration .......................................................................................See General Installation Manual, CA-1
Mounting ............................................................................................................ Foot or Flange Mounted
Shaft Rotation .................................................................................... Available in CW or CCW versions.
Pump is NOT bi-rotational.
2
MODELS WITH RELIEF VALVES
CAUTION ATTENTION
The optional built-in relief valve is intended for momentary protection of the pump
against overpressure. It is not intended to be a pressure or flow control device.
Continuous bypass of pumped liquid through this valve will cause the liquid to heat
up very rapidly. Excessive temperature rise will damage the pump.
The optional externally connected relief valve can be used as a pressure or flow
control device if its bypass line is piped back to the fluid tank and not the pump
inlet. The minimum and maximum relief valve set pressures are 60 psid (4.1 Bar)
and 255 psid (17.6 Bar) respectively.
DANGER
Relief valves are pre-set at the factory. DO NOT TAMPER WITH RELIEF VALVE. Tampering
with relief valve will void pump warrantee and can cause bodily injury or loss of life. If relief
valve must be adjusted, return pump to factory.
PARTS LIST TABLE TABLE 2
IDP QTY DESCRIPTION IDP QTY DESCRIPTION

1 1 Housing 13 1 Key
2 1 Inlet Cover 15 X 1 Retaining Ring
3 8 Bolt 16 X 1 Seal
4 1 Inboard Cover 26 X 1 Inlet Cover O-Ring
7 1 Shaft 31X 1 Inboard Cover O-Ring
8 2 Idler Rotor 47 1 Pipe Plug
11X 1 Ball Bearing 95 1 Pin
X = Minor Repair Kit Item
INSPECTION
The interval for inspection and replacement of worn parts varies with the properties of the pumped liquid
and can only be determined by experience. All internal parts of the 3G Series pumps are lubricated by the
pumped fluids. Pumping liquid which contains abrasive materials or liquid that is corrosive, will
significantly reduce service life and call for shorter service intervals. A worn pump will be noticeable by
excessive vibration, noise, reduction in flow output and/or reduction in system pressure.
3
PUMP MAINTENANCE
WARNING
Failure to observe precautions while installing, inspecting, and maintaining the pump can
cause injury to personnel from accidental handling, e.g.: Liquids that may harm skin or
clothing, fire hazard risks from flammable liquids, or injury from high pressure fluid jets.
DANGER
BEFORE working on equipment, be sure all power to the equipment is disconnected and
locked-out.
GENERAL COMMENTS
Part number identifiers (IDPs) contained in Table 2 and shown within parenthesis such as (8) refer to the
circled numbers shown on the assembly drawings.
NOTE: If upon disassembly, significant wear on power or idler rotors or rotor housing is found,
Imo Pump recommends replacement of the entire pump.
TOOLS REQUIRED
The procedures described in this manual require common mechanics hand tools, an arbor press, a torque
wrench and a suitable lifting device such as a sling for smaller pumps or a strap for larger models.
PUMP DISASSEMBLY SEE ASSEMBLY DRAWING, FIGURE 4

CAUTION ATTENTION
Fluid leakage from disassembly of pump may make the floor slippery
and cause personal injury.
The following steps are required before starting any maintenance action:
a) De-energize and lock out power to driver and tag power control box WARNING - Out of Service.
b) Close all inlet and outlet valves and tag valves WARNING - Out of Service.
c) Vent pressure from pump and drain pumping liquid.
d) Remove pipe fittings/flanges at pump inlet and outlet openings.
e) Remove bolts holding pump to its mounting.
f) Remove coupling hub and key (13) from power rotor (7) shaft and locate pump on a suitable
workbench.
NOTE: The 3G Series pumps incorporate highly finished precision parts that must be handled carefully to
avoid damage to critical machined surfaces. The parts removed should be tagged for identification
and their exact positions in the pump carefully noted so that new parts, or the removed parts can
be properly replaced.
CAUTION ATTENTION
When removing inboard cover (4) from pump in step 1, below, DO NOT pull out
the rotors (7 & 8) since they may drop to floor and be damaged. If rotors start to
come out, hold them in place.
4
1. Remove bolts (3) from inboard cover (4) and then remove inboard cover (4) from pump housing (1).
2. For lip seal installed pumps, remove lip seal (16) and O-ring (31) from inboard cover (4). For
mechanical seal installed pumps, remove stationary seat of seal (16) and O-ring (31) from inboard
cover (4).
CAUTION ATTENTION
In next step, the rotors will be removed from the pump. They will come out as a
unit. Use care to support the rotors set as it is withdrawn from the housing so the
idlers will not be dropped on the floor.
3. Remove power rotor (7) and idlers (8) by grasping shaft of power rotor and easing it out of housing
(1). Set idlers (8) aside.
4. For mechanical seal pumps, perform the following:
a) For Elastomeric Bellows Type Seals (see Figure 2 below) Slide rotating assembly (3) of
mechanical seal (16) off power rotor (7).
b) For Metal Bellows Type Seals (see Figure 3 below) Loosen set screw (3F) and slide rotating
assembly (3) from power rotor (7).
NOTE: IF ONLY REPLACING SEALS, pump disassembly is complete. For lip seal installation,
proceed to Pump Reassembly and complete steps 3, 4, 8 through 11 and 13 through 16.
For mechanical seal installation, complete steps 3, 5 through 10 and 12 through 16. If
remainder of pump needs to be disassembled, proceed below.
5. Remove ball bearing (11) from power rotor (7) by first removing the retaining ring (15) from the
groove in the power rotor (7) shaft. The ball bearing (11) can then be removed with a gear puller or
arbor press.
CAUTION ATTENTION
Removal of bearing by force applied to its outer ring could damage bearing.
NOTE: Imo Pump strongly recommends replacement of the ball bearing every time the bearing is
pressed off the power rotor.
6. Remove inlet cover (2) by removing four bolts (3).
7. Remove O-ring (26) from inlet head (2).
5
PUMP REASSEMBLY SEE ASSEMBLY DRAWING FIGURE 4
NOTE: Prior to pump assembly, all parts should be cleaned and inspected for nicks, burrs or
gouges. When ready for assembly, wipe all parts, including bolts, O-rings and seal
faces with clean, lubricating oil or pumped product, if applicable.
CAUTION ATTENTION
Bearing service life could be significantly reduced if the bearing is pushed on by its
outer race.
1. Install ball bearing (11) onto shaft (7) using an arbor press and sleeve by pushing on ball bearing
(11) inner race only until ball bearing (11) is positioned against shoulder on power rotor (7).
2. Install retaining ring (15) in groove in power rotor (7).
3. Before installing seal (16), insure power rotor (7) shaft is clean and has no burrs or sharp edges.
4. If pump has a lip seal (16), install lip seal into outboard cover (4) and skip to step 7 below.
Note: Seal Lip is graphite impregnated Teflon and should not be lubricated when installed.).
5. If pump has mechanical seal (16), apply clean lubricating oil to rotor shaft at seal diameter.
a. If seal has elastomeric rubber bellows, (see figure 2), apply light film of oil to bore of bellows
and install rotating assembly (3) on power rotor (7) shaft with a twisting motion by pushing on
seal retainer only with fingers. Do not touch carbon face with fingers. Clean carbon face of seal
with alcohol and lint free cloth. Apply light film of clean lubricating oil to carbon face.
b. If seal is metal bellows type, (see figure 3), apply a light film of oil to rotating seat O-ring of
seal and slide rotating assembly (3) on power rotor shaft (7). Tighten setscrew (3F). Do not
touch carbon seal face with fingers. Clean carbon face of seal with alcohol and lint free cloth.
Apply light film of clean lubricating oil to carbon face.
6. Apply light film of clean lubricating oil on seat and O-ring of stationary seat (3B) of mechanical seal
(16). Install stationary seat (3B) into bore in inboard cover (4) with fingers (do not touch seal face
with any tools) so slot in face of seal is facing into inboard cover (4). Be sure stationary seat (3B) is
all the way to bottom of the bore in inboard cover (4) and slot in seal mates up to pin (95) in inboard
cover (4).
7. Clean stationary seat of mechanical seal (16) in inboard cover (4) with alcohol and soft, lint free
cloth, and apply light film of clean lubricating oil to carbon face.
8. Mesh the two idler rotors (8) and power rotor (7) together into a rotor assembly making sure idler
rotors and balance piston are properly engaged.
9. Install rotors by positioning pump housing in a vertical position and sliding rotor assembly into
housing bore (1) until ball bearing (11) bottoms out in housing bore.
10. Install O-ring (31) in groove in inboard cover (4).
11. If pump has lip seal (16), install seal installation tool (see figure 8) on coupling end of power rotor (7).
Then, carefully install inboard cover (4) on housing being sure that inboard cover (4) is kept square
with power rotor shaft and inner lip seal lip (16) does not roll under as cover (4) is installed
CAUTION ATTENTION
Failure to use seal installation tool (see Figure 8) on lip seal units is likely to result
in improper lip seal installation.
6
12. If pump has mechanical seal, install inboard cover (4) on housing (1) without seal installation tool.
CAUTION ATTENTION
To maximize seal life, seal vent in cover must be oriented at 12:00
o'clock when pump is horizontally mounted in its installed position.
Vent orientation is not critical when unit is vertically mounted.
13. Install the four bolts (3) into inboard cover (4) and thread bolts into housing (1). Torque bolts to
values shown on assembly drawing.
14. Install O-ring (31) in groove in inlet head (2).
15. Install inlet head (2) onto housing (1) with cap screws (3).
16. Installing key (13) into power rotor (7) keyway and coupling on shaft (7).
17. On pumps with external relief valves, install relief valve using cap screws (5) and O-ring (10). See
figure 8. Relief valve can be installed in original position or facing 180 from original position.
INSTALLATION, ALIGNMENT AND TROUBLESHOOTING

Install coupling to driver shaft and align pump and driver as detailed in the Installation Manual, CA-1.
After pump is connected to piping and inlet and outlet valves are open, be sure to vent air from seal
chamber before starting pump by opening pipe plug at inboard end of pump until oil comes out. This will
assure that seals are lubricated at startup.
For detailed instructions regarding installation, alignment, operation and trouble shooting, see General
Installation, Operation, Maintenance & Troubleshooting Manual, CA-1.
FIELD AND FACTORY SERVICE AND PARTS
Imo Pump maintains a staff of trained service personnel that can provide pump installation, pump start-up,
maintenance/overhaul and troubleshooting supervision as well as installation and maintenance training.
Our factories provide maintenance as well as overhaul and test facilities in the event the user prefers to
return pumps for inspection or overhaul. Pumps that have been factory-overhauled are normally tested
and warranted as-new for a period of one year from date of shipment.
For either field service or factory overhaul assistance, contact your local Imo Sales Office or
representative at the Technical/Customer Service Department in Monroe, NC, USA.
Most pumps have minor repair kits available. Minor Repair Kits are used to repair leaking seals, bad
bearings and/or for re-assembly after pump tear-down. They include (as applicable) pump shaft seals,
packing, all gaskets/O-rings and bearings. Since kits have all the necessary parts, it is preferred that they
be purchased rather than selecting individual parts. When parts are individually selected from the Parts
List, some needed components are often overlooked. In addition, mixing worn or used parts with new
parts risks rapid wear and shortened service life from the new parts.
7
Figure 4 Pump Assembly Drawing
8
A MEMBER OF THE
COLFAX PUMP GROUP
Imo Pump
1710 Airport Road
PO Box 5020
Monroe, NC USA
28111.5020
tel 704.289.6511
fax 704.289.9273
email Imo.Pump@ColfaxCorp.com
web WWW.IMO-PUMP.COM
2001 Imo Pump All rights reserved.

Flexible Drive Couplings
INDEX:
Magnaloy Coupling
DesignFeatures..............2
Load Lock Design.................................2
Radial Lug Design.................................2
Lug Design Comparisons....................2
Premiium Flexible
Drive Couplings...........2
Performance Specifications................3
Dimension Specifications....................4
Standard Bore & Keyway
Combinations.........................................5
Bore Tolerances.....................................5
Additional Specifications.....................5
Splined Couplings.................................6
Clamp Type Couplings.........................6
Steel Bushed Couplings.......................6
Splined Coupling
Specifications.........................................7
Clamp Type Coupling
Specifications.........................................7
Insert Selection Guide..........................8
Service Factors & Load
Characteristics.......................................9
Selection Method..................................9
Installation...........................................10
Recommended Torques
for Fasteners........................................11
Mis-Alignment
Capabilities..........................................11
Technical Bulletin
& Notes.................................................12
PM 90
Coupling ........................13
Drive Lug Features.............................13
Performance Specifications.............14
Dimensional Specifications.............14
Bore Tolerances..................................14
Bore & Keyway Combinations........15
Insert Materials...................................15
Other Magnaloy
Products...........................16
magnaloy coupling company P.O. Box 455 Alpena, MI 49707 989-356-2186 1

A Division of Douville Johnston Corporation Fax: 989-354-4190 http://www.magnaloy.com
Magnaloy Coupling Design Features
Load-Lock Design is simple and effective. The drive-lug

configuration is tapered from top to base, as are the mating
lugs of the opposing coupling hub. Under load, the insert
conforms to the tapers, inter-locking the two hubs. This load-
lock design protects bearings and equipment by eliminating
end thrust in both directions... and it requires only one
set-screw in each hub.
Radial Lug Design is logical and efficient. The most common failure of an
elastomeric insert type drive coupling is hysteresis failure of the elastomeric
element - breakdown of the elastomer due to cyclical overworking
and associated heat generation. Magnaloy Couplings drive lugs
are in a true radial orientation. Applied forces are evenly distributed
in the compressive direction only, eliminating the heat generating
radial component. True compressive loading reduces internal heat
generation and improves elastomer life.
F
MAGNALOY COUPLING DESIGN
F Under loaded conditions, the resultant forces applied
on the element segments are evenly distributed in the
compressive direction only. This results in no radial
F forces to multiply the internal heat generation.
F
Fc Fr CONVENTIONAL DESIGN A
F Under loaded conditions this jaw design results in the
applied forces exerting components in the compressive
and radical directions. These forces change direction
and magnitude along the jaw arc which greatly increase
F the internal movement of the element which causes heat
Fc generation.
Fr
Fc
CONVENTIONAL DESIGN B
Fr
This more conventional straight sided jaw design also
F exerts component forces in the compressive and radial
directions when under load. The radial component is
outward (acting to extrude the element) and changes
Fc in magnitude only, as does the compressive component,
along the jaw surface. The component forces resulting
F
Fr from this design also causes increased internal
movement in the element.

Magnaloy is a registered trademark of the Douville Johnston Corp.
Premium Flexible Drive Couplings
Magnaloy is the original lightweight, heavy-duty

flexible drive coupling. Light weight magnesium
construction makes Magnaloy couplings 76% lighter
than cast iron and 36% lighter than aluminum units...
and theyre stronger than either!
The benefits are many... Reduced loads on
bearings, shafts and pumps, for longer component
life. Easier handling and installation. Rust proof and
corrosion resistant.
Magnaloys close machining tolerances
(TIR of .002) assures vibration - free operation and
easy, accurate alignment without need for special
tools. Solid magnesium alloy permanent mold
castings are heat treated and offer the highest
strength-to-weight ratio available.
Coupling Performance Specifications

Rated Torsional Horse Power Rating@
Coupling Maximum Wr2 Insert Torque Rigidity 100 1200 1800
Model Bore lb.- ft2. Number lb.- in. lb-in/Deg rpm rpm rpm
170N 340.7 42 .55 6.5 9.8
100 1-1/8 .0046 170U 511.0 53 .82 9.8 14.7
170H 1,022.1 182 1.65 19.8 29.7
270N 398.3 55 .64 7.6 11.5
200 1-3/8 .0068 270U 597.4 68 .96 11.5 17.2
270H 1,194.9 234 1.92 23.0 34.5
370N 701.4 81 1.12 13.5 20.2
300 1-5/8 .022 370U 1,052.1 148 1.68 20.2 30.3
370H 2,104.2 336 3.36 40.4 60.6
470N 1,056.3 138 1.69 20.3 30.4
400 1-7/8 .031 470U 1,584.5 310 2.5 30.4 45.6
470H 3,168.9 488 5.1 60.8 91.3
570N 2,194.8 314 3.5 42.1 63.2
500 2-3/8 .071 570U 3,292.2 695 5.3 63.2 94.8
570H 6,584.4 1,571 10.5 126.4 189.6
670N 4,946.7 676 7.9 94.9 142.5
600 2-5/8 .16 670U 7,420.1 1,510 11.9 142.5 213.7
670H 14,840.1 2,960 23.7 284.9 427.4
770N 11,639.8 1,805 18.6 223.5 335.2
700 2-7/8 .34 770U 17,459.7 2,104 27.9 335.2 502.8
770H 29,099.5 - 46.5 558.75 838.0
870N 21,889.4 3,680 35.0 420.3 630.4
800 3-7/8 .95 870U 32,834.1 - 52.5 630.4 945.6
870H 47,062.2 - 75.2 903.0 1,354.5
970N 47,842.3 8,428 76.5 918.6 1,377.9
900 4-3/4 4.20
970U 71,763.5 - 114.8 1,377.9 2,066.8

Dimensional Specifications
Magnaloy Coupling Dimensional Specifications
X
Models 100, 200, 300, 400 T W
100 200 300 400
A 2.54 3.10 3.58 4.24
B 2.600 2.900 3.450 3.980
C 2.00 2.25 2.90 3.05
D 0.56 0.68 0.78 1.00
E 0.68 0.84 0.96 1.06 C B
F 0.42 0.42 0.44 0.54
G 0.31 0.43 0.56 0.73
W 1/16 1/16 1/16 1/16
X 0.90 0.90 0.98 1.20
T 1/4-20 5/16-18 5/16-18 3/8-16
D E F G
TOLERANCES: 2 Place Decimals + .01
3 Place Decimals + .001 A
X
Model 500 T W
500
A 4.67
B 4.800
C 4.00 X*: Maximum Space between
D 1.04 shaft ends to allow full
E 1.23
shaft engagement
in Hub Bore.
CB
F 0.64
G 0.70 Y*: Minimum spacing
between shaft ends.
W 1/16
X 1.41
T 3/8-16
* Given for reference only.
TOLERANCES: 2 Place Decimals + .01
D E F G
X
Models 600, 700, 800, 900 T W
600 700 800 900
A 5.98 6.99 7.99 10.15
B 5.975 6.900 8.600 11.400
C 4.50 5.19 7.00 8.30
D 1.60 2.08 2.25 2.75
E 1.33 1.32 1.62 2.20 C B
F 0.62 0.89 1.00 1.32
G 1.13 1.13 1.58 1.88
W 1/16 1/16 1/16 1/16
X 1.36 1.97 2.25 2.89
T 3/8-16 1/2-13 1/2-13 3/4-10
TOLERANCES: 2 Place Decimals + .01 D E F G


Bore & Keyway Combinations
Standard Bore and Keyway Combinations

Magnaloy Standard Bore & Key Combinations Magnaloy Standard Bore & Key Combinations
Model Bore/Key Model Model Bore/Key Model
100
200
300
400
500
600
700
800
100
200
300
400
500
600
700
800
900
900
Code Code Bore Key Code Code Bore Key
M __ __ __ 01203 3/8 x 3/32 M __ __ __ 12414 1 3/4 x 7/16
M __ __ __ 01403 7/16 x 3/32 M __ __ __ 12816 1 7/8 x 1/2
M __ __ __ 01404 7/16 x 1/8 M __ __ __ 13016 1 15/16 x 1/2
M __ __ __ 01604 1/2 x 1/8 M __ __ __ 20016 2 x 1/2
M __ __ __ 01804 9/16 x 1/8 M __ __ __ 20416 2 1/8 x 1/2
M __ __ __ 02005 5/8 x 5/32 M __ __ __ 20816 2 1/4 x 1/2
M __ __ __ 02006 5/8 x 3/16 M __ __ __ 21220 2 3/8 x 5/8
M __ __ __ 02206 11/16 x 3/16 M __ __ __ 21620 2 1/2 x 5/8
M __ __ __ 02404 3/4 x 1/8 M __ __ __ 22020 2 5/8 x 5/8
M __ __ __ 02406 3/4 x 3/16 M __ __ __ 22420 2 3/4 x 5/8
M __ __ __ 02806 7/8 x 3/16 M __ __ __ 22824 2 7/8 x 3/4
M __ __ __ 02808 7/8 x 1/4 M __ __ __ 30024 3 x 3/4
M __ __ __ 03008 15/16 x 1/4 M __ __ __ 30824 3 1/4 x 3/4
M __ __ __ 10006 1 x 3/16 M __ __ __ 31228 3 3/8 x 7/8
M __ __ __ 10008 1 x 1/4 M __ __ __ 31628 3 1/2 x 7/8
M __ __ __ 10408 1 1/8 x 1/4 M __ __ __ 32028 3 5/8 x 7/8
M __ __ __ 10608 1 3/16 x 1/4 M __ __ __ 32428 3 3/4 x 7/8
M __ __ __ 10808 1 1/4 x 1/4 M __ __ __ 32832 3 7/8 x 1
M __ __ __ 10810 1 1/4 x 5/16 M __ __ __ 40032 4 x 1
M __ __ __ 11210 1 3/8 x 5/16 M __ __ __ 40432 4 1/8 x 1
M __ __ __ 11212 1 3/8 x 3/8 M __ __ __ 40832 4 1/4 x 1
M __ __ __ 11412 1 7/16 x 3/8 M __ __ __ 41232 4 3/8 x 1
M __ __ __ 11610 1 1/2 x 5/16 M __ __ __ 41632 4 1/2 x 1
M __ __ __ 11612 1 1/2 x 3/8 M __ __ __ 41640 4 1/2 x 1 1/4
M __ __ __ 12012 1 5/8 x 3/8 M __ __ __ 42040 4 5/8 x 1 1/4
M __ __ __ 12412 1 3/4 x 3/8 M __ __ __ 42440 4 3/4 x 1 1/4
Shaded Area: AGMA semi-standard bore key combinations.
Bore Tolerances
Part Number Usage: Magnaloy Coupling Hub part numbers Over Include Tolerance
may be specified using the following format: Start with let- -- 1 +.0008/ +.0003
ter M designating Magnaloy, followed by 3 digit Model 1 2 +.0013/ +.0005
2 3 +.0018/ +.0008
Code (100, 200, etc.), then the specific 5 digit Bore Key 3 4 +.0020/ +.0010
Code. 4 5 +.0023/ +.0010
Example: Model 500 hub with a 1 3/8 bore and 5/16 key-
way would be specified as: M50011210 - No bore hubs are
designated as R code, ie: M500R.
Additional Coupling Specifications

Model Number 100 200 300 400 500 600 700 800 900
Maximum Bore 1-1/8 1-3/8 1-5/8 1-7/8 2-3/8 2-5/8 2-7/8 3-7/8 4-3/4
Complete Coupling Approx. Wght. 3/4 1 2 3 4 7 12 18 38
(Solid Hub)
Number of Drive Lugs 3 3 3 3 4 6 6 6 6

Hub Movement for Insert Removal .74 .74 .75 .98 1.12 1.02 1.50 1.63 2.27
Basic Insert Number 170 270 370 470 570 670 770 870 970

Splined Couplings
Magnaloy couplings are available with a variety

of special features which include splined bores.
The Splined Coupling Specifications chart on
page 7 shows several in-house splines available
for quick delivery. Many additional splined bores
are available upon contacting the factory, including
straight side PTO type splines and metric splines.
The Clamp-Type Coupling utilizes the basic Magnaloy

coupling with the addition of the clamp feature.
Developed to compensate for variations in spline
formation methods and tolerances. Assures centering
of the coupling and positive retention on the shaft.
The clamp feature is suggested for all splined couplings,
but is also available in smooth bored and keyed models.
Magnaloys Steel Bushed Splined Bore* Coupling

combines all the design and lightweight features of the
Magnaloy Coupling with the added spline tooth strength and
wear resistance of steel. Under normal conditions the stan-
dard Splined Bore coupling will perform satisfactorily and
the addition of the Clamp Feature compensates for various
fit conditions. When heavy cyclic loads, reverse loading and
high torque loads exist in combination with fit variations,
spline tooth failures and fretting can be corrected by utilizing
Magnaloys steel bushed coupling. Of course, to achieve
optimum benefits, Magnaloys clamp feature is
recommended - assuring accurate centering and positive
retention of the coupling on the shaft.
*Although the steel bushing feature was designed primarily
for spline bores, it is also available smooth bored and keyed.

Spline & Clamp Specifications
Splined Coupling Specifications

Spline Size Pressure Major Std. Coupling Steel Bushed Coupling
Number Spline Angle SAE Diameter Available Bushing Available
of Teeth Pitch Code (Degrees) Design (Inches) Model Sizes O Model Sizes
o
9 16/32 0916 30 A .625 100-900 1.250 200-900
o
13 8/16 1308 30 D,E 1.750 400-900 2.625 600-900
o
13 16/32 1316 30 B .875 100-900 1.500 300-900
o
14 12/24 1412 30 C 1.250 200-900 2.250 500-900
o
15 8/16 1508 30 F 2.000 500-900 3.500 800-900
o
15 16/32 1516 30 BB 1.000 100-900 1.750 400-900
o
17 12/24 1712 30 CC 1.500 300-900 2.250 500-900
o
21 16/32 2116 30 1.375 300-900 2.250 500-900
o
23 16/32 2316 30 1.500 300-900 2.250* 500-900
o
27 16/32 2716 30 1.750 400-900 2.625 600-900
o
40 16/32 4016 30 2.562 600-900 3.875 800-900
*NOTE: With Model 600-900 Bushing O.D. is 2.625

Spline Type Identifier Code -- A = Spline B = Steel Bushing Spline C = Clamp Type
Part Number Usage: Magnaloy Splined Coupling part numbers may be specified using the
following format: Start with letter M designating Magnaloy, follow with 3 digit model code
(100, 200, etc.), next use single letter Spline Type Identifier Code (A for regular spline or B
for steel bushing) then the specific 4 digit spline code.
If a clamp type coupling is specified - use the letter code C after the spline code.
Example: Model 300 hub with 13 tooth 16/32 splined bore, M300A1316; same as above with
steel bushing, M300B1316; same as above with steel bushing and clamp, M300B1316C.
Clamp Type Coupling Specifications Optional

Clamp Bolt
Coupling Bolt Location U Z U
Model Z Y Bolt Size Torque Spec.
100 .31 .68 1/4-20 130-140 in. lbs.
200 .43 .75 1/4-20 130-140 in. lbs. Y
300 .47 .95 5/16-18 210-220 in. lbs.
400 .69 1.06 5/16-18 210-220 in. lbs.
500 .72 1.25 3/8-16 300-310 in. lbs.
600 1.13 1.50 7/16-14 35-36 ft. lbs.
700 1.13 1.75 7/16-14 35-36 ft. lbs.
800 1.44 2.56 1/2-13 49-50 ft. lbs.
900* .75 & 2.19 3.00 3/4-10 100-110 ft. lbs. Optional
Steel Bushing Bushing
* Model 900 utilizes two bolt clamp design. O

Insert Selection Guide
Magnaloy Couplings full range of flexible inserts

permit custom design performance for a wide range
of applications. All insert materials offer complete
electrical insulation, as Magnaloys design elimi-
nates all metal-to-metal contact.
Neoprene (Code N) - Black material -

Standard material with Magnaloy Coupling.
Good general purpose material offering good
resiliency
o
and
o
load
o
capabilities.
o
Temp range -
30 F to +250 F (-34 C to =121 C) optional 80A
durometer (painted gold) and 90A durometer
(painted silver) are available for slight
increased load capability and less resiliency.
Nitrile (Buna N) (Code B) - Painted blue -
Excellent material with petroleum products.
Excellent compression set and abrasion o
resistance
o o
characteristics.
o
Temp range -60 F to
+250 F (-51 C to +121 C).
Urethane (Code U) - Yellow
Excellent mechanical and physical
properties. Offers good medium duty
durability and resiliency. Urethane tends to
soften in higher temperatureso
ando humid con-
ditions.
o
Temp o
Range -30 F to +150 F
(-34 C to +66 C).
Part Number Usage: Magnaloy Coupling Viton (Fluorocarbon) (Code V) - Red material -
Insert part numbers may be specified using Excellent fluid compatibility and high
the following format: Start with letter M temperature characteristics. Good
designating Magnaloy followed by 3 digit compression
o o
set and
o
resiliency.
o
Temp range -
20 F to +350 F (-29 C to +177 C).
insert model size (170, 270, etc.) then the
specific material code letter. If an optional Hytrel (Code H) - Blue-green material - Superior
durometer is being specified, after the physical and mechanical properties and
material code letter supply the durometer excellent fluid compatibility and high temper-
number divided by 10. ature characteristics. Hardness (50D)
EXAMPLES: Urethane insert for Model 300, M370U; approaches that of plastic and offers little
80 Duro Neoprene for Model 200, M270N8. resiliency. Excellent performanceo under heavy
o
dutyo conditions.
o
Temp range -65 F to +300 F
(-54 C to +149 C).
Other materials are available for special applications.
Consult factory for recommendations and availability.

Insert Selection Guide
Service Factors - Load Characteristics
Type of Prime Mover
Load Standard Motor High Torque I.C. Engine I.C. Engine
Classification or Turbine Motor 6 or more cyl. less than 6 cyl.
Uniform (U) 1.0 1.5 1.5 2.0*
Moderate (M) 1.5 2.0 2.0* 2.5*
Heavy (H) 2.0* 2.5* 2.5* 3.0*
Uniform Load: Steady loading, non-reversing, torque does not exceed rating.
Moderate Load: Uneven loading with moderate shock, frequent starts,
infrequent reversals, peak torque may exceed average rate of prime
mover by 125%.
Heavy Load: Uneven loading with heavy shock, frequent reversals, peak
torque may exceed average rating of prime mover by 150%.
*Recommend use of Urethane or Hytrel Insert.
Drive Unit Load Sym. Selection Method

Agitators U 1. Several specifics must be considered to make the best
Blowers U choice of couplings:
Compressors Centrifugal U
Rotary M A. Type of prime mover and load characteristics
Reciprocating H* (see table above).
Conveyors U B. Shaft diameter and key size or spline configuration
Reciprocating M
Screw M (No. of teeth, pitch ratio, pressure angle).
Shaker H C. Horsepower rating of loads to be transmitted.
Cranes & Hoists M D. Maximum operating speed (rpm).
Crushers H* E. Maximum operating misalignment.
Elevators M
Freight & Pass. H* F. Clearance limitations.
Fans Centrifugal U 2. Calculate effective hp/100 rpm by use of table above
Propeller M and select the minimum size couplings recommended.
Cooling Tower H
3. VERIFY YOUR SELECTION:
Generators U
Welding H A. Check for maximum bore size.
Mills H* B. Check dimensions for adequate clearance.
Machine Tools M C. Indicate any special insert specification and/or
Mixers M coupling coating for environmental protection, if
Paper Mill Machinery M
required.
Pumps Centrifugal U
Rotary M Equation: Effective HP per 100 RPM = rated HP x Service
Reciprocating H* Factor x 100/RPM
On Injection H*
Molding Equip. Example: 150 HP 4 cyl. Diesel Engine Driving
Screens Air & Water U Reciprocating Irrigation Pump operating
Washing at 3250 RPM
Freight & Pass. H
Service Factor = 3.0 (Hytrel Insert recommended)
Stokers U
Textile Machinery M Eff. HP per 100 RPM = 150 HP x 3.0 x 100/3250
Woodworking Machinery M RPM = 13.85 HP/100 RPM Model 600 rating with
Winches H* Hytrel Insert is 23.7 HP/100 RPM
NOTE: Above service factors are intended for use as a general guide only.
* Recommend use of Steel Bushing and Clamp with Splined Bores.

Installation Instructions
Shaft spacing should be within range given by

dimensions W and X as shown in charts on page 4.
Position each hub on proper size shaft - Magnaloy
couplings are bored to standard push fit tolerances,
if a tight fit exists check shaft for burrs.
Maximum benefits are obtained with hubs posi-
tioned to allow complete shaft engagement within
bore. However, some equipment designs do not
permit this condition - maximum shaft engagement
should be utilized in any case.
Alignment - Place a straight edge (scale) at top

and side of coupling. Use a .005 inch feeler gauge
under scale for final inspection. This will indicate
accurate parallel and angular alignment.
Magnaloys precision tooled outside surfaces
permit this simple, but accurate alignment method.
Secure equipment mounts and recheck alignment

for movement.
Install the insert in the coupling positioning hubs in
contact with lip around outside of insert.
Before tightening set screws, run the coupling and
check for separation of hubs or creep . Recheck
alignment and tighten set screws.
With the Steel Bushed/Clamp type couplings, to
facilitate installation on the shaft, it may be necessary
to slightly loosen the set-screw over the keystock.
When securing the coupling to the shaft, first tighten
the clamp bolt, then tighten the set--screw against
the keystock.

Mis-Alignment Capabilities
Magnaloy couplings offer four-way flexibility (parallel,

angular, axial and torsional) and require no lubrica-
tion. They are easily installed and properly aligned
without use of special tools or equipment - a straight
edge and hex wrench are the only tools required.
Magnaloys insert reduces noise and vibration and
permits needed flexibility for proper operation within
alignment capabilities.
Recommended Torques
for Fasteners
Model Set Screw Clamp Screw
100 60-70 in. lbs. 130-140 in. lbs.
200 130-140 in. lbs. 130-140 in. lbs.
300 130-140 in. lbs. 210-220 in. lbs.
400 190-200 in. lbs. 210-220 in. lbs.
500 190-200 in. lbs. 300-310 in. lbs.
600 190-200 in. lbs. 35-36 ft. lbs.
700 300-310 in. lbs. 35-36 ft. lbs.
800 300-310 in. lbs. 49-50 ft. lbs.
900 100-110 ft. lbs. 100-110 ft. lbs.
Intended as a general guide for fastener torques
with Magnaloy Couplings.
Perfect alignment of equipment shafts, in most cases, is impractical to obtain or maintain,

and misaligned equipment produces excess stress on bearings and coupling. Magnaloys
insert design will accept misalignment strain and, when excessive, will cause insert wear as
a visual and audible indication of misalignment problems. However, Magnaloys inserts are
inexpensive and easily replaced; under normal conditions the insert seldom requires
replacement.
Maximum
1o Angular
Mis-Alignment
Mis-Alignment
Capabilities
Maximum
.015 in. Parallel
Mis-Alignment

Technical Bulletin & Notes
Keystock Interference with Drive Lug
Since the Magnaloy Coupling keyway in a bored and keyed hub is broached between the
drive lugs, there is a potential for interference with the keystock of the drive lugs and the
driver lugs of the driven hub. Interference will result when ALL the following conditions exist:
A) The shaft diameter is GREATER than listed below.
B) T h i s shaft extends into the hub insert core area.
C) The keystock on this shaft extends with the shaft.
The interference condition can be corrected by shortening the keystock so it does not
extend into the coupling hub insert core area.
Interference Potential exists when
shaft diameters are greater than Area of Interference Cut Keystock even
shown in this chart with this Surface
Model Size Shaft Diameter Key Size

100 7/8 1/4
200 1 - 3/16 1/4
300 1 - 5/16 5/16
400 1 - 1/2 3/8
500 1 - 15/16 1/2
600 2 - 1/2 5/8
700 2 - 3/4 5/8
800 3 - 1/2 7/8
900 4 - 1/2 1 - 1/4
Failure to correct this condition will result in assembly difficulty and could cause damage
to the drive or driven equipment.
Notes

Powdered Metal PM90 Couplings
The Strong, High Quality, Low Cost, Powdered Metal Coupling from Magnaloy
When your priorities for a coupling are economy and strength...
specify the all-new Magnaloy Type PM 90.
The PM 90 is made from high-density powdered metal
and is available in standard bores up to 1 1/8 inch
maximum. Double set screws are standard in all bores
1/2 inch and over. The set screws are placed over the
keyway and at a 45o angle to the keyway to allow
greater hoop-stress generation and maximum shaft
gripping. The increased drive lug surface area on the
PM 90 provides low unit loads on insert drive elements
while insuring more rapid heat dissipation. Magnaloys
exclusive insert design allows easy installation and replacement
without hub removal. The drive lug design provides even compressive
loading with no radial loading of insert drive elements
It is a well established fact that the major cause of failure in an elastomeric insert type drive
coupling is hysteresis failure which results from overworking the insert by application of
cyclic loads and the associated heat generation. These cyclic loads can be internal in ori-
gin as a result of coupling design (see page 2) and when coupled with externally applied
loads can greatly reduce elastomer life. Specifying Magnaloys Type PM Coupling with
radial designed drive lugs results in true compressive loads and improved insert life.

PM 90 Specifications
Model PM 90 Performance Specifications
Torque Torsional Complete Coupling Wr2
Maximum Minimum Insert Rating HP Rating Rigidity Approx. Weight (lb) (lb. Ft.2)
Bore Bore Number (in.lb.) Per 100 RPM (in.lb./deg.) Solid Max. Bore (Solid)
P097N7 224 0.36 38.3
1-1/8 7/16 P090U9 336 0.54 69.9 1.8 1.3 0.946
P090H5 672 1.08 158.7
Model PM 90 Dimensional Specifications

T W
A- Over all length (Assembled) - 2.78

B- Outside Diameter - 2.125
T- Set Screw 1/4 -20 UNC, 2 places
B W- Distance between shaft ends 3/16 min.
X- Distance between shaft ends 3/4 max.
Y- Hub movement required for insert removal (1.20 total)
Y X
Notes

PM 90 Specifications
Model PM 90 - Standard Bore - Keyway Sizes (Per AGMA Class 1, Clearance Fit)
Part Bore & Keyway Set Screw
Number Combinations Bore Size** Key Width Key Depth Size Quantity
P090014N 7/16 x No.Key .4375 / .4385 No Keyway - 1/4 - 20 UNC 1
P09001403 7/16 x 3/32 .4375 / .4385 .0938 / .0958 .484 / .495 1/4 - 20 UNC 1
P09001404 7/16 x 1/8 .4375 / .4385 .125 / .127 .496 / .507 1/4 - 20 UNC 2
P09001604 1/2 x 1/8 .500 / .501 .125 / .127 .560 / .571 1/4 - 20 UNC 2
P09001804 9/16 x 1/8 .5625 / .5635 .125 / .127 .623 / .634 1/4 - 20 UNC 2
P09002005 5/8 x 5/32 .625 / .626 .1562 / .1582 .698 / .709 1/4 - 20 UNC 2
P09002006 5/8 x 3/16 .625 / .626 .1875 / .1895 .709 / .720 1/4 - 20 UNC 2
P09002206 11/16 x 3/16 .6875 / .6885 .1875 / .1895 .773 / .784 1/4 - 20 UNC 2
P09002404 3/4 x 1/8 .750 / .751 .125 / .127 .812 / .823 1/4 - 20 UNC 2
P09002406 3/4 x 3/16 .750 / .751 .1875 / .1895 .837 / .848 1/4 - 20 UNC 2
P09002806 7/8 x 3/16 .875 / .876 .1875 / .1895 .964 / .975 1/4 - 20 UNC 2
P09002808 7/8 x 1/4 .875 / .876 .250 / .252 .982 / .993 1/4 - 20 UNC 2
P090010006 1 x 3/16 1.000 / 1.001 .1875 / .1895 1.090 / 1.101 1/4 - 20 UNC 2
P090010008 1 x 1/4 1.000 / 1.001 .250 / .252 1.114 / 1.125 1/4 - 20 UNC 2
P090010408 1 1/8 x 1/4 1.125 / 1.126 .250 / .252 1.241 / 1.252 1/4 - 20 UNC 2
*Shaded combinations are Semi-special - See price sheet
**Other Bore/Keyway combinations available. Consult factory for quotation.
Model PM 90 Bore Tolerances

Key
Width
Features Tolerance
Bore -.000 / +.001
Key
Key Width -.000 / +.002 Depth Bore
Key Depth +.005 / +.016
As with Magnaloys standard line of Nitrile, 70A Durometer.....

couplings, insert elastomer selection Standard elastomer material offering
allows variable performance excellent resistance to petroleum
characteristics. Insert design products and superior compression
eliminates metal-to-metal set characteristics.
contact and assures Urethane, 90A Durometer....
electrical isolation Excellent mechanical and physical
properties. Note: Urethane material
of shafts. tends to soften when exposed to
elevated temperatures or humid
conditions
Hytrel, 50D Durometer....
Superior mechanical and physical
properties and offer excellent fluid
compatibility and high temperature
characteristics.
Additional insert materials available upon request from factory.

See page 8 for additional information on insert selection.

Make the Connection
with ......
Whatever your Fluid Power Unit needs,
magnaloy has the products
to keep you connected.
PM 90 Couplings
Economical PM-90 Iron Powder
Couplings have long lasting
Flexible Drive Couplings nitrile, hytrel or urethane inserts.
Top-of-the-line magnesium couplings Double set screws give excellent
are lighter, yet stronger than either Pump/Motor Mounts gripping power.
cast iron or aluminum. They also Precision machined aluminum & custom
offer better corrosion resistance steel pump/motor mounts directly connect
and easier handling. the motor and pump while ensuring
accurate shaft alignment and enclosing the
coupling. Vertical and horizontal models
readily available from stock.
Magnaloy Hydraulic Bar Magnaloy Reservoirs

Manifolds & Accessories Complete line of J.I.C. Style and
custom reservoirs from 10 to 5,000
Complete line of inline Bar Manifolds, Rod End Couplers gallons. Drip Pans, Stacking
Subplates, Cover Plates, Valve Adaptors, Two models of accurately machined Modules, Clean Out Covers and
Integrated Circuit Manifolds, and high tensile cylinder rod end alignment many other accessories are also
Accessories to make the design and o o
available from stock.
couplers offer 7 or 10 spherical
fabrication of Hydraulic Circuitry simple
and 1/8 parallel misalignment
and easy. Wide range of sizes include:
capabilities.
D03, D05, D05H & D08 in aluminum and
steel with ports available in SAE, NPTF,
BSPP, and BSTP styles. Custom design and
fabrication also available, consult factory.
Magnaloy Pressure Switch
Accessories Pressure Sensing switch capable of sensing up
Filler Breather Adaptors, Filler Breathers, to three (3) separate pressures. Each sensor
Reservoir Flanges, Suction Strainers, is externally independently adjustable from
Gauge Isolators, Liquid Level Gauges, 200 to 4000 psi. Viton seals provide wide
Modular O-Ring Kits. fluid compatibility range.

Return To Contents A1
SOLFRUNT Pressure Gauges and

Other Products for the Process Industries
AMETEKs line of high quality process gauges are styles, case materials, and mounting arrangements,
specifically designed to meet the demanding needs and wetted parts are available in bronze, stainless
of the chemical and petroleum processing steel, alloy steel, and MONEL. Recalibration
industries, and are also widely used in industries adjustments can be made from the rear of the case
such as fossil fuel and nuclear power generation, without removing the internals. On the 1900 Series
aerospace and marine. The gauges design and the pointer is adjusted by removing the ring and
materials of construction provide reliable service in front window. Most SOLFRUNT gauges are factory
applications where corrosive atmospheres, stock and are readily available through your U.S.
corrosive media, pressure pulsation, vibration, and Gauge Distributor.
wide variations in ambient temperatures are
Visit our Web site for a list of local stocking distributors:
present. SOLFRUNT gauge cases feature an www.ametekusg.com/products/distributors.cfm
integral wall between the measuring element and 1
It is recommended that users of gauges become familiar with American National
the window, and a pressure relieving back for Standard ASME B40.100-1998 entitled Pressure Gauges and Gauge
Attachments. This specification is available from the American Society of
increased safety1. They are available in various Mechanical Engineers, United Engineering Center, 345 East 47th Street, New York,
New York 10017.
2002, by AMETEK, Inc. All rights reserved. 15M1102A (160126) Specifications are subject to change without notice. Visit our Web sites for the most up-to-date information.
For Gauges/Thermometers: For Electronic Products: For Diaphragm Seals:

U.S. GAUGE PMT PRODUCTS M&G PRODUCTS
820 Pennsylvania Blvd. 820 Pennsylvania Blvd. 8600 Somerset Drive
Feasterville, PA 19053 U.S.A. Feasterville, PA 19053 U.S.A. Largo, FL 33773 U.S.A.
Tel: (215) 355-6900 Tel: (215) 355-6900 Tel: (727) 536-7831
Fax: (215) 354-1802 Fax: (215) 354-1800 Fax: (727) 539-6882
www.ametekusg.com www.ametekusg.com www.ametek.com/tci
Customer Service Tel: (863) 534-1504
Customer Service Fax: (863) 533-7465
A4 Return To Contents
Process Gauges
SOLFRUNT 4-1/2 Models 1980, 1982, and 1986
DESCRIPTION SPECIFICATIONS
The Models 1980, DIAL SIZE: 4-1/2
1982, and 1986 CASE AND RING:
4-1/2 Process For Stem or Wall Mounting:
Gauges have a PET TURRET CASE (black) with glass-filled polypropylene
threaded ring and pressure-relieving back
PET turret style
case for chemical WINDOW: High temperature acrylic, other options available
and petrochemical POINTER: Anodized aluminum, micro-adjustable with black
processing finish
applications. The DIAL: Aluminum with baked white background and black
PET material gives this markings
case superior impact MOVEMENT: Geared movement with components of
strength and a broad spectrum corrosion-resistant 300 series stainless steel
of chemical resistance. These
BOURDON TUBE: Phosphor bronze/silver brazed; 316L
models are available with wetted surface material in stainless steel/TIG welded; or K MONEL, MONEL/micro-
brass/phosphor bronze, alloy steel/316L or brazed
MONEL for NACE Standard MR0175 applications. CONNECTION: Brass, alloy steel, or MONEL, 1/2-14 ANPT
They are available dry or liquid filled from the standard (1/4-18 ANPT, optional)
factory or your local stocking distributor, liquid fill ACCURACY: 0.5% of span (Grade 2A), except where
kit, or the E-Z Fill design to facilitate filling in the stainless steel bourdon tubes are used in following ranges:
field without special tools. Type 316L from 10,000 to 11,600 psi; accuracy is 0.5% on
ascending pressure and 1.0% on descending pressure
Models 1980, 1982, and 1986 4-1/2
SOLFRUNT gauges are supplied in 30 vacuum,
compound, and pressure ranges from 30 Hg
vacuum through 11,600 psi. The low-connected
PET turret case can be easily liquid filled in the field
using the appropriate conversion kit.
Span adjustments can be accomplished from
rear of case without disturbing the gauge internals.
INCHES
Pointer adjustments are easily made by removing (MM)
ring and window.
5.84 3.13 PET TURRET CASE

(148.3) (79.5) MOUNTING CONFIGURATION
MAX.
270
ARC
5.38
5.06 (136.5)
(128.6)
2.62
(66.5)
.88 .58 .25

(22.2) .22 (14.6) (6.4)
SQUARE (5.6) MINIMUM
3 HOLES 3 HOLES EQUALLY SPACED
THREAD 1/2-14 ANPT 1.58
(40.1)
Please see the MODEL SELECTION CHART on page A11

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Fax: (215) 354-1802 Fax: (215) 354-1800 Fax: (727) 539-6882
Process Gauges
SOLFRUNT 4-1/2 Models 1980, 1982, and 1986
SPEC NUMBER SELECTION CHART
Model Number 1980 1982 1986
Bourdon Tube Phosphor Bronze 316L Stainless Steel K MONEL
Socket Brass Alloy Steel MONEL
Size 4-1/2" 4-1/2" 4-1/2"
Range* Spec No. Spec No. Spec No.
0-30" Hg VAC 150000 150038 150060
30"-0-15 psi 150001 150039 150061
30"-0-30 psi 150002 150040
30"-0-60 psi 150003 150041 150063
30"-0-100 psi 150004 150042 150064
30"-0-150 psi 150005 150043 150065
0-15 psi 150006 150044 150066
0-30 psi 150007 150045 150067
0-60 psi 150008 150046 150068
0-100 psi 150009 150047 150069
0-150 psi 150010 150048 150070
0-200 psi 150011 150049 150071
0-300 psi 150012 150050 150072
0-400 psi 150013 150051 150073
0-600 psi 150014 150052 150074
0-800 psi 150053
0-1000 psi 150015 150054 150075
0-1500 psi 150055
0-2000 psi 150525 150529
0-2300 psi 150056
0-3000 psi 150526 150530
0-3500 psi 150057
0-5000 psi 150527 150531
0-6000 psi 150058
0-10,000 psi 150528 150532
0-11,600 psi 150059
* Metric and dual scale dials are available on all 1900 Series gauges. Please refer to
page A12 for part numbers or call Customer Service at (863) 534-1504
1/4-18 ANPT available use 155XXX when ordering
When ordering EZ Fill Option use 170XXX (for 1/2-14 ANPT); use 175XXX (for
1/4-18 ANPT)
SPARE PARTS
Item Description Part No.
Lazy Hand Lazy Hand 1980 132371
Fill Kit 1980 Series Bladder Design 150300
Fill Kit 1980 Series O-Ring Design 150298

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Process Gauges
SOLFRUNT 4-1/2 Liquid Filled Gauges
4-1/2 PET or aluminum cased DIAL SIZE: 4-1/2
SOLFRUNT liquid filled gauges CASE AND RING:
are designed to extend For Wall Mounting Only:
PET TURRET CASE with threaded polypropylene ring, black
service life wherever finish; BUNA-N O-ring sealed, pressure-relieving back.
corrosive atmosphere and/or Externally vented or internal diaphragm case available for
severe operating conditions temperature/ atmospheric compensation (Model 1980L,
1981L, 1982L and 1986L)
(such as compressors,
For Stem or Wall Mounting:
pulsating pumps, machine tool CAST ALUMINUM, BACK-FLANGED CASE with aluminum
applications, etc.) affect the bayonet ring, black finish; BUNA-N O-ring sealed, pressure-
performance of standard gauges. The relieving back. Externally vented case or internal diaphragm
liquid fill may be a mixture of glycerine* case available for temperature/atmospheric compensation
(Model 1901L, 1911L, and 1931L)
and water, silicone oil, or mineral oil.
WINDOW: High temperature acrylic, other options available
The liquid effectively dampens
POINTER: Anodized aluminum with black finish
mechanism and pointer
DIAL: Aluminum with baked white background and black
oscillation and vibration while markings
providing continuous lubrication MOVEMENT: Geared movement with components of
and protection from corrosion for corrosion-resistant 300 series stainless steel
the gauge internals. A specially BOURDON TUBE: Phosphor bronze/silver brazed; 316L
designed rear blowout panel with a stainless steel/TIG welded; or K MONEL, MONEL/nicro-
vent for atmospheric pressure and brazed
temperature compensation is standard. CONNECTION: Brass, alloy steel, 316L stainless steel or
MONEL. 1/2-14 ANPT, standard (1/4-18 ANPT, optional)
U.S. Gauge liquid filled gauges are available in three
optional configurations: liquid filled at factory; dry with ACCURACY: 0.5% of span (Grade 2A), except where
stainless steel bourdon tubes are used in following ranges:
liquid fill kit sold separately; E-Z Fill (PET case only) Type 316L from 10,000 to 11,600 psi; accuracy is 0.5% on
design to facilitate filling in the field without special ascending pressure and 1.0% on descending pressure
tools or fixtures. RANGES: See Standard Dial Ranges charts on page A11
* NOTE: Glycerin not suitable for use with alloy steel or 403 stainless steel sockets. DIMENSIONS: See drawings on page A4 for PET turret case
and page A7 cast aluminum case
MODEL SELECTION CHART

MODEL BOURDON
MOUNTING CASE RING SOCKET CONNECTION*
NUMBER TUBE
1901L Stem/Wall Aluminum Back Flange Aluminum Bayonet Phosphor Bronze Brass 1/2-14 ANPT LM
1911L Stem/Wall Aluminum Back Flange Aluminum Bayonet 316L Stainless Steel Alloy Steel 1/2-14 ANPT LM
1931L Stem/Wall Aluminum Back Flange Aluminum Bayonet 316L Stainless Steel 316L Stainless Steel 1/2-14 ANPT LM
1980L Stem/Wall PET turret Threaded Polypropylene Phosphor Bronze Brass 1/2-14 ANPT LM
1981L Stem/Wall PET turret Threaded Polypropylene 316L Stainless Steel 316L Stainless Steel 1/2-14 ANPT LM
1982L Stem/Wall PET turret Threaded Polypropylene 316L Stainless Steel Alloy Steel 1/2-14 ANPT LM
1986L Stem/Wall PET turret Threaded Polypropylene MONEL MONEL 1/2-14 ANPT LM
* 1/4-18 ANPT optional
Liquid Fill Conversion Kits

U.S. Gauge offers two liquid fill kits; one provides a hermetically sealed back cover with screws and a special window retaining ring. Kits
case incorporating a pressure equalizing diaphragm, the other contains a available for both PET and aluminum case styles.
vent for temperature/pressure compensation. These kits, complete with Vented case kits contain: window, socket and back cover O-rings,
easy-to-follow instructions, enable the user to quickly and conveniently fill a rubber vent plug with metal vent pin, stainless steel back cover with
dry gauges without special tools or fixtures. screws and a special window retaining ring. Kits available for both PET
For hermetically sealed gauges the kit contains: window and socket and aluminum case styles.
O-rings, an elastomeric diaphragm with integral O-ring, a stainless steel

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Fax: (215) 354-1802 Fax: (215) 354-1800 Fax: (727) 539-6882
Process Gauges
SOLFRUNT 4-1/2 Standard Gauge Summary
This information applies for all 4-1/2 Process Gauges:
Models 1981, 1981 Advantage, 1980, 1982, 1986, 1901, 1931, 1911, 1903, 1933, and 1913
STANDARD DIAL RANGES STANDARD DIAL RANGES

PRESSURE RANGES COMPOUND & VACUUM RANGES
(psi) (In. Hg0psi)
MAXIMUM FIGURE INTERMEDIATE MINOR FIGURE INTERMEDIATE MINOR
RANGE
INDICATIONS INTERVALS GRADUATIONS GRADUATIONS INTERVALS GRADUATIONS GRADUATIONS
15 1 0.5 0.1 30-0-15 5 3 1 1 0.5 0.2
30 5 1 0.2 30-0-30 10 5 5 1 1 0.5
60 5 1 0.5 30-0-60 10 10 5 5 1 1
100 10 5 1 30-0-100 30 10 10 5 2 1
160 20 5 1 30-0-150 30 25 10 5 5 2
200 20 10 2 30-0-200 30 20 10 5 2
300 30 10 2 30-0-300 30 30 10 5 2
400 50 25 5 30-0 5 1 0.2
600 50 25 5
800 100 50 10
1,000 100 50 10
1,500 300 50 10
2,000 2,000 100 20
BOURDON ASSEMBLIES
2,300 500 100 20
3,000 500 100 20 Bourdon and connection assemblies are stamped with the
3,500 500 100 50 following codes plus the bourdon tube pressure range:
5,000 500 100 50
BOURDON TUBE MATERIAL CONNECTION MATERIAL
6,000 1,000 200 50
MATERIAL CODE MATERIAL CODE
10,000 1,000 500 100
Phosphor Bronze C51000 Brass C36000
11,600 2,000 500 100
316L Stainless Steel S31600 316L Stainless Steel S31600
K MONEL N05500 Alloy Steel G10180
MONEL N04405
MODEL SELECTION CHART

MODEL BOURDON
MOUNTING CASE RING SOCKET CONNECTION*
NUMBER TUBE
1980 Stem/Wall PET Turret Threaded Polypropylene Phosphor Bronze Brass 1/2-14 ANPT LM
1981 Stem/Wall PET Turret Threaded Polypropylene 316L Stainless Steel 316L Stainless Steel 1/2-14 ANPT LM
1981 Advantage Stem/Wall PET Turret Threaded Polypropylene 316L Stainless Steel 316L Stainless Steel 1/2-14 ANPT LM
1982 Stem/Wall PET Turret Threaded Polypropylene 316L Stainless Steel Alloy Steel 1/2-14 ANPT LM
1986 Stem/Wall PET Turret Threaded Polypropylene K-MONEL / MONEL K-MONEL / MONEL 1/2-14 ANPT LM
1901 Stem/Wall Aluminum Back Flange Aluminum Bayonet Phosphor Bronze Brass 1/2-14 ANPT LM
1931 Stem/Wall Aluminum Back Flange Aluminum Bayonet 316L Stainless Steel 316L Stainless Steel 1/2-14 ANPT LM
1911 Stem/Wall Aluminum Back Flange Aluminum Bayonet 316L Stainless Steel Alloy Steel 1/2-14 ANPT LM
1903 Flush Panel Cast Aluminum Hinged Steel Phosphor Bronze Brass 1/2-14 ANPT LBM
1933 Flush Panel Cast Aluminum Hinged Steel 316L Stainless Steel 316L Stainless Steel 1/2-14 ANPT LBM
1913 Flush Panel Cast Aluminum Hinged Steel 316L Stainless Steel Alloy Steel 1/2-14 ANPT LBM
* 1/4-18 ANPT optional

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Process Gauges
SOLFRUNT 4-1/2
Metric and Dual Scale Dial Part Numbers
The metric and dual scale dials listed below can be used on any of the following SOLFRUNT
4-1/2 Gauges: Models 1981, 1981 Advantage, 1980, 1982, 1986, 1901, 1931, 1911, 1903, 1933, and
1913. Please call Customer Service at (863) 534-1504 for questions about metric or dual scale dials.
kPa Scales Bar Scales

Single Scale Dual Scale Single Scale Dual Scale
Range Part No. Range Part No. Range Part No. Range Part No.
(vac)-100 Kpa D110421 (vac) 30" hg / -100 Kpa D166661M -1 bar D216580 30" Hg / -1 bar D132181
-100-0-100 Kpa D131401M 30"-0-15 psi / -100-0-100 Kpa D124381M -1-0-1 bar D220400 30"-0-15 psi / -1-0-1 bar D132161
-100-0-150 Kpa D245360 -1-0-1.5 bar D220780
-100-0- 200 Kpa D110721M 30"-0-30 psi / -100-0-200 Kpa D124141M -1-0-2 bar D916200 30"-0-30 psi / -1-0-2 bar D127983
-100-0-400 Kpa D110741M 30"-0-60 psi / -10-0-400 Kpa D193760M -1-0-3 bar D220760
-100-0-700 Kpa D110761 30"-0-100 psi / -100-0-700 Kpa D128063M -1-0-4 bar D896621 30"-0-60 psi /-1-0-4 bar D130441M
-100-0-900 Kpa D216340 30"-0-100 psi / -1-0-7 bar D149240
-100-0-1000 Kpa D110781 30"-0-150 psi / -100-0-1000 Kpa D193840M 30"-0-150 psi / -1-0-10 bar D129740
-100-0-2000 Kpa D110821 0-1 bar D165160 0-15 psi / 0-1 bar D128181M
0-100 Kpa D131261M 0-15 psi / 0-100 Kpa D131281M 0-2 bar D154360 0-30 psi / 0-2 bar D124121M
0-200 Kpa D110441M 0-30 psi / 0-200 Kpa D124181M 0-2.5 bar D214780
0-250 Kpa D187920M 0-4 bar D137782 0-60 psi / 0-4 bar D124261M
0-400 Kpa D110462M 0-60 psi / 0-400 Kpa D124201M 0-6 bar D214800M
0-600 Kpa D108941M 0-7 bar D137802 0-100 psi / 0-7 bar D128023
0-700 Kpa D108841M 0-100 psi / 0-700 Kpa D124221M 0-8 bar D187980
0-800 Kpa D101680M 0-10 bar D188000
0-1000 Kpa D099701 0-11 bar D134982 0-160 psi / 0-11 bar D124101
0-1100 Kpa D110481M 0-160 psi / 0-1100 Kpa D124241M 0-14 bar D115902 0-200 psi / 0-14 bar D128241
0-1400 Kpa D110502M 0-200 psi / 0-1400 Kpa D129201M 0-16 bar D188020M
0-1600 Kpa D101700M 0-21 bar D154380M 0-300 psi / 0-21 bar D128281M
0-2500 Kpa D107960M 0-28 bar D165200 0-400 psi / 0-28 bar D128201
0-5500 Kpa D110581M 0-800 psi / 0-5500 Kpa D129241M 0-55 bar D237340M 0-800 psi / 0-56 bar D106302
0-6000 Kpa D189120M 0-60 bar D214860
0-8000 Kpa D187940M 0-105 bar D154420M 0-1500 psi / 0-105 bar D128141
0-2000 psi / 0-14000 Kpa D226280M 0-160 bar D154440 0-2300 psi / 0-160 bar D083380
0-20000 Kpa D245980 0-3000 psi / 0-21000 Kpa D226300M 0-240 bar D154460 0-3500 psi / 0-240 bar D128261
0-5000 psi / 0-35000 Kpa D215220M 0-11600 psi / 0-800 bar D129720
0-40000 Kpa D110661M 0-6000 psi / 0-40000 Kpa D190260
0-60000 Kpa D108000
0-10000 psi / 0-70000 kpa D239400
0-80000 Kpa D101740 0-11600 psi / 0-80000 kpa D220740
0-100000 Kpa D108801

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Process Gauges
SOLFRUNT 4-1/2
Metric and Dual Scale Dial Part Numbers
The metric and dual scale dials listed below can be used on any of the following SOLFRUNT
4-1/2 Gauges: Models 1981, 1981 Advantage, 1980, 1982, 1986, 1901, 1931, 1911, 1903, 1933, and
1913. Please call Customer Service at (863) 534-1504 for questions about metric or dual scale dials.
kgcm2 Scales
Single Scale Dual Scale
Range Part No. Range Part No.
-1 kgcm2 D216680
760 mm Hg (Vac) D150420 30" Hg / 760 mm Hg (Vac) D211580
30" Hg / 76 cm Hg (Vac) D167940
-1-0-1 kg/cm2 D188860 30"-0-15 psi / -1-0-1 kgcm2 D137921
760 mm-0-1 kgcm2 D208580
-1-0-1.5 kgcm2 D228100
760 mm-0-2 kgcm2 D849302 30"-0-30psi / 76 cm-0-2 kgcm2 D128003
-1-0-3 kgcm2 D213440
760 mm-0-4 kgcm2 D188840 30"-0-60 psi / 76 cm-0-4 kgcm2 D192860M
-1-0-4 kgcm2 D215740
-1-0-5 kgcm2 D212380
76 cm-0-7 kgcm2 D189480 30"-0-100 psi / 76 cm-0-7 kgcm2 D127923M
760 mm-0-7 kgcm2 D209420
-1-0-7 kgcm2 D215760
-1-0-9 kg/cm2 D212400
76 cm-0-10 kgcm2 D190820 30"-0-150 psi / 76 cm-0-10 kgcm2 D128861
-1-0-10 kgcm2 D215780
0-1 kgcm2 D154221 0-15 psi / 0-1 kgcm2 D127960
0-2 kgcm2 D127441M 0-30 psi / 0-2 kgcm2 D124281
0-2.5 kgcm2 D212420
0-4 kgcm2 D111501M 0-60 psi / 0-4 kgcm2 D124301M
0-6 kgcm2 D212440 0-85 psi / 0-6 kgcm2 D236740
0-7 kgcm2 D139221 0-100 psi / 0-7 kgcm2 D124321M
0-10 kgcm2 D192480
0-11 kgcm2 D111521 0-160 psi / 0-11 kgcm2 D127943M
0-16 kgcm2 D212480
0-20 kgcm2 D192500
0-25 kgcm2 D212500
0-28 kgcm2 D153421 0-400 psi / 0-28 kgcm2 D131241M
0-40 kgcm2 D212520
0-42 kgcm2 D146820 0-600 psi / 0-42 kgcm2 D124161M
0-60 kgcm2 D216620 0-800 psi / 0-56 kgcm2 D192840M
0-70 kgcm2 D146840 0-1000 psi / 0-70 kgcm2 D167440
0-100 kgcm2 D213700
0-105 kgcm2 D140820 0-1500 psi / 0-105 kgcm2 D137901M
0-2000 psi /0-140 kgcm2 D192880M
0-160 kgcm2 D216640 0-2300 psi / 0-160 kgcm2 D167460M
0-3000 psi / 0-210 kgcm2 D192900
0-250 kgcm2 D215100 0-3500 psi / 0-250 kgcm2 D166541
0-350 kgcm2 D242420 0-5000 psi / 0-350 kgcm2 D192920
0-400 kgcm2 D215120 0-6000 psi / 0-400 kgcm2 D167480M
0-10000 psi / 0-700 kgcm2 D218140
0-800 kgcm2 D208600

Tel: (215) 355-6900 Tel: (215) 355-6900 Tel: (727) 536-7831
Fax: (215) 354-1802 Fax: (215) 354-1800 Fax: (727) 539-6882
V-SERIES VALVES
V-SERIES
VALVES
Standard Standard Stainless Steel Handwheel Handwheel
with Screw with Flange with Screw with Screw with Flange
Connections Connections Connections Connections Connections
APPLICATION Widely used in a variety of applications, the V

series valves are ideally suited in hydraulic and
The Fulflo V Series range in size from 1/4 lubricating systems for load regulation and
through 2 and operate efficiently with liquids of system protection. Special trim or packings are
any viscosity at pressures from 2 to 1000 P.S.I. available for use with fire resisting fluids and
The V series valves are available in flange or other liquids of this type. Unusual applications
screw type...cartridge or handwheel in a choice and special requirements should be referred to
of brass, cast iron, steel and stainless steel. our engineering staff for recommendation.
INSTALLATION should be piped back to the tank. Care must be

taken to have the discharge well below the oil
Fulflo valves can be mounted in any position. A level in the tank to prevent air entrainment and
tee may be inserted in the pump discharge line erratic operation.
to mount the valve. The correct size of valve
should be installed, preferably matching the Only if the valve is used as safety or overload
pump discharge line. Screw the valve into the relief and operates infrequently may its
nipple in the tee, or in the case of the flange discharge be piped back into the pump suction
style, bolt the valve to the companion flange line. Frequent or continuous operation under
screwed into the nipple. When the valve is used these conditions will cause excessive heating of
for frequent bypassing of oil pressure, its outlet the oil and possible damage.
11
V-SERIES
SETTING VALVES having a flow meter in the pump discharge line must
be available. With a valve adjusted for cracking
Valves may be set with a hydraulic hand pump for pressure as above, continue closing bypass until the
cracking pressure. If a test stand is available, valve required flow registers on the flow meter and observe
should be connected to the discharge header with the pressure. Readjust pressure, if necessary, to obtain
pump bypass open, and the bypass gradually closed desired pressure at desired flow.
until the desired pressure registers on the gauge.
Adjust valve adjusting screw until valve slightly bleeds
at the set bypass pressure and lock adjusting screw. MAINTENANCE
Fulflo valves are not designed to be positive shut-off, Fulflo valves provide reliable chatter-free operation
and will pass a minimal amount of leakage before the when the system is free of abrasives and foreign
V-SERIES
VALVES
set pressure. If a valve is required to bypass a given matter. Continuous filtration of the liquid used is
amount of fluid at a given pressure, a test stand strongly recommended.
TYPICAL DISASSEMBLY OF STANDARD TYPE VALVE
To dismantle valve for inspection or cleaning:

G 1. Remove cap B
2. Remove O-Ring E
3. Remove lock nut F
B
I 4. Remove adjusting screw C
5. Remove retainer D
E H 6. Remove spring G
7. Remove piston I
F 8. Remove stop ring H (Not Recommended)
A (Special tooling is required to install new stop ring.)
C Inspect valve bore and piston for wear and scoring. Replace
broken or damaged parts. Clean all parts thoroughly and
re-assemble by reversing the above procedure.
D
TYPICAL DISASSEMBLY OF HANDWHEEL TYPE VALVE

To dismantle the valve for inspection or cleaning:
1. Release spring tension by backing off handwheel as far as it
will go.
2. Remove lock nut A or set screw and take off handwheel B
3. Remove lock nut D
4. Unscrew and remove gland E
5. Unscrew and remove bonnet F
J 6. Remove O-Ring H
A
F 7. Remove adjusting screw C (turn clockwise and pull out from
B bottom of bonnet F)
D K 8. Remove O-ring packing G
9. Remove spring J
E H 10. Remove piston K
11. Remove stop ring L (Not Recommended)
G L (Special tooling is required to install new stop ring.)
Inspect valve bore and piston for wear or scoring. Replace broken
C or damaged parts. Clean all parts thoroughly and re-assemble by
reversing the above procedure.
I
12
V-SERIES
ASSEMBLY NUMBER IDENTIFICATION CHART
Symbol No. Designation Code Description
1 Style None Standard Model
H Handwheel Model
2 Series V
3 Material J Cast iron
B Brass
S Steel
SS 316 Stainless Steel
4 Connections None Screw Connections
F Flange Connections 300# Flange Class Standard (250# Flange Class - Cast Iron Standard)
V-SERIES
VALVES
5 Size -1 1/4
-2 3/8
-3 1/2
-4 3/4
-5 1
-6 11/4
-7 11/2
-8 2
6,7,8 ASA None 300# Flange Standard (no designation required)
Flange -150
Rating -600
9 Flange A Raised Face, Staggered Bolt Centers (standard on all Flange rating)
Style B Smooth Face, Staggered Bolt Centers
150# & 600# C Raised Face, Bolts on Valve Centerline
Only D Smooth Face, Bolts on Valve Centerlne
10 O-Ring R Buna O-Ring Cap Seal (standard)
Material RV Viton O-Ring Cap Seal
RS Silicone O-Ring Cap Seal
RT Teflon O-Ring Cap Seal (standard on VSS Series)
RA Aflas O-Ring Cap Seal
11 Options SP Steel Parts (used on cast iron only)
P Panel Mount on Handwheel Series
12 Piston /HS Hardened Steel
Material /SS 416 Stainless Steel
/3SS 303 Stainless Steel
13 Spring AS
US
WS
XS
YS
ZS
14 Setting Desired Pressure Setting
EXAMPLES:
VJ-1RVSP/HS/WS VJF-5R/HS/WS VJF-5-150AR/HS/WS
V J -1 RV SP /HS WS V J F -5 R /HS WS V J F -5 -150 A R /HS WS
Series Cast Iron 1/4 Viton O-Ring Steel Parts H.S. Piston WS Spring Series Cast Iron Flanged 1 Buna O-Ring H.S. Piston WS Spring Series Cast Iron Flanged 1 Rating Style Buna O-Ring H.S. Piston WS Spring
NOTE: Stainless steel pistons are supplied on brass valves, unless hardened steel is specified. Hardened steel pistons are supplied on cast iron or steel unless stainless steel is
specified. Buna O-Rings are supplied as standard unless other material is specified.
STANDARD PRESSURE RANGE CHART

Valve Valve SPRING PRESSURE AND IDENTIFICATION NO.
Pipe Flange BLACK-AS RED-US GREEN-WS YELLOW-XS WHITE-YS BLUE-ZS PURPLE-TS BROWN-RS
Size Size
Low High Low High Low High Low High Low High Low High Low High Low High
1/4 3 15 7 35 30 100 60 175 150 350 300 500 400 600 550 750
3/8 3 15 7 35 30 100 60 175 150 350 300 500 400 600 550 750
1/2 3 15 7 35 30 100 60 175 150 350 300 500 400 600 550 750
3/4 3 15 7 35 30 100 60 175 150 350 300 500
1 1 3 15 7 35 30 100 60 175 150 350 300 500
11/4 11/4 3 15 7 35 30 100 60 175 150 350 300 500
11/2 11/2 3 15 7 35 30 100 60 175 150 350 300 500
2 2 3 15 7 35 30 100 60 175 150 350 250 600
13
VJ VB Brass
V-SERIES VS
Cast Iron
Steel VSS Stainless Steel VJ-SP Cast Iron with Steel Parts
DIMENSIONS Valve
Size
DIMENSIONS IN INCHES
AA BB CC DD
1/4 5 / 11
32 1 /
11
32 1 /
11
32 13/8
J B 3/8 511/32 111/32 111/32 13/8
C 1/2 6 /163
1 /16
11
1 /16
7
17/16
F 3/4 615/16 115/16 113/16 111/16
1 87/32 29/32 29/32 21/16
K E
D 11/4 99/16 29/16 29/16 21/2
FULFLO
V-SERIES
AA REF.
G 1 /2 1
11 /16 1
2 /16
11
2 /16
11
27/8
VALVES
CAP A 2 13 3 3 31/4
(GASKET SEAL) I
PIPE SIZE
OUT
DD
REF
BB
H IN
CC
PIPE SIZE
DD
REF
PARTS LIST
SYM. NAME MODEL VALVE SIZE
1/4 3/8 1/2 3/4 1 11/4 11/2 2
VJ, VJ-SP 100 200 300 400 500 600 700 800
VB 100-B 200-B 300-B 400-B 500-B 600-B 700-B 800-B
A BODY VS 100-S 200-S 300-S 400-S 500-S 600-S 700-S 800-S
VSS 100-SS 200-SS 300-SS 400-SS 500-SS 600-SS 700-SS 800-SS
VJ, VJ-SP 201-SR 201-SR 301-SR 401-R 501-R 601-R 701-R 801-R
CAP VB 201-BR 201-BR 301-BR 401-BR 501-BR 601-BR 701-BR 801-BR
B (O-RING SEAL) VS 201-SR 201-SR 301-SR 401-SR 501-SR 601-SR 701-SR 801-SR
VSS 201-SSR 201-SSR 301-SSR 401-SSR 501-SSR 601-SSR 701-SSR 801-SSR
VJ, VB 202-B 202-B 302-B 402-B 502-B 602-B 702-B 802-B
C ADJUSTING VS, VJ-SP 202-S 202-S 302-S 402-S 502-S 602-S 702-S 802-S
SCREW VSS 202-SS 202-SS 302-SS 402-SS 502-SS 602-SS 702-SS 802-SS
VJ, VB 203-B 203-B 303-B 403-B 503-B 603-B 703-B 803-B
D RETAINER VS, VJ-SP 203-S 203-S 303-S 403-S 503-S 603-S 703-S 803-S
VJ, VJ-SP, VB, VS 204-* 204-* 304-* 404-* 504-* 604-* 704-* 804-*
E O-RING VSS 204-RT 204-RT 304-RT 404-RT 504-RT 604-RT 704-RT 804-RT
VJ, VJ-SP, VB, VS 205-S 205-S 305-S 405-S 505-S 605-S 705-S 805-S
F LOCK NUT VSS 205-SS 205-SS 305-SS 405-SS 505-SS 605-SS 705-SS 805-SS
G SPRING ALL MODELS 207-** 207-** 307-** 407-** 507-** 607-** 707-** 807-**
VJ, VB 208-B 208-B 308-B 408-B 508-B 608-B 708-B 808-B
H STOP RING VS, VJ-SP 208-S 208-S 308-S 408-S 508-S 608-S 708-S 808-S
HARDENED STEEL 206 206 306 406 506 606 706 806
I PISTON 416 STAINLESS STEEL 206-A 206-A 306-A 406-A 506-A 606-A 706-A 806-A
303 STAINLESS STEEL 206-SS 206-SS 306-SS 406-SS 506-SS 606-SS 706-SS 806-SS
CAP VJ, VJ-SP 201-S 201-S 301-S 401 501 601 701 801
J VB 201-B 201-B 301-B 401-B 501-B 601-B 701-B 801-B
(GASKET SEAL)
VS 201-S 201-S 301-S 401-S 501-S 601-S 701-S 801-S
VJ, VB 204 204 304 404 504 604 704 804
K GASKET 204-S 204-S 304-S 404-S 504-S 604-S 704-S 804-S
VS, VJ-SP
* See o-ring selection chart

** See spring pressure chart
Recommended spare parts
14
VJF Cast Iron VSF Steel
V-SERIES VBF Brass VSSF Stainless Steel VJF-SP Cast Iron with Steel Parts
DIMENSIONS DIMENSIONS IN INCHES
Valve
Size AA BB
J B
C 1 91/2 31/2
F
11/4 1013/16 33/4
K E
11/2 127/16 41/16
D
2 149/16 49/16
V-SERIES
G
VALVES
Note: Dimensions reflect
CAP 150# and 300# only
A
AA REF.
(GASKET SEAL) 45
I
45
221/2
PIPE SIZE
45
H
221/2
BB
-------
-------
-------
-------
FOR 2 VALVE ONLY
PIPE SIZE
BB
PARTS LIST
1 11/4 11/2 2
VJF, VJF-SP 500-F 600-F 700-F 800-F
VBF 500-BF 600-BF 700-BF 800-BF
A BODY VSF 500-SF 600-SF 700-SF 800-SF
VSSF 500-SSF 600-SSF 700-SSF 800-SSF
VJF, VJF-SP 501-R 601-R 701-R 801-R
CAP VBF 501-BR 601-BR 701-BR 801-BR
B (O-RING SEAL) VSF 501-SR 601-SR 701-SR 801-SR
VSSF 501-SSR 601-SSR 701-SSR 801-SSR
VJF, VBF 502-B 602-B 702-B 802-B
C ADJUSTING VSF, VJF-SP 502-S 602-S 702-S 802-S
SCREW VSSF 502-SS 602-SS 702-SS 802-SS
VJF, VBF 503-B 603-B 703-B 803-B
D RETAINER VSF, VJF-SP 503-S 603-S 703-S 803-S
VSSF 503-SS 603-SS 703-SS 803-SS
VJF, VJF-SP 504* 604* 704* 804*
E O-RING VBF, VSF 504-* 604-* 704-* 804-*
VSSF 504-RT 604-RT 704-RT 804-RT
VJF, VJF-SP 505-S 605-S 705-S 805-S
F LOCK NUT VBF, VSF 505-S 605-S 705-S 805-S
VSSF 505-SS 605-SS 705-SS 805-SS
G SPRING ALL MODELS 507-** 607-** 707-** 807-**
VJF, VBF 508-B 608-B 708-B 808-B
H STOP RING VJF-SP, VSF 508-S 608-S 708-S 808-S
VSSF 508-SS 608-SS 708-SS 808-SS
HARDENED STEEL 506 606 706 806
I PISTON 416 STAINLESS STEEL 506-A 606-A 706-A 806-A
303 STAINLESS STEEL 506-SS 606-SS 706-SS 806-SS
VJF, VJF-SP 501 601 701 801
J CAP VBF 501-B 601-B 701-B 801-B
(GASKET SEAL)
VSF 501-S 601-S 701-S 801-S
VJF, VBF 504 604 704 804
K GASKET VJF-SP, VSF 504-S 604-S 704-S 804-S
15
HVJ Cast Iron HVS Steel HVJ-P Cast Iron HVS-P Steel
V-SERIES HVB BRASS HVSS Stainless Steel HVB-P Brass HVSS-P Stainless Steel
DIMENSIONS Valve
Size
A AA BB CC DD EE
1/4 8/
1
8 1 /
11
32 1/3
16 1/3
8 7/8
B
C 3/8 81/8 111/32 13/16 13/8 7/8
D
E 1/2 9 /8
5
1 /16
11
1 /16
7
1 /16
7
11/8
F 3/4 93/16 115/16 111/16 113/16 13/8
AA MAXIMUM REF.
G 1 127/16 29/32 21/16 29/32 13/8
EE 11/4 137/16 29/16 21/2 29/16 15/8
THD. DIA. H
V-SERIES
1 /2
1
17 /16
1
2 /16
11
2 /8
7
2 /16
11
21/4
VALVES
M I
FULFLO
J 2 171/16 3 33/8 3 21/4
K
F
PIPE SIZE
REF
OUT
CC
BB
L
PANEL MOUNT IN
PIPE SIZE DD
CC
REF.
PARTS LIST
1/4 3/8 1/2 3/4 1 11/4 11/2 2
A LOCK NUT OR 1/4-20 1/4-20 1/4-20 205-S 205-S 1/4-20 1/4-20 1/4-20
SET SCREW ALL MODELS
COMM. COMM. COMM. COMM. COMM. COMM.
B HANDWHEEL ALL MODELS 229 229 229 429 429 629 629 629
ADJUSTING HVJ(P), HVS(P) 222-S 222-S 322-S 422-S 522-S 622-S 722-S 822-S
C HVB(P) 222-B 222-B 322-B 422-B 522-B 622-B 722-B 822-B
SCREW HVSS(P) 222-SS 222-SS 322-SS 422-SS 522-SS 622-SS 722-SS 822-SS
HVJ(P), HVS(P) 205-S 205-S 205-S 305-S 305-S 655-S 655-S 655-S
D LOCK NUT HVB(P) 205-S 205-S 205-S 305-S 305-S 655-S 655-S 655-S
HVSS(P) only 205-SS 205-SS 205-SS 305-SS 305-SS 655-SS 655-SS 655-SS
E GLAND HVB(P) 225-B 225-B 325-B 525-B 525-B 625-B 725-B 825-B
HVSS(P) 225-SS 225-SS 325-SS 525-SS 525-SS 625-SS 725-SS 825-SS
HVJ, HVS 223-SR 223-SR 323-SR 423-SR 523-SR 623-SR 723-SR 823-SR
HVB 223-BR 223-BR 323-BR 423-BR 523-BR 623-BR 723-BR 823-BR
HVSS 223-SSR 223-SSR 323-SSR 423-SSR 523-SSR 623-SSR 723-SSR 823-SSR
F BONNET 228-SR 228-SR 328-SR 428-SR 528-SR 628-SR 728-SR 828-SR
HVJP, HVSP
HVBP 228-BR 228-BR 328-BR 428-BR 528-BR 628-BR 728-BR 828-BR
HVSSP 228-SSR 228-SSR 328-SSR 428-SSR 528-SSR 628-SSR 728-SSR 828-SSR
HVJ(P), HVS(P) 224* 224* 224* 424* 424* 624* 624* 624*
G O-RING HVB(P) 224-* 224-* 224-* 424-* 424-* 624-* 624-* 624-*
HVSS(P) only 224-RT 224-RT 224-RT 424-RT 424-RT 624-RT 624-RT 624-RT
HVJ(P), HVS(P) 204* 204* 304* 404* 504* 604* 704* 804*
H O-RING HVB(P) 204-* 204-* 304-* 404-* 504-* 604-* 704-* 804-*
HVSS(P) only 204-RT 204-RT 304-RT 404-RT 504-RT 604-RT 704-RT 804-RT
HVJ(P) 100 200 300 400 500 600 700 800
HVB(P) 100-B 200-B 300-B 400-B 500-B 600-B 700-B 800-B
I BODY HVS(P) 100-S 200-S 300-S 400-S 500-S 600-S 700-S 800-S
J SPRING ALL MODELS 207-** 207-** 307-** 407-** 507-** 607-** 707-** 807-**
HARDENED STEEL 206 206 306 406 506 606 706 806
K PISTON 416 STAINLESS STEEL 206-A 206-A 306-A 406-A 506-A 606-A 706-A 806-A
L STOP RING HVB(P) 208-B 208-B 308-B 408-B 508-B 608-B 708-B 808-B
HVJP, HVSP, 505-S 505-S 605-S 705-S 705-S 805-S 745-S 745-S
M LOCK NUTS 505-S 505-S 605-S 705-S 705-S 805-S 745-S 745-S
HVBP
2 REQD HVSSP 505-SS 505-SS 605-SS 705-SS 705-SS 805-SS 745-SS 745-SS
16
V-SERIES HVJF
HVBF
Cast Iron
Brass
HVSF Steel HVJF-P Cast Iron HVSF-P Steel
HVSSF Stainless Steel HVBF-P Brass HVSSF-P Stainless Steel
DIMENSIONS A DIMENSIONS IN INCHES
B Valve
Size AA BB EE
C
D 13 /16 31/2 13/8
11
1
E
11/4 1411/16 33/4 15/8
F
G 11/2 187/16 41/16 21/4
AA MAXIMUM REF.
2 185/8 49/16 21/4
H
EE Note: Dimensions reflect
THD. DIA. 150# and 300# only
I
V-SERIES
M
VALVES
J 221/2
K 45
45
45
PIPE SIZE
F
221/2
L
BB
PANEL MOUNT
PIPE SIZE
-------
-------
-------
-------
BB FOR 2 VALVE ONLY
PARTS LIST
SYM. NAME MODEL DIMENSIONS IN INCHES
1 11/4 11/2 2
A LOCK NUT OR ALL MODELS 1/4-20 1/4-20 1/4-20
SET SCREW 205-S COMM. COMM. COMM.
B HANDWHEEL ALL MODELS 429 629 629 629
HVJF(P) HVSF(P) 522-S 622-S 722-S 822-S
ADJUSTING HVBF(P) 522-B 622-B 722-B 822-B
C
SCREW HVSSF(P) 522-SS 622-SS 722-SS 822-SS
HVJF(P), HVSF(P) 305-S 655-S 655-S 655-S
D LOCK NUT HVBF(P) 305-S 655-S 655-S 655-S
HVSSF(P) only 305-SS 655-SS 655-SS 655-SS
HVJF(P), HVSF(P) 525-S 625-S 725-S 825-S
E GLAND HVBF(P) 525-B 625-B 725-B 825-B
HVSSF(P) 525-SS 625-SS 725-SS 825-SS
HVJF, HVSF 523-SR 623-SR 723-SR 823-SR
HVBF 523-BR 623-BR 723-BR 823-BR
HVSSF 523-SSR 623-SSR 723-SSR 823-SSR
F BONNET HVJPF, HVSPF 528-SR 628-SR 728-SR 828-SR
HVBPF 528-BR 628-BR 728-BR 828-BR
HVSSFP 528-SSR 628-SSR 728-SSR 828-SSR
HVJF(P), HVSF(P) 424* 624* 624* 624*
G O-RING HVBF(P) 424-* 624-* 624-* 624-*
HVSSF(P) only 424-RT 624-RT 624-RT 624-RT
HVJF(P), HVSF(P) 504* 604* 704* 804*
H O-RING HVBF(P) 504-* 604-* 704-* 804-*
HVSSF(P) only 504-RT 604-RT 704-RT 804-RT
HVJF(P) 500-F 600-F 700-F 800-F
HVBF(P) 500-BF 600-BF 700-BF 800-BF
I BODY HVSF(P) 500-SF 600-SF 700-SF 800-SF
HVSSF(P) 500-SSF 600-SSF 700-SSF 800-SSF
J SPRING ALL MODELS 507-** 607-** 707-** 807-**
HARDENED STEEL 506 606 706 806
K PISTON 416 STAINLESS STEEL 506-A 606-A 706-A 806-A
303 STAINLESS STEEL 506-SS 606-SS 706-SS 806-SS
HVJF(P), HVSF(P) 508-S 608-S 708-S 808-S
L STOP RING HVBF(P) 508-B 608-B 708-B 808-B
HVSSF(P) 508-SS 608-SS 708-SS 808-SS
LOCK NUTS HVJFP, HVSFP, 705-S 805-S 745-S 745-S
M HVBFP 705-S 805-S 745-S 745-S
2 REQD HVSSFP 705-SS 805-SS 745-SS 745-SS
17
V-SERIES PERFORMANCE CHARTS
All valve tests 110F. to 120F. Oil Viscosity 150 S.S.U. at 100F.
(Charts good from 30 to 500 S.S.U.)
1/4 VALVE TESTS 3/8 VALVE TESTS
V-SERIES
6
VALVES
5 XS
4 Rated Capacity WS 10 XS
3 G.P.M.
3 Rated Capacity
5 G.P.M.
WS
2 US 5
GALLONS PER MINUTE
RS
GALLONS PER MINUTE

AS 4 US RS
TS
3
1 ZS AS TS
.8 2 ZS
YS PRESSURE RANGE IN P.S.I. PRESSURE RANGE IN P.S.I.
.6 207-AS = 3-15 207-AS = 3-15
207-US = 7-35 YS 207-US = 7-35
207-WS = 30-100 207-WS = 30-100
.4 207-XS = 60-175 1 207-XS = 60-175
207-YS = 150-350 207-YS = 150-350
207-ZS = 300-500 207-ZS = 300-500
207-TS = 400-600 207-TS = 400-600
207-RS = 600-750 207-RS = 600-750
.2 .5
1 2 4 6 8 10 20 40 60 80 100 150 1 2 4 6 8 10 20 40 60 80 100 150
OVERPRESSURE IN P.S.I. OVERPRESSURE IN P.S.I.
PRESSURE RANGE IN P.S.I.

307-AS = 3-15
307-US = 7-35
307-WS = 30-100
307-XS = 60-175 40
307-YS = 150-350
307-ZS = 300-500 30
307-TS = 400-600
25 307-RS = 600-750
20 Rated Capacity
20 16 G.P.M.
15 15
Rated Capacity
11 G.P.M. WS ZS
GALLONS PER MINUTE
GALLONS PER MINUTE
10 10 US
XS YS
AS
RS
5 WS XS
5
4 US TS 4
3 AS ZS 3 407-AS = 3-15
407-US = 7-35
407-WS = 30-100
2 YS 2 407-XS = 60-175
407-YS = 150-350
407-ZS = 300-500
1 1
1 2 4 6 8 10 20 40 60 80 100 150 1 2 4 6 8 10 20 40 60 80 100 150
18
1 VALVE TESTS 11/4 VALVE TESTS
PRESSURE RANGE IN P.S.I. PRESSURE RANGE IN P.S.I.

507-AS = 3-15 607-AS = 3-15
507-US = 7-35 607-US = 7-35
507-WS = 30-100 607-WS = 30-100
507-XS = 60-175 607-XS = 60-175
V-SERIES
507-YS = 150-350 607-YS = 150-350
VALVES
507-ZS = 300-500 120 607-ZS = 300-500
60 507-R = 500-900 607-R = 500-800
50 100
40 80
Rated Capacity Rated Capacity
30 25 G.P.M.
60 50 G.P.M.
20 ZS
GALLONS PER MINUTE
GALLONS PER MINUTE

WS 40 WS
ZS
US US YS
YS
10 AS R 20 XS
8 XS 16 AS
6 12
R
4 8
21 2 4 6 8 10 20 40 60 80 100 150 41 2 4 6 8 10 20 40 60 80 100 150

11/2 VALVE TESTS 2 VALVE TESTS

707-AS = 3-15 807-AS = 3-15
707-US = 7-35 807-US = 7-35
707-WS = 30-100 807-WS = 30-100
707-XS = 60-175 807-XS = 60-175
707-YS = 150-350 807-YS = 150-350
707-ZS = 300-500 807-ZS = 250-600
707-R = 500-900
200
160 200 Rated Capacity
150 G.P.M.
120 Rated Capacity 150
80 G.P.M.
80 100
GALLONS PER MINUTE
GALLONS PER MINUTE
R
WS ZS
40 AS
50
32 US YS ZS 40
WS XS
24 AS 30 US
16 XS 20 YS
8 10
1 2 4 6 8 10 20 40 60 80 100 150 1 2 4 6 8 10 20 40 60 80 100 150
19
SERVICE MANUAL
~
HEAT EXCHA AND TRANSF
('
500 Superior S
. . C~rneglt,p,
(412) 276-3388 FAX:(412) 276-3397 SM-102A
~ Email: sales@heat-inc.com
WEB:www.heat-inc.com February, 2001
OCH - OPEN COIL HEATERS

A
C B
A = OVERALL LENGTH D = CERAMIC DIAMETER

B = HEATED LENGTH E = END PLATE DIAMETER
C = COLD LENGTH F = TAB EXTENSION
General Description Installation
H.E.A.T.'s Open Coil Heaters (OCH) are designed and con- NOTE: High heating efficiency, low element temperatures
structed for long life. When properly installed, operated and and longer heater life result when the OCH's are installed
maintained, they give dependable, trouble free service. properly.
The OCH's are available in 2" and 3" nominal sizes. They are 1. To avoid chipping or cracking the ceramic insulators,
intended for installation inside a horizontally mounted metal carefully unpack, handle and install the heater
(\ pipe or tube and are available in lengths from 2' to 40' or
longer. 2. Remove crating materials and inspect for possible dam-
age during transport. If any, contact the carrier. Notify
The use of temperature regulating and limiting controls is Heat Exchange and Transfer, Inc. before repairing any
recommended, since excessive temperature can permanently damages.
damage the heater and cause premature failure.
3. Heater mounting must allow for linear expansion. A mini-
CAUTION: Install adequate temperature regulating con- mum allowable length for this expansion is 1/3" per foot
trols, fusing and back-up safety devices with electric of heater length. Provide at least 1/8" clearance between
heating equipment. Back-up protective devices are the ceramic insulators and the wall of the pipe for ease of
essential, when the consequences of control failure may installation when mounting the heater assembly inside a
be severe. Although the safety of the installation is the metal pipe.
responsibility of the user, H.E.A.T.will make equipment
recommendations upon request. 4. The OCH elements are flexible for easy installation in
cramped areas, but, only bend the element in a vertical
plane. The minimum bending radius is 18". A shorter
Model Number Code radius may result in electrical problems causing prema-
MODEL OCH -- -- ture heater failure. Do not bend heating elements in a
Nominal Size ~ horizontal plane unless they have been specially designed
2 = 2"
3 = 3"
-=r for this application.
5. When mounting inside a metal pipe or tube, clean the

kW Rating of Heater inside surface of any foreign materials that might contam-
inate the ceramic insulators.
Overall Length in inches
NOTE: H.E.AT. cannot be responsible for failures or damage
Voltage Code caused by contamination on the ceramic insulators. Do ~:
First Two Digits of Voltage not expose the heaters to contaminants.
20 = 208V 41 = 415V
n 24 = 240V
38 = 380V
48 = 480V
57 = 575V
Phase
1 = Single
3 = Three
r- J-
6. DANGER- Hazard of fire. Since the basic OCH ele- 1. Do not operate heaters at voltages higher than that
ment is capable of developing high temperatures, take
precautions to:
stamped on the heater since excess voltage will shorten
heater life. n
A. Avoid mounting or exposing elements to an atmos- 2. Do not operate heaters in environments with factors that
phere containing combustible gases and vapors. can destroy the electrical insulating characteristics of the
ceramic insulators. Foreign contaminants can create leak-
B. Avoid contact between the heating elements and age (shock) hazards, cause permanent heater damage or
combustible materials. result in heater failure.
C. Ensure that the inside surface of the pipe or tube is

clean of all foreign materials, especially combustible
ones, when the heating element is mounted in a pipe
or tube. CAUTION: Hazard of severe shock. Disconnect all
power to the heater before servicing or replacing the
7. Do not mount the OCH element in the vertical position as heater.
the resistance wire could sag and cause uneven heating
or a short circuit. 1. Verify that the terminals and the ceramic insulators are
free from contact with oil, liquid or other foreign matter.
2. Check electrical connections at heater terminals and

lighten if necessary. This helps avoid hot terminals which
CAUTION: Hazard of electrical shock. OCH elements may destroy wire insulation or heater terminals.
contain exposed electrical terminals and must be
properly guarded to prevent electrical shock. Any 3. Monitor overheat operation to ensure heater protection.
installation involving electric heaters must be grounded.
1. Size and install electrical wiring to the heating elements in

accordance with the National Electric Code and applica-
ble local codes.
2. Temperatures at the heater terminals require the use of

high temperature lead wire.
n
L~
n
HEAT EXCHANGE AND TRANSFER, INC.
500 Superior St., Carnegie, PA 15106. (412) 276-3388. FAX: (412) 276-3397
BACK MOUNT WITH NEEDLE VALVES,
LIQUID LEVEL GAGE - PIPE ADAPTERS
LUBE DEVICES series G608 closed circuit liquid level gages are furnished with shut-off valves between
the tank wall and gage. The gage body can be removed from the valves without loss of fluid. Configured
with pipe adapters. Bottom closure cap may be used as a drain. An exclusive construction feature provides a
.06 (1.52mm) lateral adjustment at each mounting bolt to facilitate mounting. All metal parts are precision
machined from solid bar stock with the sight opening recessed into the gage body for maximum protection.
Aluminum valves are optional. Please specify when ordering.
STANDARD MATERIALS: OPERATING CONDITIONS:
! Aluminum construction ! Maximum working temperature with standard
! Brass valves seals up to 250F (121.1C)
! Buna N seals ! Maximum working pressure as noted in table
! Borosilicate glass with redline on white below at 150F (65.6C), no corrosion
background for distinct level reading and
maximum fluid compatibility
MODIFICATIONS AVAILABLE - MADE TO ORDER - CONSULT OUR FACTORY
(MINIMUM ORDER MAY BE REQUIRED)
HOW TO ORDER: G608 PATENTED
WHEN ORDERING, SPECIFY THE FOLLOWING,
AFTER THE SERIES NUMBER SEPARATING EACH
WITH A DASH (-):
-A- Aluminum gage body (standard)
-B- Brass gage body (optional)
-1- Buna N seals (standard)
-2- Butyl seals (optional)
-3- Viton A seals (optional)
-4- Ethylene propylene seals (optional)
-5- Silicone seals (optional)
- SPECIFY PIPE THREAD SIZE:
-2- 1/4 male pipe thread
EXAMPLE: G608-10-A-1-4 1/2 Pipe thread
Buna N seals
Aluminum gage body
10.00 (254.00mm) Centers
Series G608
SERIES A - CENTER B - SIGHT C - LENGTH MAX. WORK. E F

NUMBER INCHES (mm) INCHES (mm) INCHES (mm) PSI (kPa) D INCHES INCHES
(mm) (mm)
10 (254.00) 8.50 (215.90) 11.62 (295.15) 275 (1896)
12 (304.80) 10.50 (266.70) 13.62 (345.95) 270 (1862) 1/4-18 .56 2.06
15 (381.00) 13.50 (342.90) 16.62 (422.15) 260 (1793) 3/8-18 (14.22) (52.32)
G608
18 (457.20) 16.50 (419.10) 19.62 (498.35) 240 (1655)
1/2-14 .75 2.25
24 (609.60) 22.50 (571.50) 25.62 (650.75) 210 (1448)
3/4-14 (19.05) (57.15)
30 (762.00) 28.50 (723.90) 31.62 (803.15) 185 (1276)
LIQUID LEVEL GAGE - BACK MOUNT

WITH NEEDLE VALVES, PIPE ADAPTERS
LUBE DEVICES, INC.
1864 NAGLE AVE., P.O. BOX 1810, MANITOWOC, WI 54221-1810
10/03 BULLETIN F327-8 PHONE: (920) 682-6877
E-MAIL: sales@lubedevices.com
FAX: (920) 684-7210
WEBSITE: www.lubedevices.com
Drexelbrook Page 1 of 1
Drexelbrook > On/Off Level Switch
RELIABLE, LOW COST ON/OFF LEVEL SWITCH, Z-TRON III OFFERS COTE-SHIELD CIRCUITRY
With no moving parts to wear, break or fail, the economical Z-tron III level switch offers a maintenance-
free alternative to electromechanical switches.The compact, one-piece unit installs through a standard
3/4-inch NPT fitting located at the desired high- or low-level position. Sensing element wetted parts are
Type 316 SS or PEEK (polyether-ether-ketone) high-temperature thermoplastic, with Cote-Shield
circuitry that allows the Z-tron III to ignore coatings or build-up on the sensing element, while
preventing false signals from dust or tunneling. The unit can operate on 230Vac, 120Vac or 24Vdc
input, with output signal provided by a DPDT relay.
http://www.alliancecontrols.com/DREXELBROOK/On_Off_Level_Switch.html 11/8/2005
DREXELBROOK

A Leader In Level Measurement Solutions
Z-tron III Z02X-Series

Easy-Installation
One-piece unit is easily installed through a single
3/4-inch vessel opening. Calibration is quick and
simple.
Z-tron III Point Level Switch, a reliable
low-cost, on/off level switch
The low-cost, Drexelbrook Z-tron III level switch is
unaffected by sticky coatings and impervious to
corrosive liquids. The all-electronic design means
no moving parts to wear, break or fail. Based
on field-proven RF technology, the Z-tron III is a
simple and reliable on/off level switch.
The compact one-piece unit is inserted through

a standard 3/4-inch NPT opening into the vessel
so that the sensing element is positioned at the
desired high or low level. (Other connection
types and sizes are also available.) When the
material level reaches a predetermined point on
the sensing element, it causes a change in status
at the electronic unit, resulting in actuation of the
Economical DPDT relay. The relay can be used to operate
Effective, low-cost material level detection in alarms, annunciators, valves, or other control or
a wide variety of applications, and a desirable indication devices.
alternative to electromechanical level switches.
No expendable parts to buy and stock. No Drexelbrook's exclusive Cote-ShieldTM
expensive, extra-cost options. circuitry enables the Z-tron III to ignore
dust pileups, coatings, and sticky
Maintenance-Free buildups on the sensing element.
Unlike paddle wheels, vibrating tines or other
mechanical instruments, there are no components Suspended dust particles are also no problem as
to jam, break or wear out. No need for routine the Z-tron III reacts only to actual high or low level
maintenance, cleaning or replacing of worn parts. conditions.
Reliable Operation
Cote-Shield circuitry allows the Z-tron III to ignore
coatings or build up on the sensing element.
There are no false signals from dust or tunneling.
Z-tron III Z02X-Series
Specifications Dimensions Wiring
Power requirement 4 1/2
120 25 Vac, 50/60 Hz (std.) (114)
230 25 Vac, 50/60 Hz (optional) 2 9/16

(65)
15-30 Vdc (optional) LED ALARM
WHEN OUT
(1 Watt maximum)
3 5/8
NEMA 4X
Output ALUMINUM
(92) TIME DELAY
DPDT relay HOUSING ADJUSTMENT
ASSEMBLY SET POINT
ADJUSTMENT FAIL SAFE SELECTOR
Contact Rating 3/4 NPT
FWD/REVERSE TIME
WIRE ENTRY
Non-inductive 5A @ 120 Vac or 700-0206-SERIES 4 3/16 DELAY SELECTOR
2A @ 230 Vac 3-TERMINAL (106)
SENSING ELEMENT NOTE: FAIL SAFE AND TIME DELAY
Min. Rating 100mA/12VDC SELECTED WITH DIP SWITCHES
Spark Tolerance 3/4" NPT MOUNTING POWER RELAY CONNECTIONS

100 A (std) A
1 2 3 4 5 6 7 8 9
7/8 DIA
CSL
(22)
Fail Safe C
GND L1 L2 NC C NO NC C NO
High (HLFS) or I.L.
Low (LLFS) field adjustable
Response Time
Approx. 0.2 sec.
Adjustable 0-60 seconds 3/8 (9.5)
Sensitivity Model Number

0.3 pF
Technology
Differential Z RF Admittance
Worst case with horizontal sensing Reserved for future use
element, 1/64"(.4mm) or less 0
Input
Recommended Ambient 0 120Vac
Electronics Temperature 1 24Vdc
3 230Vac
-40F to 145F*
(-40oC to 63oC) Output
2 Double pole Double Throw Relay
*Unit will operate above 145F Sensing Element
but with reduced component life. Application Sensing Element Pressure/Temperature Wetted Parts
05 General 700-0206-201 14bar@121C 316SS
Temperature Effect Purpose (200psi@250F) & PEEK
0.5 pF/50F(10oC) Cote-Shield Length
A 10 inch/254mm
Line Voltage Effect B 3.5 inch/88.9mm
0.2 pF/20V C 2 inch/51mm
Insertion Length (IL)
Sensing Element Connection A 6 inch/152mm
3/4" NPT (Optional Flange Mount) B 12 inch/305mm
C 18 inch/457mm
Sensing Element Wetted Parts D 36 inch/914mm
316SS & PEEK (2) E 48 inch/1219mm
F 60 inch/1524mm
Process Pressure & Temperature H 72 inch/1829mm
200 psi at 250F Z Other
14 BAR at 121C
Approvals
UL/CUL/508 General Purpose
CE Mark (1) Private label/OEM optimization available. Contact your Drexelbrook representative or factory for more
detailed information.
Housing (2) PEEK (Polyether-Ether-Ketone) is a special, high-temperature thermoplastic similar to TFE but with
better abrasion resistance.
NEMA 1through 5 & 12
U.S.A. Sales: 800-553-9092 24-Hour Service: 800-527-6297 International Support: 215-674-1234 Fax: 215-674-2731
AMETEK Nihon Drexelbrook AMETEK Singapore Pte. Ltd. AMETEK Precision Instruments Europe
2 Chome 12-7 Minami Gyotoku 10 Ang Mo Kio Street 65 Rudolf-Diesel-Strasse 16
Ichikawa City Chiba 27201 Japan #05-12 Techpoint 569059 Singapore D-40670 Meerbusch Germany
DREXELBROOK Phone: 81-473-56-6513 Phone: 65-6484-2388 Phone: 49-2159-9136-0
205 Keith Valley Road Fax: 81-473-56-6535 Fax: 65-6481-6588 Fax: 49-2159-9136-39
Horsham PA 19044 U.S.A. E-mail: nd@nihon-drexelbrook.co.jp E-mail: aspl@ametek.com.sg Web: www.ametek.de
E-mail - drexelbrook.info@ametek.com
Web - www.drexelbrook.com 2003, by AMETEK, Inc. All rights reserved. Printed in the U.S.A. Z0X-A EDO#3-03-251
Leader in
Level Measurement
For Assistance Call 1-800-527-6297

Outside North America + 215-674-1234
Installation and
Operating Instructions
Series Z0X-2
Z-tron IIITM Level Control
+ 215-674-1234 Outside North America

1-800-553-9092 US and Canada
www.drexelbrook.com
drexelbrook.service@ametek.com
AMETEK Drexelbrook makes no warranty of any kind with regard to the material contained
in this manual, including, but not limited to, implied warranties or fitness for a particular
purpose. Drexelbrook shall not be liable for errors contained herein or for incidental or
consequential damages in connection with the performance or use of material.
Copyright 2002 AMETEK Drexelbrook

EDO #10-03-243
Z0X-2-LM
Series Z0X-2
Z-tron IIITM Level Control
205 Keith Valley Road, Horsham, PA 19044

US and Canada: 1-800-553-9092
International: +1 215-674-1234
24-Hour Service: +1 215-527-6297
Fax: +1 215-674-2731
An ISO 9001 Certified Company E-mail: drexelbrook.info@ametek.com
Website: www.drexelbrook.com
EDO #10-03-243
Z0X-2-LM
Table of Contents
Section 1: Introduction ................................................................................................ 1
1.1 System Description ...................................................................................... 1
1.2 Technology ................................................................................................... 1
1.3 Model Number ............................................................................................. 2
Section 2: Installation .................................................................................................. 3

2.1 Unpacking .................................................................................................... 3
2.2 Mounting the Level Control ......................................................................... 3
2.3 Mounting Dimensions .................................................................................. 5
2.4 Power Wiring ................................................................................................ 6
2.5 Relay Wiring................................................................................................. 8
Section 3: Operation .................................................................................................... 9

3.1 Setpoint Control ........................................................................................... 9
3.2 Time Delay Control ...................................................................................... 9
3.3 Time Delay Action ........................................................................................ 10
3.4 Failsafe ........................................................................................................ 10
3.5 Start-up ........................................................................................................ 10
Section 4: Calibration .................................................................................................. 11

4.1 Calibration in Conducting Material ............................................................... 11
4.2 Calibration in Insulating Material [Horizontal Mount].................................... 11
4.3 Calibration in Insulating Material [Vertical Mount] ........................................ 12
Section 5: Troubleshooting ......................................................................................... 13

5.1 Introduction .................................................................................................. 13
5.2 Testing Electronic Unit.................................................................................. 13
5.3 Testing Sensing Element.............................................................................. 13
5.4 Testing Relay Circuits................................................................................... 15
5.5 Possible Problems and Causes ................................................................... 16
5.6 Factory Assistance....................................................................................... 17
5.7 Field Service ................................................................................................ 17
5.8 Customer Training ........................................................................................ 17
5.9 Equipment Return........................................................................................ 18
Section 6: Specifications............................................................................................. 19
Appendix A: Shortening or Lengthening the Sensing Element.................................. A-1

Introduction
Section 1: Introduction
These instructions are for the AMETEK Drexelbrook
Z-tron III Series Point Level Control.
The label on top of the electronic unit identifies the model number of the
Z-tron III level control.
If the model number on the electronic unit is a 402-3000, the

instructions are included in the 502-3000-LM Instruction Manual.
Both of these manuals can be downloaded from our resource library at
www.Drexelbrook.com
1.1 System Description

Cote-Shield action is designed into all Z-tron III level controls and
enables the instrument to ignore the effect of buildup or material coating
on the sensing element.
The electronic unit:

k air
Provides double-pole double-throw dry relay contact closure when
d d material reaches a specific point on the sensor. The relay contacts
C
A
k air C
A
k media may be used to operate alarms, solenoid valves, or other low power
devices.
k media Provides a 0-60 second time delay for agitated vessels.
kA kA The 700-series sensing element:
C= d C = d
Figure 1-1 Is mounted on the tank or in the process.
Capacitance Probe Provides a change in radio frequency (RF) admittance indicating
(Insulating Media) presence or absence of material.
1.2 Technology
In a simple capacitance probe type sensing element, when the level rises
and material covers the probe, the capacitance within the circuit between
the probe and the medium (conductive applications) or the probe and the
vessel wall (insulating applications) increases. This is due to the dielectric
constant (k) of the material, which causes a bridge misbalance. The signal
is demodulated (rectified), amplified and the output is increased. There
are drawbacks, however, especially when there is coating of the probe.
An RF Admittance level transmitter is the next generation. Although
similar to the capacitance concept, The Z-tron employs a radio frequency
signal and adds the Cote-Shield circuitry within the Electronics Unit.
This patented Cote-Shield circuitry is designed into Z-tron series and
enables the instrument to ignore the effect of buildup or material coating
Figure 1-2
on the sensing element. The sensing element is mounted in the vessel
RF Admittance Probe
and provides a change in RF admittance indicating presence or absence of
with Cote-Shield
material.
The Cote-Shield element of the sensor prevents the transmission of
RF current through the coating on the sensing element. The only path
to ground available for the RF current is through the material being
measured.
The result is an accurate measurement regardless of the amount of
coating on the probe, making it by far the most versatile technology, good
for very wide range conditions from cryogenics to high temperature, from
vacuum to 10,000 psi pressure, and works with all types of materials.
1
Z0X-2 Series Z-tron IIITM Point Level Control
1.3 Model Number
Technology
Z RF Admittance
Reserved for future use

0
Input
0 120Vac
1 24Vdc
3 230Vac
Output
2 Double Pole Double Throw Relay
Sensing Element
Application Sensing Element Pressure/Temperature Wetted Parts
05 General 700-0206-201 14bar@121C 316SS
Purpose (200psi@250F) & PEEK
Cote-ShieldTM Length
A 10 inch/254mm
B 3.5 inch/88.9mm
C 2 inch/51mm
Insertion Length (IL)

A 6 inch/152mm
B 12 inch/305mm
C 18 inch/457mm
D 36 inch/914mm
E 48 inch/1219mm
F 60 inch/1524mm
H 72 inch/1829mm
Z Other
{
2
Installation
Section 2: Installation
2.1 Unpacking
Carefully remove the contents of the shipping carton and
check each item against the packing list before destroying
any packing materials. If there is any shortage or damage,
report it to the factory at 1-800-527-6297 (US and Canada)
or + 215-674-1234 (International).
2.2 Mounting the Level Control

The Z-tron III Level Control is available with the
electronic unit and sensing element as a single integral
assembly. Extended sensing element lengths and special
mountings can be provided to fit specific applications.
The Z-tron III Level Control is designed for industrial

applications, but it should be mounted in a location as
free as possible from vibration, corrosive atmospheres,
or any possibility of mechanical damage.
For convenience when adjusting, place the electronic

unit in a reasonably accessible location. Ambient
temperature should be between -40F and 145F (-40C
to 63C).
It may be mounted either vertically or horizontally. See

Figures 2-1 and 2-2.
Avoid mounting closer than 1 inch to any tank

structure. Material bridging from structure to sensing
element can cause false alarms. Close proximity to tank
structure also increases the sensing elements standing
capacitance.
The actual mounting location often depends on the

placement of nozzles or openings into the vessel. Do not
mount the instrument through a nozzle which exceeds
the Cote-Shield element on the sensing element. See
Figure 2-1.
Protect the insulation on the sensing element against

cuts and scrapes during installation.
Figure 2-3 provides typical mounting dimensions.
3
2.2 Mounting the Level Control (continued)

Best
Cote-shield must
All Connections Sealed Wall build-up extend through
and Gaskets In Place nozzle and wall
does not extend
past first build-up by 2".
insulator.
Best
No Nozzle
Wrong
WRONG CORRECT
Nozzle too long;
Cote-shield too short.
NOZZLE
Conduit
Breather
Good Drain NOZZLE
Long Nozzle
Factory-supplied Cote-shield
extends through nozzle and
wall build-up.
Figure 2-1
Z-tron III Level Control Mounting Recommendations
All Connections Sealed

and Gaskets In Place
WRONG CORRECT
CONDULET
Packing WRONG CORRECT

Gland Hold here when
tightening Conduit
Assembly
Breather
Do Not Condulet
Drain
Disturb!
Hold here to install

or remove Sensing
Element from
Vessel
WRONG CORRECT
Figure 2-2
Z-tron III Level Control Installation Guidelines
CONDULET
Packing
Gland Hold here when
Assembly tightening
4 Do Not Condulet
Disturb!
Introduction
2.3 Mounting Dimensions

4 1/2
(114) 4 1/2"
(114)
2 9/16
(65)
3 5/8
NEMA 4X (92)
ALUMINUM 3 3/4
HOUSING
(95)
ASSEMBLY
3/4 NPT
WIRE ENTRY
700-0206-SERIES 4 3/16
3-TERMINAL (106)
SENSING ELEMENT
3/4" NPT MOUNTING
A
7/8 DIA
CSL
(22)
C
I.L.
3/8 (9.5)
Figure 2-3
Mounting Dimensions, Integral Z-tron III Level Control
5
2.4 Power Wiring

CAUTION
Do not open enclosure cover or make/break any

electrical connections without first
disconnecting electrical power at the source. Ensure
that area is non-hazardous. Ensure that wiring,
electrical fittings and conduit connections conform to
electrical codes for the specific location and hazard
level.
The Z-tron III level control is a general purpose device

and is not agency approved for use in hazardous
locations. If agency approval is required, contact your
local AMETEK Drexelbrook representative or call 1-
800-553-9092.
Refer to Figures 2-5 through 2-7 for the appropriate power

wiring and use the following procedure to wire the Z-tron III
level control:
1. Ensure that all power to the wiring is off.
2. Remove the cover.
3. The power connections are made to terminals 1, 2, and

3 on the electronic chassis as shown in Figures 2-5
through 2-7, using 12-28 gauge wire. The Z-tron III
level control requires at least 1 watt of power.
4. The alarm relays are wired as shown in Figure 2-8.
5. Review Checklist:
a. Wiring correct.
b. Input voltage matches instrument label.
c. Proper output connections.
6. Replace the cover prior to restoring power if in a

hazardous area.
7. Turn power on.
6
Installation
2.4 Power Wiring (continued)
Use 12-28 gauge wire.
Relay Connections
}
HOT (L2)
Neutral (L1) Power Connections
Ground (GND) (120Vac)
Figure 2-5
Wiring the (120 VAC) Electronic Unit
24 VAC
GND +
Relay Connections
}
+
Power Connections
(24Vdc)
Figure 2-6
Wiring the (24 VDC) Electronic Unit
240 VAC
Relay Connections
}
HOT (L2)
Neutral (L1) Power Connections
Ground (GND) (240Vac)
Figure 2-7
Wiring the (240 VAC) Electronic Unit
7
2.5 Relay Wiring

Refer to Figure 2-8 for the relay contact wiring. The Z-tron
III relay has double-pole, double-throw (DPDT) dry contacts.
The relay serves as a switch and does not provide the power
to operate an annunciator or other equipment. All relay
connections are made to the terminal strip on the electronic
unit.
HIGH LEVEL
HIGH LEVEL
FAIL-SAFE FAIL-SAFE
Switch 1 RIGHT 1 2 3 4 5 6 7 8 9
ON
= High Level Fail Safe 1
2
LED ON
(NORMAL) Level Below Sensing Element
TANK EMPTY
HIGH LEVEL HIGH LEVEL

FAIL-SAFE FAIL-SAFE
Switch 1 RIGHT ON
1 2 3 4 5 6 7 8 9
= High Level Fail Safe 1
2
LED OFF
(ALARM)
Level Above Sensing Element
TANK FULL
N.C. =
Normally Closed
N.O. = LOW LEVEL LOW LEVEL

Normally Open FAIL-SAFE FAIL-SAFE
1 2 3 4 5 6 7 8 9
Switch 1 LEFT ON
= Low Level Fail Safe 1
2
LED OFF
(ALARM) Level Below Sensing Element
TANK EMPTY
LOW LEVEL LOW LEVEL

FAIL-SAFE FAIL-SAFE
1 2 3 4 5 6 7 8 9
Switch 1 LEFT ON
1
= Low Level Fail Safe 2
LED ON
(NORMAL) Level Above Sensing Element
TANK FULL
Figure 2-8
Wiring the Relays
8
Operation
Section 3: Operation
This section describes the operating switches of the Z-tron
III level control. Remove the dome lid and use a small
screwdriver to set the operating controls.
3.1 Setpoint Control
There is a single operating point adjustment used to control
the level at which the relay operates. See Figures 2-8 & 3-1.
This adjustment is an 20-turn potentiometer and does

not have a mechanical stop. When in High Level Fail
Safe condition, if light (LED) is ON - turn CCW to find
SP (relay changes state w/click & light turns OFF)...
turn CW if light is initially OFF. Opposite is true in
Low Level Fail Safe.
Turning the setpoint adjustment clockwise (CW) raises
the level at which the relay operates.
Turning the setpoint counterclockwise (CCW) lowers the
level at which the relay operates.
The LED (on) indicates that the relay is energized.
Hold-down Screws
LED
(Alarm when
Setpoint NOT illuminated)
Adjustment
Time Delay
Adjustment
Switch 1 LEFT = Low Level Fail Safe
Switch 1 RIGHT = High Level Fail Safe ON
1
2
Switch 2 LEFT = Reverse Time Delay
Switch 2 RIGHT = Forward Time Delay
Figure 3-1
Z-tron III Operating Controls and LED
3.2 Time Delay Control

The time delay adjustment is located on top of the
instrument, as shown in Figure 3-1. It is used to help stop
an oscillating relay output due to agitation or waves in the
vessel.
CAUTION:
THIS adjustment is a 270 (34 turn) potentiometer. Do
not turn it beyond its mechanical stops or damage to
unit may occur.
The unit is shipped with the Time Delay set to zero (0)
seconds. Using a small screwdriver, turn the adjustment
clockwise to set anywhere from 0 to 60 seconds.
9
3.3 Time Delay Action

Time delay action describes whether the relay contacts are
delayed from going into the alarm state or recovering from an
alarm state.
FWD: Forward delays the system from coming OUT of
alarm.
REV: Reverse delays the system from going INTO
alarm.
The instrument is supplied with the time delay action
set in the forward mode position.
The time delay action may be selected in the field using
the slide switch #2 located on the top of the instrument.
See Figure 3-1.
Selecting Time Delay with Slide Switch #2:
Forward Acting - Switch #2 is ON, or to the RIGHT.
Reverse Acting - Switch #2 is OFF, or to the LEFT.
3.4 Failsafe
Failsafe describes the level condition which causes the
output relay to de-energize, and determines the condition
of the relay upon loss of power or upon the failure of most
components.
The failsafe mode may be selected in the field by
changing the position of slide switch #1 located on the
top of the instrument. See Figure 3-1.
High Level Failsafe (HLFS) means the relay will de-
energize when level is high, indicating high level upon
loss of power. (N.O. contacts open/N.C. contacts closed)
Low Level Failsafe (LLFS) means the relay will de-
energize when level is low, indicating low level upon loss
of power. (N.O. contacts open/N.C. contacts closed)
The instrument is supplied in the failsafe mode that is
requested when the order is placed. If none specified, it
will be shipped as High Level Failsafe (HLFS).
Selecting Failsafe with Slide Switch #1:

High Level Failsafe (HLFS) - Switch #1 is ON, or to the
RIGHT.
Low Level Failsafe (LLFS) - Switch #1 is OFF, or to the
LEFT.
3.5 Start-up
Before applying power to the instrument, be sure that the
power wiring is correct. See Section 2.3.
10
Calibration
Section 4: Calibration
This section contains the calibration information for the
Z-tron III Level Control.
CAUTION:
Do not open enclosure cover or make/break any
electrical connections without first disconnecting
electrical power at the source. Ensure that area is
non-hazardous. Ensure that wiring, electrical fittings
and conduit connections conform to the electrical
codes for the specific location.
The Z-tron III level control is a general purpose device
and is not agency approved for use in hazardous
locations. If agency approval is required, contact your
local AMETEK Drexelbrook representative or call
1-800-553-909
4.1 Calibration in Conducting Material
All Z-tron III controls are factory set to switch in water-
based conducting materials [setpoint adjustment is set to
full clockwise (CW) position]. No calibration adjustment is
necessary.
If this instrument had been previously adjusted for use in a
insulating materials, and is now intended for use in a
conducting material, use a small screwdriver to turn the
setpoint adjustment to the full clockwise (CW) position. No
other adjustment is necessary.
4.2 Calibration in Insulating Material [Horizontal Mount]

Use the following procedure:
1. Be sure the material level is well below the sensing
element. See Figure 4-1.
2.. Turn the setpoint adjustment to the full
counterclockwise (CCW) position.
This 20-turn potentiometer does not have a
mechanical stop. Turn 20 times to assure that you are
at the extreme end. No damage will occur.
The LED (on) indicates that the relay is energized or
in normal condition (not alarm).
3. Turn setpoint adjustment slowly clockwise (CW) until
the relay just operates. (LED changes state).
4. Increase the material level until it is well above the
sensing element. See Figure 4-2. (LED changes state).
5. Mentally note the position of the screwdriver.
6. Counting the number of turns, turn the setpoint
adjustment slowly clockwise (CW) until the relay once
again just operates.
11
4.2 Calibration in Insulating Material [Horizontal Mount]- (Continued)

If less than one turn of the adjustment was observed
between the sensing element covered and uncovered,
the sensor is not generating enough signal. Consult
the factory for further options.
7. Turn the adjustment back counterclockwise (CCW) one
half the number of turns that were counted.
8. Record number of turns and save for future calibration
reference
Calibration is now complete.
4.3 Calibration in Insulating Material [Vertical Mount]

This 20-turn potentiometer does not have a
mechanical stop. Turn 20 times to assure that you are
at the extreme end. No damage will occur.
The LED (on) indicates that the relay is energized or in
normal condition (not alarm).
1. Set the level to a point on the active section of the
sensing element where control is desired (3 inches [76.2
mm] of coverage minimum). See Figure 4-3.
2. Start from the full counterclockwise (CCW) position.
Turn the setpoint adjustment clockwise (CW) until the
relay just operates (LED changes states).
If dielectric constant or conductivity of material
changes, point of operation may change. Consult
factory.
Calibration is now complete.
DESIRED
CONTROL
POINT
Figure 4-1 Figure 4-2 Figure 4-3

Level Below Horizontal Level Above Horizontal Level Covering Vertical
Sensing Element Sensing Element Sensing Element
12
Troubleshooting
Section 5: Troubleshooting
5.1 Introduction
The Z-tron III Level Control is a solid-state device with
no moving parts other than its relays, and requires no
maintenance or adjustments. The units are designed to give
years of unattended service.
A spare electronic chassis is recommended for every 10 units

so that, in case of a failed unit, a critical application will not
be delayed while the unit is returned to the factory for repair.
Use the following troubleshooting procedures to check out the

Z-tron III Level Control. If attempts to locate the difficulty
fail, notify your local Drexelbrook representative, or call the
factory direct at 1-800-527-6297 (US and Canada) or
+1 215-674-1234 (International).
5.2 Testing Electronic Unit
It is recommended to begin with Electronic Unit:
1. Verify that voltage is reaching unit.
2. Change fail-safe selector switch (Fig 3-1). If LED does

not change state along with relays, Electronic Unit has
failed.
3. Remove power from unit, loosen hold-down screws , then

remove unit, and SAFELY reapply power.
4. As in Section 3.1, start with setpoint adjustment

in extreme counterclockwise (CCW) position, turn
screwdriver clockwise (CW) until relay just operates.
5. Rotate setpoint adjustment back and forth about this

point, observing travel of screwdriver between relay
pull-in and relay drop-out. If properly operating,
screwdriver should travel less than 14 turn to operate
the relay. If not, Electric Unit has failed.
5.3 Testing Sensing Element

Be sure to first test Electronic Unit. Then:
1. Remove Electric Unit, as above, but do not apply power.
2. Use an analog ohmmeter1 that is set to the R x 1K ohm

scale. Measure the resistances between each pair of
sensing element connections. See Figure 5-1.
Center spring to housing __________ohms

Center spring to outer spring __________ohms
Outer spring to housing __________ohms
13
5.3 Testing Sensing Element (continued)

3. A new sensing element that is clean and not coated
or wet should look like an open circuit on all sensing
element tests.
4. If the sensing element is clean and dry, and shows
resistance between terminals of less than 10K ohms, it
is possible that moisture has soaked into the packing
gland of the sensing element. In this case, the sensing
element may need to be dried until the resistance
increases to its maximum value.
5. If the process material is conductive, you may read some
resistance between sensing element connections. The
lowest permissible resistance values are:
Center spring to housing 1000 ohms.

Center spring to outer spring 600 ohms.
Outer spring to housing 300 ohms.
6. Resistance values lower than this could mean:
Extremely conductive coating on probe, which is an
application problem. You may wish to call the factory for
suggestions for another technique.
Probe is damaged and needs to be replaced.
Probe is touching vessel.
7. A resistance reading of less than 10 ohms on any
sensing element terminal is usually due to a metal-to-
metal short circuit. Check that the sensing element is
not touching any vessel structure.
1
An analog ohmmeter has a lower ohms/volt rating and
provides more current to measure the resistance than a
digital ohmmeter.
ANALOG ANALOG
OHMMETER OHMMETER
TO CENTER TO OUTER
CONDUCTOR GROUNDED CONDUCTOR GROUNDED
SPRING TO SPRING TO
HOUSING HOUSING
PACKING PACKING
GLAND GLAND
DO NOT DISTURB DO NOT DISTURB
Figure 5-1
Checking the Sensing Element
Center Spring = Probe
Outer Spring = Shield
Housing = Ground
PROBE MEASUREMENT SHIELD MEASUREMENT
14
Troubleshooting
5.4 Testing Relay Circuits

Using an ohmmeter, perform the following steps to check out
the relay circuits:
1. The relay circuits consist of double-pole double-throw

relay contacts brought out to terminal strips. When
the relays are operating properly, one pair of contacts
will be open with high or low level, and one pair will be
closed with high or low level. Refer to Figures 2-10 and
5-2.
2. Relay operation may generally be heard as an audible

click when the background noise is not too high. Use
one of the methods shown in Figure 5-3 to determine if
the relay contacts are switching.
3. Difficulty in calibration can often be traced to improper

wiring of the relay terminals to an annunciator or other
panel device. Check the wiring against the relay chart in
Figure 2-10.
Figure 5-2
Relay Circuit Operation
OHMMETER
OR
115Vac LAMP
115Vac
Figure 5-3
Relay Circuit Troubleshooting
15
5.5 Possible Problems and Causes
Problem Possible Cause Solution

1. Instrument indicates a. Severe coating build upon a. Need longer Cote-Shield.
alarm at all times. sensing element (HLFS). Consult factory.
b. Sensing element not b. Need longer insertion
seeing material (LLFS) length. Consult factory.
due to fill angle. c. See Section 5.3.
c. Defect in sensing element. d. Check power wiring.
d. Loss of power. See Figure 2-4.
e. Improper relay wiring. e. See Section 2.5.
f. Improper calibration. f. See Section 4.
g. Electronic unit g. See Section 5.2.
malfunction. h. See Section 5.3.
h. Shorted sensor. i. Consult factory.
i. Water in housing or
conduit.
2. Instrument never a. Severe coating build-up on a. Need longer Cote-Shield.

indicates alarm. sensing element (LLFS). Consult factory.
b. Sensing element not b. Need longer insertion
seeing material (HLFS) length. Consult factory.
due to fill angle. c. See Section 2.
c. Improper wiring. d. See Section 4.
d. Improper calibration. e. See Section 5.2.
e. Electronic unit
malfunction.
3. Instrument cant be a. Improper wiring. a. See Section 2.

calibrated. b. Insufficient signal from b. Need longer insertion
sensing element. length. Consult factory.
c. Setpoint is beyond the c. Consult factory.
tuning range of the e. See Section 5.2.
electronics.
d. Electronic unit
malfunction
e. Sensor covered with
conducting material.
4. Instrument gives a false a. Improper calibration. a. See Section 4.

alarm. b. Loose wiring. b. See Section 2.
c. Electronic unit c. See Section 5.2.
malfunction. d. Consult factory.
d. Time delay required. e. See Section 5.3.
e. Intermittent short of
sensor.
5. Instrument operates a. Improper calibration. a. See Section 4.

intermittently. b. Loose wiring. b. See Section 2.
c. Electronic unit c. See Section 5.2.
malfunction. d. Need high sensitivity unit.
d. Dielectric (k) of material Consult factory.
is too low.
16
Troubleshooting
5.6 Factory Assistance

AMETEK Drexelbrook can answer any questions about The
Z-tron III series instrument. Call Customer Service at
1-800-553-9092 (US and Canada) or
+1 215 674-1234 (International).
If you require assistance and attempts to locate the problem

have failed:
Contact your local Drexelbrook representative,
Telephone the Service department toll-free:

1-800-527-6297 (US and Canada)
+1 215 674-1234 (International)
FAX: Service Department + 215-443-5117

E-Mail: drexelbrook.service@ametek.com
Please provide the following information:
Instrument Model Number

Sensing Element Model Number and Length
Original Purchase Order Number
Material being measured
Temperature
Pressure
Agitation
Brief description of the problem
Checkout procedures that have failed
5.7 Field Service

Trained field servicemen are available on a time-plus-
expense basis to assist in start-ups, diagnosing difficult
application problems, or in-plant training of personnel.
Contact the service department for further details.
5.8 Customer Training

Periodically, AMETEK Drexelbrook instrument training
seminars for customers are held at the factory. These
sessions are guided by Drexelbrook engineers and specialists,
and provide detailed information on all aspects of level
measurement, including theory and practice of instrument
operation. For more information write to:
AMETEK Drexelbrook, Communications/ Training Group
or call 215-674-1234.
17
5.9 Equipment Return

In order to provide the best service, any equipment being
returned for repair or credit must be pre-approved by the
factory.
In many applications, sensing elements are exposed to

hazardous materials.
OSHA mandates that our employees be informed and
protected from hazardous chemicals.
Material Safety Data Sheets (MSDS) listing the

hazardous materials to which the sensing element has
been exposed MUST accompany any repair.
It is your responsibility to fully disclose all chemicals

and decontaminate the sensing element.
To obtain a return authorization (RA#), contact the

Service department at 1-800-527-6297 (US and Canada) or
+ 215-674-1234 (International).
Please provide the following information:
Model Number of Return Equipment
Serial Number
Original Purchase Order Number
Process Materials to which the equipment has been

exposed.
MSDS sheets for any hazardous materials
Billing Address
Shipping Address
Purchase Order Number for Repairs
Please include a purchase order even if the repair is

under warranty. If repair is covered under warranty,
you will not be charged.
Ship equipment freight prepaid to:
AMETEK-DREXELBROOK.
205 KEITH VALLEY ROAD
HORSHAM, PA 19044-1499
COD shipments will not be accepted.
18
Specifications
Section 6: Specifications
Power Requirements:
AC Units:
95-145 Vac, 50/60 Hz, 1 Watt
215-265 Vac, 50/60 Hz, 1 Watt
DC Units:
24 Vdc Unit: 19-29 Vdc input, 1 Watt
Sensitivity:
0.3pF or less
Load Resistance:
Center to Ground, 1500 ohms
Center to Shield, 750 ohms
Shield to Ground, 750 ohms
Failsafe:
Field adjustable to either High-Level Fail-Safe (HLFS)
or
Low-Level Fail-Safe (LLFS)
Output:
DPDT relay closure
Contact Rating:
5A @ 120 Vac non-inductive
2A @ 230 Vac non-inductive
Ambient Temperature:
-40F to 145F (-40C to 60C)
Temperature Effect:
0.5pF/50F
Line Voltage Effect:

0.2pF/20V @ 120 Vac
Stability:
0.15pF/6 mo. maximum shift
Spark Protection:
100 Amp
Mounting:
34-inch NPT standard
19
Section 6: Specifications (Continued)

Housing:
The standard explosionproof housing meets the following
classifications:
Nema 1 General-Purpose
Nema 2 Drip-Tight
Nema 3 Weather-Resistant
Nema 4 Waterproof
Nema 5 Dust-Tight
Nema 12 Industrial Use
FM approved for Class I, Groups A, B, C, and D (Div. 1

or 2) and Class II, Groups E, F, and G, (Div. 1 or 2). FM
approval on housing only. If agency approval is required,
use the Drexelbrook 506-6000 LCS instrument for point
level control.
Time Delay:
0-60 seconds
Sensing Element:
Sensing Process Process Center

Element Temperature Wetted Rod
Model and Pressure Parts O.D.
Number
700-206-201 250F @ 200 psi 316 SS and Peek 3/8 inch
20
Appendix
Appendix A:Shortening or Lengthening the Sensing Element
The Need
Sometimes your application calls for probe lengths
CAUTION: other than the standard 18-inch or longer insertion
The insulation length of
lengths supplied. Shortening the sensing element is
either Flush Sensing
quite simple and can be done in the field. Lengthening
Elements or Insulated
Sensing Elements can the sensing element, however, is more difficult because
NOT be changed. Cable the metal rod, typically 304 SS or 316 SS, must be
Sensing Elements welded.
can only be shortened.
Instructions are included Before making any Adjustments:
with each unit. 1) Read the following instructions thoroughly.
2) Remove power.
3) Disconnect the electronics.
4) Protect electronics from any static discharge.
5) Protect electronics from any heat.
Shortening
The bare metal center rod of the sensing element can
NOTE: be shortened with a hacksaw. Be careful not to cut
Insulators Cote-Shield either of the two insulators. See Figure on this page.
element must
NEVER be
modified. In applications using conductive or water-based
materials, shortening is not a problem. Leave a
minimum bare metal center rod length of two (2)
inches.
For dry granular materials, such as powder, sand,

Insertion Length corn, clinker, etc., you must leave a minimum bare
(18" or 36" std.) metal center rod length of eight (8) inches. Consult the
factory before shortening beyond this point.
Center Rod Lengthening

To lengthen the sensing element, an extension rod can
be welded onto the end of the bare metal center rod.
Make sure that the extension rod is the same metal as
Note: the sensing element.
Any changes to probe
length after calibration An alternate option is to add a pipe coupling and a
requires re calibration to section of metal pipe after threading the tip of the
ensure proper operation. sensing element. In this case, the metal pipe need not
be identical to the metal of the sensing element.
A-1
205 Keith Valley Road, Horsham, PA 19044
US and Canada: 1-800-553-9092
International: +1 215-674-1234
24-Hour Service: +1 215-527-6297
Fax: +1 215-674-2731
An ISO 9001 Certified Company E-mail: drexelbrook.info@ametek.com
Website: www.drexelbrook.com
Product Data Sheet
00813-0100-2654, Rev DA
September 2003 Volume 1
Temperature Sensors and Accessories

(Volume 1)
Content
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2
Threaded Mount Sensors and Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 9
Ordering Tables
Series 68 RTD Sensor Assemblies WITHOUT Thermowell. . . . . . . . . . . . . . . . . . . . . . page 12
Series 68 RTD Sensor Assemblies WITH Thermowell . . . . . . . . . . . . . . . . . . . . . . . . . page 14
Series 68Q Sanitary Platinum RTD Sensor Assemblies . . . . . . . . . . . . . . . . . . . . . . . . page 26
Series 58C Cut-to-Fit RTD Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 28
Series 58C Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 28
Series 183 Thermocouple Sensor Assemblies WITHOUT Thermowell . . . . . . . . . . . . . page 30
Series 183 Thermocouple Sensor Assemblies WITH Thermowell . . . . . . . . . . . . . . . . page 32
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 36
Mounting Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 48
Ordering Tables
Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 48
Connection Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 49
Compression Fittings, 316 SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 50
Series 91 Thermowells. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 55
Hazardous Area Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 64
Configuration Data Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 69
www.rosemount.com
Product Data Sheet
00813-0100-2654, Rev DA
Volume 1 September 2003
Introduction
OVERVIEW Hazardous Area Approvals
Emerson Process Management offers a wide variety Includes descriptions of the FM, CSA, and
of RTD and thermocouple sensors that are available CENELEC approvals for sensors and
connection heads.
alone or as complete assemblies including
connection heads, thermowells, and extension Configuration Data Sheet
fittings. In addition to complete assemblies, Emerson Provides a form used for thermowell
Process Management offers heads, coupling/nipple application calculations.
and union/nipple extensions, compression fittings,
and thermowells. Series 58C, 68, 68Q, and 78 platinum RTD
temperature sensors are primarily used when high
Using this Product Data Sheet (PDS) accuracy, durability, and long-term stability are
required. These sensors conform to international
Use this PDS to order complete temperature sensor standards: IEC-751, EN 60751, and BS EN 60751.(1)
assemblies, which include sensors, thermowells,
extensions, and connection heads. These options Series 58C platinum RTD temperature sensors:
can also be ordered separately. For example, you Combine an economical thin-film design with a
can order a thermowell, extension, or connection sheath that can be shortened to any length
head for use with an existing sensor. In each case it with tubing cutter.
is important to know and understand the sections of
Series 68Q Quick Response Sanitary RTD sensors:
this PDS when specifying the items.
Conform to 3A Sanitary Standards and
Threaded Sensors and Assemblies feature product contact surfaces designed for
Includes descriptions, specifications, and CIP cleaning.
ordering information for Series 58C, 68, 68Q, Series 68 platinum RTD temperature sensors:
and 78 RTDs, and the Series 183
thermocouples. Provide high performance in an economical
thin-film design.
Includes information for ordering sensors,
connection heads, extensions, and Series 78 platinum RTDs temperature sensors:
thermowells as complete assemblies. Use a wire-wound element which allows for a
broader measurement range.
Calibration
Includes characterization schedules and Thermocouples
information for ordering calibrated Series 68,
68Q, and 78 RTD Sensors. Series 183 thermocouple temperature sensors
conform to ASTM E-230, and are available in types
Includes information regarding the use of
J, K, E, and T.
Callendar-Van Dusen constants to match
specific Series 68, 68Q, and 78 RTDs to Series 183 thermocouple temperature sensors are
Rosemount Smart Temperature Transmitters. available:
Mounting Accessories grounded or ungrounded
Includes descriptions, specifications, and isolated or unisolated
ordering information for temperature with immersion lengths from 2 to 48 inches.
accessories such as thermowells, extensions,
connection heads, mounting adapters, lead
wire extensions, connectors, seals, and
thermowells.
(1) 100 ohms at 0 C, = 0.00385 ohms/ohm/C
-2
Product Data Sheet
00813-0100-2654, Rev DA
The Use of 2-, 3-, and 4- wire RTDs
To help you attain the highest possible temperature measurement accuracy, Rosemount provides 4-wire sensors
for all single element RTDs. You can use these RTDs in 2-, 3-, or 4-wire configurations by simply securing the
unneeded leads with tape. To properly wire the 4-wire RTD for use in a 2-, 3-, or 4-wire configuration, refer to the
following wiring diagrams:
2-wire Configuration
2-wire RTDs provide one connection to each end of the sensor. In a 2-wire
configuration, lead wires add resistance to the circuit which cannot be compensated.
The 2-wire configuration is rarely used because the added lead wire resistance can
cause substantial errors in the temperature reading.
3-wire RTDs provide one connection to one end of the sensor, and two connections to
the other end. The 3-wire approach does not eliminate all lead wire effects. However,
for sensors with lead wires of the same length, lead wire effects are slight, and the
approach provides reasonable accuracy.
The most effective way to eliminate lead wire effects is with two connections at each
end of the sensor. 4-wire RTDs fully compensate for lead wire effects.
Benefits and Limitations of RTDs when compared to Thermocouples

Benefits:
Higher accuracy
Better linearity and long-term stability
Cold junction compensation not required
Special extension lead wire not required
Less susceptible to noise
Can be matched to a Rosemount transmitter with transmitter sensor matching
Limitations
Lower maximum temperature limit
Slower response time in applications without a thermowell
-3
Product Data Sheet
00813-0100-2654, Rev DA
HOW TO DECIDE WHAT TO ORDER
Start
(Select One)
Is a sensor for an Is a thermowell for an

Is a sensor with a existing thermowell existing sensor
thermowell needed? needed? needed?
Yes Yes Yes
Refer to Table 1. Do any Select a sensor without a Select a thermowell

standard lagging thermowell
length/immersion length
combinations meet the
requirements?
Yes No
Select a sensor with 1. Select a sensor

a thermowell without a thermowell
combination combination
2. Select a thermowell
Finish
-4
Product Data Sheet
00813-0100-2654, Rev DA
SPRING-LOADED SENSOR DIMENSIONS

When a spring-loaded sensor is used properly, the spring should be compressed approximately 1/2-inch. Therefore, all measurements of
spring-loaded sensors are made with the spring compressed. If you measure an existing spring-loaded sensor while it is in a relaxed state, you
must subtract 1/2-inch to arrive at the installed length (X) that must be ordered. See Figure 1.
FIGURE 1. Spring Loaded Sensors Dimensions
Compressed Spring Loaded Sensor
3.45 (88) Installed (X) Length

Max. [Spring Compressed
Sensors-0005C
0.5 (13) nominal]
Spring loaded sensor in a compressed state: The actual sensor length is measured when the spring is compressed approximately 1/2-in.
shorter than the relaxed sensor.
Relaxed Spring Loaded Sensor
2.95 (88) Max.

Installed (X) Length + 0.5 in.
Sensors-0005D
Spring loaded sensor in a relaxed state: Normally, when a spring loaded sensor is measured, it is in a relaxed state. You must subtract 1/2-in.
from your measurement to order a replacement sensor. Rosemount Inc. assumes that the sensor length you specify is that of a compressed
sensor.
Determining the Length (L) of a spring-loaded sensor to be used with an existing non-Rosemount Thermowell
See Figure 1, Figure 3, and Figure 4.
1. Remove the existing generic sensor from the installed thermowell. Length Code Key
2. Measure the sensor length with the spring in the relaxed state (as shown in L Thermowell length minus 0.25 in.
Figure 1). Measure from the tip of the sensor to the maximum thread engagement U Immersion length into process
point (0.53 in. into the threads). T Lagging length
3. Subtract 0.5 inches from your measurement. The resulting length is (X). E Extension fitting length
4. If the sensor is installed with an extension, measure the extension length (E), as X Sensor length
shown in Figure 4. If the sensor is not installed with an extension, let (E) = 0. Use the following equations to determine
5. Since (X) = (E) + (L), subtract (E) from (X) to find (L). all lengths
Use the resulting length (L) in the Section 2 ordering tables to choose the correct length
L = U + T + 1.5
of sensor. X=E+L
X = E + U + T + 1.5
-5
Product Data Sheet
00813-0100-2654, Rev DA
FIGURE 2. Thermowell Dimensions (use with Table 1)
Sensor with Thermowell (no extensions)
0.25-in.
L
Sensors-0007B
T U
1.75-in.
TABLE 1. Dimensions for thermowells when ordered with sensors (U), (L), and (T). Use with Figure 2.
Dimensions (in.)(1)
Code (U) (L) (T) Code (U) (L) (T) Code (U) (L) (T)
020 2.0 4.0 0.5 090 9.0 12.0 1.5 160 16.0 18.0 0.5
025 2.5 4.0 0.0 095 9.5 12.0 1.0 165 16.5 18.0 0.0
030 3.0 6.0 1.5 100 10.0 12.0 0.5 170 17.0 21.0 2.5
035 3.5 6.0 1.0 105 10.5 12.0 0.0 175 17.5 21.0 2.0
040 4.0 6.0 0.5 110 11.0 15.0 2.5 180 18.0 21.0 1.5
045 4.5 6.0 0.0 115 11.5 15.0 2.0 185 18.5 21.0 1.0
050 5.0 9.0 2.5 120 12.0 15.0 1.5 190 19.0 21.0 0.5
055 5.5 9.0 2.0 125 12.5 15.0 1.0 195 19.5 21.0 0.0
060 6.0 9.0 1.5 130 13.0 15 0.5 200 20.0 24.0 2.5
065 6.5 9.0 1.0 135 13.5 15.0 0.0 205 20.5 24.0 2.0
070 7.0 9.0 0.5 140 14.0 18.0 2.5 210 21.0 24.0 1.5
075 7.5 9.0 0.0 145 14.5 18.0 2.0 215 21.5 24.0 1.0
080 8.0 12.0 2.5 150 15.0 18.0 1.5 220 22.0 24.0 0.5
085 8.5 12.0 2.0 155 15.5 18.0 1.0 225 22.5 24.0 0.0
(1) L = U + T + 1.5
Ordering a Sensor and a Thermowell

See Figure 2 and Table 1 and Figure 3 and Figure 4. Use the following Procedure to determine if a standard lagging length can be use with the
sensor and thermowell.
1. Determine the (U), (T), and (E) lengths necessary for your installation. Length Code Key
If you do not need an extension, (E) = 0 (zero). L Thermowell length minus 0.25 in.
Note: If your existing sensor/thermowell combination is different than Figure 3, refer to U Immersion length into process
the drawings on the following pages. T Lagging length
2. Find your immersion length (U) on Table 1 above and compare the corresponding E Extension fitting length
lagging length (T) to the lagging length that you previously determined. X Sensor length
3. If your lengths match the values on the line that corresponds to your required
immersion length, order your sensor and thermowell together.
Use the following equations to determine
all lengths
If your lengths do not match the values on the line that corresponds to your measured
immersion length, order your sensor and thermowell separately. Solve for (L) using the L = U + T + 1.5
equation (L) = (U) + (T) + 1.5 (since (L) is required when ordering the sensor separately X = E + L
from the thermowell). X = E + U + T + 1.5
-6
Product Data Sheet
00813-0100-2654, Rev DA
FIGURE 3. Series 68, 78, and 183 Sensor Assembly Dimensional Drawings
Capsule Sensor Only
1.75 (44) Nominal (X) Length

Lead Wires (see Table 2)
Sensors-0007A
0.25 (6)
1.25 (32)
Housing Diameter (see Table 2)

0.6 (15) Max. Sensing Element*
* Maximum sensing element length for Series 78 dual-element = 1-in. (25 mm)
General Purpose Sensor Assembly
3.2 (81) Max. Nominal (X) Length**

Weld 360 0.25 (6)
Sensors-0008A
0.25 (6)
Fixed-Position Process Mounting 0.6 (15) Max. Sensing Element*

Connection (1/214 ANPT, both sides) 0.53 (13) Max. Thread Engagement
** Actual length is 0.25 (6) less to avoid bottoming in thermowell
Spring Loaded Sensor Assembly
Installed (X) Length **

Lead Wires (see Table 2) 3.45 (88)
Max.
Sensors-0000B06A
0.25 (6)

Spring-Positioned Process Mounting 0.53 (13) Max. Thread Engagement
Connection (1/214 ANPT, both sides)
** Spring Compressed 0.5 (13)
Bayonet Spring Loaded Sensor Assembly
4.75 (121) Installed (X)

Max. Length **
2.5 (64) 0.6 (15) Max. Sensing Element*
Max.
0.25 (6)
Sensors-3144-07A
Bayonet Adapter Mounting Connection 0.53 (13) Max. Thread Engagement
(1/214 ANPT, both sides)
Spring is shown compressed 0.5 -in.(13 mm.) Do not adjust the equations in Table 2 when calculating X, L, U, and T lengths. The equation
already accounts for spring compression.
Dimensions are in inches (millimeters)
TABLE 2. Sensor Series and Dimensions

Series Housing Diameter Lead Wires Lead Wire Length Series Housing Diameter Lead Wires Lead Wire Length
in mm in mm in mm in mm
68 0.350 8.0 4 6.0 152.4 183 single 0.375 9.53 2 6.0 152.4
78 single 0.350 8.0 4 6.0 152.4 183 dual 0.375 9.53 4 12.0 304.8
78 dual 0.350 8.0 6 6.0 152.4
-7
Product Data Sheet
00813-0100-2654, Rev DA
FIGURE 4. Series 68, 78, and 183 Sensor Assembly Length Code Drawings
Sensor with Thermowell (No Extension)
X 0.25 (6)
Sensor Mounting Connection
L
Sensors-0007A
T + 1.75 (44) U
Sensor with Extension (No Thermowell)
Nipple
Coupling
1
/214 ANPT Thread
Sensors-0008A
E L
Sensor Installed in Connection Head (Flat Cover) with Union and Nipple Extensions and Thermowell
0.25 (6)
X
5.5 (140)
Extended Cover
3.5 (89) E L
Flat
Cover Union
Nipple
Sensor Mounting Thermowell

Connection
Sensors-000B06A
T + 1.75 (44) U
3/414 ANPT
Chain
-8
Product Data Sheet
00813-0100-2654, Rev DA
Threaded Sensors and Assemblies

Series 68, 68Q, and 78 RTD and Series 183 Thermocouple One assembly model number, derived from one ordering table,
Sensors may be ordered as complete assemblies. These completely defines the type of sensing element, as well as the
assemblies provide a complete, yet simple means of specifying material, length, and style of both the extension fittings and
the proper industrial hardware for most temperature thermowells. All sensor assemblies are sized and inspected by
measurements. Rosemount Inc. to ensure complete component compatibility and
performance.
FIGURE 5. Individual Components of a Complete Temperature Assembly
Standard Adapter Sensor Assembly

X
Optional Identification Tag
0.5 (13) Nominal Engagement
Extensions
Coupling-Nipple
E L
0.5 (13) Nominal

Engagement
Lead Wire Extensions and Seals
Union-Nipple
Threaded
Welded
Thermowells
Flanged
Flat or Extended Cover Aluminum Connection Heads
Threaded
Welded
Sensors-0009A04A
Flanged
Polypropylene Connection Head
-9
Product Data Sheet
00813-0100-2654, Rev DA
MOUNTING CONFIGURATIONS SERIES 68 PLATINUM RTD

Rosemount Series 68 RTD temperature sensors measure from
Capsule 50 to 400 C (58 to 752 F). Series 68 sensors are available in
Capsules are designed for direct immersion without mounting capsule, general purpose, and spring-loaded designs in sensor
fittings. Accessory compression fittings are available for adjustable lengths from 1 to 48 inches.
mounting into a thermowell. See Mounting Adapters for Series 58, Table 3 shows the interchangeability of the Series 68 RTD. As an
68, 78, and 183. option, for maximum system accuracy, Rosemount Inc. can
provide sensor calibration. See Sensor Characterization
General-Purpose Sensor Assemblies (Calibration) Schedules Option Code V. In addition, Rosemount
Designed with a welded, fixed-position 1/214 ANPT process Inc. offers optional sensor-to-transmitter matching capability
connection fitting for direct immersion or thermowell applications, obtainable through the use of Callendar-Van Dusen Constants.
this sensor design provides a moisture-proof and vapor-tight seal. See Option Code V Callendar-van Dusen Constants.
The maximum static working pressure at 20 C (68 F) with no
TABLE 3. Series 68 Interchangeability
vibration or flow condition is 31.59 MPa (3,500 psig). The use of a
thermowell is recommended for process pressure containment. 0.55 C (0.99 F) at -50 C (-58 F)
Note that standard lengths are 1/4 inch less than nominal 0.30 C (0.54 F) at 0 C (32 F)
dimension to prevent bottoming of the sensor in a thermowell.
0.80 C (1.44 F) at 100 C (-212 F)
Spring-Loaded Sensor Assemblies 1.30 C (2.34 F) at 200 C (392 F)
Spring-loaded sensors have a spring-positioned, 1.60 C (2.88 F) at 260 C (500 F)
1
/214 ANPT process connection fitting that ensures good surface
contact in thermowells for faster time response and vibration 2.30 C (4.14 F) at 400 C (752 F)
resistance. Spring-loaded sensors are not intended to provide a
process seal. They must be used in conjunction with a thermowell Construction
for this purpose.
FIGURE 7. Construction of a Platinum Thin Film RTD
NOTE
When a spring-loaded sensor is used properly, the spring should
be compressed approximately 1/2-inch. Connection Seal
Connection Leads
Connection Pads
Bayonet Spring-Loaded Sensor Assemblies
Bayonet assemblies have the same advantages as the Passivation with
Sensors-3144_05A
Glass Layers
spring-loaded sensor. However, the bayonet connector permits the
Photolithography
sensor to be easily removed from the process without tools. Structured Platinum
Thin Film
FIGURE 6. Series 68, 68Q, 78, and 58C
Al2 O3 Substrate
Lead Wire Configurations
Single Element Dual-element(1)

Design and construction of the Series 68 Platinum Sensors
Red Red provides the optimum combination of accuracy and durability
Red available for temperature measurements. The construction of the
Sensors-0002A, C
White sensor allows for direct immersion in non-corrosive fluids at

White
reasonable static pressures. For corrosive environments or many
Black industrial applications, these sensors are widely used with
White standard thermowell assemblies.
Green
White Green
Platinum Element and Lead Wire Configurations
(1) Dual-element sensors are only available on Series 68Q and 78 Single-element temperature sensors have four lead wires and may
sensors. be used in 2-, 3-, and 4-wire signal conditioning systems.
-10
Product Data Sheet
00813-0100-2654, Rev DA
Specifications Lead Wire

Teflon insulated, nickel-coated, 22-gauge stranded copper wire.
Performance
Identification Data
Temperature Range The model, serial numbers, and up to six lines of permanent
50 to 400 C (58 to 752 F) tagging information are etched on each sensor. Stainless steel
tags are available upon request.
Effect of Temperature Cycling
0.05% (0.13 C or 0.23 F) maximum ice-point resistance shift Weight
following 10 cycles over the specified temperature range. Capsule sensors: 5 oz
General-purpose and spring-loaded sensors: 9 oz
Stability
0.11% maximum ice-point resistance shift following 1,000 hours Environmental
at maximum specified temperature (400 C). Humidity Limits
Lead seal can withstanding 100% relative humidity.
Maximum Hysteresis Vibration Limits
0.1% of operating temperature range. 0.05% maximum ice-point resistance shift due to 30 minutes
of 14 g peak vibration from 5 to 350 Hz at 20 C (68 F) for
Time Constant unsupported stem length of less than 6 inches.
12 seconds maximum required to reach 63.2% sensor response in Quality Assurance
water flowing at 3 ft/s (0.91 m/s). Each sensor is subjected to a resistance accuracy test at 0 C
and a insulation resistance test.
Self Heating Enclosure Ratings
16 mW minimum power dissipation required to cause a 1 C (1.8 When installed properly, Rosemount Series 68 sensors are
F) temperature measurement error in water flowing at 3 ft/s. suitable for indoor and outdoor NEMA 4X and CSA Enclosure
Type 4X installations. See Hazardous Area Approvals for
Physical Specifications complete installation information.
Sheath Material Insulation Resistance

316 SST. 500 106 ohms minimum insulation resistance when measured at
500 Vdc at room temperature.
-11
Product Data Sheet
00813-0100-2654, Rev DA
ORDERING INFORMATION
TABLE 4. Series 68 RTD Sensor Assemblies WITHOUT Thermowell
Model Product Description

0068 Platinum Thin-Film Temperature Sensors and Sensor Assemblies
Code Sensor Lead Wire Termination
R Aluminum Connection Head, Six Terminals, Flat Cover, Unpainted
T Aluminum Connection Head, Six Terminals, Extended Cover, Unpainted
P Aluminum Connection Head, Six Terminals, Flat Cover, Painted
L Aluminum Connection Head, Six Terminals, Extended Cover, Painted
W(1) Polypropylene Connection Head
N Sensor only with 6-in. Teflon -insulated, 22-gauge lead wires
Code Sensor Type (single element -50 to 400 C (-58 to 752 F))
(2)(3)
01 Capsule Style
11(4) General-purpose style
21(5) Spring-loaded style
31(6) Bayonet spring-loaded style (available in 1-in. increments from 1 to 21 inches)
Code Extension Type Material
A Nipple Coupling SST
C Nipple Union SST
N None (Use with extension length option code 00)
Code Extension Length (E)
00 0.0 in.
30 3.0 in. (X) sensor length = (E) extension length + (L) thermowell length minus 0.25 in. (see Figure 4.)
60 6.0 in.
Code Thermowell Material
N No thermowell required
Code Sensor Immersion Length (L) Code Sensor Immersion Length (L) Code Sensor Immersion Length (L)
010(2)(7) 1.0-in. 130 13.0-in. 250 25.0-in.
015 1.5-in. 135 13.5-in. 260 26.0-in.
020 2.0-in. 140 14.0-in. 270 27.0-in.
025 2.5-in. 145 14.5-in. 280 28.0-in.
030 3.0-in. 150(8) 15.0-in. 290 29.0-in.
035 3.5-in. 155 15.5-in. 300 30.0-in.
040(8) 4.0-in. 160 16.0-in. 310 31.0-in.
045 4.5-in. 165 16.5-in. 320 32.0-in.
050 5.0-in. 170 17.0-in. 330 33.0-in.
055 5.5-in. 175 17.5-in. 340 34.0-in.
060(8) 6.0-in. 180(8) 18.0-in. 350 35.0-in.
065 6.5-in. 185 18.5-in. 360 36.0-in.
070 7.0-in. 190 19.0-in. 370 37.0-in.
075 7.5-in. 195 19.5-in. 380 38.0-in.
080 8.0-in. 200 20.0-in. 390 39.0-in.
085 8.5-in. 205 20.5-in. 400 40.0-in.
090(8) 9.0-in. 210 21.0-in. 410 41.0-in.
095 9.5-in. 210 21.5-in. 420 42.0-in.
100 10.0-in. 220 22.0-in. 430 43.0-in.
105 10.5-in. 225 22.5-in. 440 44.0-in.
110 11.0-in. 230 23.0-in. 450 45.0-in.
115 11.5-in. 235 23.5-in. 460 46.0-in.
120(8) 12.0-in. 240 24.0-in. 470 47.0-in.
125 12.5-in. 245 15.5-in. 480 48.0-in.
-12
Product Data Sheet
00813-0100-2654, Rev DA
Code Options
Product Certifications
E5 FM Explosion-proof approval (See Figure 26)
E6 CSA Explosion-proof approval (See Figure 27)
E7(9) SAA Flameproof approval (See Figure 29)
E1(10) CENELEC / ATEX Flameproof approval (See Figure 28)
Calibration
V1-V7 Choose from option code VCallendar-van Dusen Constants. See Option Code V Callendar-van Dusen Constants.
Option code V4 is not available with Series 68 sensors.
X8Q4 Calibrate to customer-specified temperature range (See Option X8Q4: Sensor Calibrated to a Customer-Specified Temperature Range)
X9Q4 Calibrate to customer-specified single temperature point (See Option X9Q4: Sensor Calibrated to a Customer-Specified Single Point)
Mounting Adapters, Lead Wire Extensions, Connectors, and Seals
M5-M7 Mounting adapters
A1-A8 Twisted lead wire extensions
B1-B8(11) Shielded cable lead wire extensions
C1-C8(11) Armored cable lead wire extensions
D1-D8(11) Armored cable lead wire extensions with electrical plugs
L1-L8 Armored cable mating plugs with lead wire extensions
F1 4-pin bayonet connector
H1-H8 4-pin connector mating plugs with lead wire extensions
J1 Moisture-proof seal assembly for armored cables
XA(12) Assemble connection head or transmitter to a sensor assembly (Teflon (PTFE) paste where appropriate, fully wired.)
(1) FM, CSA, SAA, and CENELEC approvals are not available with the polypropylene connection head.
(2) Capsule style available in 1-in. increments only, starting at 1-in. (i.e. 1, 2, 3-inches, etc.) See See Mounting Adapters for Series 58, 68, 78, and 183 on
page 50.
(3) This option must be used with Sensor Lead Wire Termination code N and is not available with assembly code XA or with Approval codes E1, E5, E6, and E7.
(4) General-purpose sensors are only available in (L) lengths of 2.5-in. or greater.
(5) Spring loaded sensors must be installed in a thermowell assembly to meet the requirements of explosion-proof approvals code E6.
(6) Not available with Sensor Lead Wire Termination codes R, P, or W or with approval codes E1, E5, E6, or E7.
(7) 1-in. length without extension is only available in capsule style.
(8) Standard configuration with best delivery.
(9) SAA Flame-proof Approval is only applicable if installed with Rosemount 244E, 248, 644, 3144P, or 3244MV transmitters.
(10) CENELEC / ATEX Flame-proof approval is only applicable if installed with Rosemount 144, 244E, 248, 644, 3144P, or 3244MV transmitters.
(11) These options are not available with Sensor Lead Wire Termination codes R, P, or W.
(12) If ordering code XA with a transmitter, specify the same option on the transmitter model code.
Ordering Example
Typical Lead Wire Extension Extension Thermowell Immersion Additional
Model Model Termination Sensor Type Type Length Material Length Options
Number
0068 N 11 N 00 N 045 E5
-13
Product Data Sheet
00813-0100-2654, Rev DA
TABLE 5. Series 68 RTD Sensor Assemblies WITH Thermowell

0068 Platinum Thin Film Temperature Sensors and Sensor Assemblies
Single Element Temperature Sensors
11 General-purpose style
21 Spring-loaded style
31(2)(3) Bayonet spring-loaded style (available in (X) lengths of 1 to 21-in., increments of 1-in.)
A(4) Nipple Coupling SST
C(4) Nipple Union SST
00 0.0 in.
60 6.0 in.
Code Thermowell Material Code Thermowell Material
A Type 316 SST(5) J Hastelloy C (with 304 SST flange, if flange style is ordered)
B Type 304 SST L Hastelloy B (with 304 SST flange, if flange style is ordered)
C Carbon Steel M 304 SST with Teflon (PTFE) coating
D 316L SST P Chrome Molybdenum F22
E 304L SST R Nickel 200
F Alloy 20 T Titanium
G Monel U(6) 316 SST with Tantalum Sheath
H Inconel 600 W 321 SST
Z Chrome Molybdenum F11
Code Length Code Length Code Length
U(7) L T(8) U(7) L T(8) U(7) L T(8)
015 1.5-in. 4.0-in. 1.0-in. 130 13.0-in. 15.0-in. 0.5-in. 260 26.0-in. 30.0-in. 2.5-in.
035 3.5-in. 6.0-in. 1.0-in. 150(5) 15.0-in. 18.0-in. 1.5-in. 300 30.0-in. 33.0-in. 1.5-in.
045(5) 4.5-in. 6.0-in. 0.0-in. 160 16.0-in. 18.0-in. 0.5-in. 320 32.0-in. 36.0-in. 2.5-in.
090 9.0-in. 12.0 1.5-in. 205(9) 20.5-in. 24.0-in. 2.0-in. 410 41.0-in. 45.0-in. 2.5-in.
105(5) 10.5-in. 12.0-in. 0.0-in. 220(9) 22.0-in. 24.0-in. 0.5-in. 440 44.0-in. 48.0-in. 2.5-in.
-14
Product Data Sheet
00813-0100-2654, Rev DA
Code Thermowell Mounting Stem

1
T20(5) Threaded /2-14 ANPT Stepped
3
T24(5) Threaded 1-11.5 ANPT Stepped
3
T26 Threaded /4-14 ANPT Tapered
T28 Threaded 1-11.5 ANPT Tapered
T30 Threaded 11/2-11 ANPT Tapered
1
T32(10) Threaded /2-14 ANPT Straight
3
T36(10) Threaded 1-11.5 ANPT Straight
3
1
3
W38 Welded /4-in. pipe Stepped
W40 Welded 1-in. pipe Stepped
3
W42 Welded /4-in. pipe Tapered
W44 Welded 1-in. pipe Tapered
W46 Welded 11/4-in. pipe Tapered
3
W48(10) Welded /4-in. pipe Straight
W50(10) Welded 1-in. pipe Straight
F10(10) Flanged 2-in., Class 150 Straight
F52 Flanged 1-in., Class 150 Stepped
F54 Flanged 11/2-in., Class 150 Stepped
F58 Flanged 1-in., Class 150 Tapered
F60 Flanged 11/2-in., Class 150 Tapered
F62 Flanged 1-11.5 ANPT Stepped
F66(10) Flanged 11/2-in., Class 150 Straight
F88(11) Flanged 1-in., Class 600 Stepped
F90(11) Flanged 11/2-in., Class 600 Stepped
F94(11) Flanged 1-in., Class 600 Tapered
F96(11) Flanged 11/2-in., Class 600 Tapered
F02(10)(11) Flanged 1-in., Class 600 Straight
F04(10)(11) Flanged 11/2-in., Class 600 Straight
Q02 Sanitary, Tri-Clamp 1-in., Tri-Clamp Stepped
Q04 Sanitary, Tri-Clamp 11/2-in., Tri-Clamp Stepped
3
Q20 Sanitary, Tri-Clamp /4-in., Tri-Clamp Straight
Q22 Sanitary, Tri-Clamp 1-in., Tri-Clamp Straight
Q24 Sanitary, Tri-Clamp 11/2-in., Tri-Clamp Straight
Code Options
-15
Product Data Sheet
00813-0100-2654, Rev DA
Calibration
Thermowell Options
Q8 Thermowell material certificate
R01 Thermowell special external pressure testing
R03 Thermowell dye penetration testing
R04 Special cleaning for oxygen service
R05 Thermowell NACE approval
R06 Stainless steel plug and chain
R07(14) Full penetration weld
R09(14)(15) Concentric serrations of thermowell flange face
R10 (14)(15) Thermowell flat faced flange
R11 Thermowell vent hole
R14 Thermowell special surface finish (12 Ra Max) (Maximum (U) length = 22.5 in.)
R16(14)(15) Ring joint flange (Not available with 0-in. (T) length)
R20 Electropolishing
R21 Thermowell Wake Frequency Calculation (Configuration Data Sheet required)
R22 Internal pressure testing
R23 Brass plug and chain
F1(2) 4-pin bayonet connector
(1) FM, CSA, SAA, and CENELEC / ATEX approvals are not available with the polypropylene connection head.
(2) Not available with Sensor Lead Wire Termination codes R, P, or W.
(3) Not available with option codes E1, E5, E6, and E7.
(4) Codes A and C must be used with an extension length. Additional non-standard (E) lengths are available in 1/2-in. increments from 2.5 to 9-in.
(6) Available only with straight stem thermowells.
(7) Thermowells with an overall length (U + T = 1.75-in.) of 42-in. or less are machined from solid barstock. Thermowells with an overall length larger than
42-in. will be constructed using a welded 3-piece design and are available only with a stepped stem style.
(8) For additional (T) lengths, see Table 23 on page -47.
(9) Straight or tapered stem only
(10) Straight thermowells are not recommended for (U) lengths greater than 6-in.
(11) F88 to F08 cannot be used with 0-in. (T) length. F08 cannot be used with 0- or 1/2-in. (T) length)
(12) SAA flame-proof approval is only applicable if installed with a Rosemount 248, 244E, 644, 3144P, or 3244MV transmitter.
(13) CENELEC / ATEX flame-proof approval is only applicable if installed with a Rosemount 144, 248, 244E, 644, 3144P, or 3244MV transmitter.
(14) Available on flanged thermowells only.
(15) Only one flange face option allowed.
(16) If ordering option code XA with a transmitter, specify the same option on the transmitter model code.
TABLE 6. Ordering Example

Typical Lead Wire Extension Extension Immersion Mounting Additional
Model Model Termination Sensor Type Type Length Material Code Length Style Options
Number
0068 N 21 A 30 A 075 T22 E5
-16
Product Data Sheet
00813-0100-2654, Rev DA
SERIES 78 PLATINUM RTD FIGURE 8. Wiring Configuration of a

Dual-Element Sensor to Function as a Single
Series 78 sensors are intended for applications that require high
accuracy, dual-elements, and/or are subjected to high
Element Sensor with a Compensation Loop
temperatures. Rosemount Series 78 RTD temperature sensors
measure from 200 to 600 C (328 to 1112 F). These sensors Red
are available in capsule, general-purpose, spring-loaded, and Measurement points
Sensors-0002A, C
bayonet spring-loaded designs in sensor (X) lengths from 1 to 68 White
inches. White (extra leave disconnected)
Table 7 shows the interchangeability of the Series 78 sensors. The Black (extra leave disconnected)
performance of the standard Series 78 sensor conforms to the
standard set by IEC 751 Class B. Additionally, IEC-751 Class A Green Lead wire compensation
accuracy is available as an option. For maximum system Green
points
accuracy, Rosemount Inc. can provide sensor calibration. See
Sensor Characterization (Calibration) Schedules Option Code
Note: Isolate the two extra leads with electrical tape to ensure
V. Rosemount Inc. also offers optional sensor-to-transmitter
that they do not contact the terminals.
matching capability obtainable through the use of Callendar-Van
Dusen Constants. See Option Code V Callendar-van Dusen
Constantsand Option X8Q4: Sensor Calibrated to a Construction
Customer-Specified Temperature Range.
The wire-wound design and construction of the General-Purpose
FIGURE 9. Construction of a Platinum Wire-wound RTD
Series 78 sensor allows direct immersion in non-corrosive fluids at
reasonable static pressures. For corrosive environments and in Lead Wires
many industrial applications, these sensors are commonly used
with standard thermowell assemblies.
Seal
Sensors-3144_06A
Platinum Element and Lead Wire Configurations High Purity Insulator
Single-element high-temperature sensors have four lead wires
Platinum Resistance
and may be used in 2-, 3-, and 4-wire signal conditioning systems. Element
Dual-element sensors have redundant elements to provide
separate readout and control signals from a single measurement
point. Dual-element sensors have three lead wires for each
element and may be used with 2- or 3-wire systems. Dual-element
sensors can also be wired to be used as compensation loop
sensors (see Figure 8).
-17
Product Data Sheet
00813-0100-2654, Rev DA
Specifications Vibration Limits

Standard single- and dual-element sensors:
Performance 0.03% maximum ice-point resistance shift due to 30 minutes
of 21 g peak vibration from 5 to 350 Hz continuous sweep at
Temperature Range 20 C (68 F) for unsupported stem length of less than 5.5
Series 78 single- and dual-element sensors may be used in inches (140 mm).
temperatures from 200 to 500 C (328 to 932 F). Series 78 Single-element high-temperature sensors:
single-element high-temperature sensors are provided for Meet ASTM E 1137-95. Cycling time is 3 hours per
high-temperature service over the range of 0 to 600 C (32 to 1112 longitudinal axis, less the time spent at resonant dwells at the
F). axis, from 5 to 500 Hz. The test level is 1.27 mm (0.05 in.)
double amplitude displacement or peak g-level of 3, whichever
Effect of Temperature Cycling is less.
0.04% (0.10 C or 0.18 F) maximum ice-point resistance shift
following 10 cycles between 200 and 500 C (328 to 932 F). Quality Assurance
Each sensor is subjected to a resistance accuracy test at 0 C and
Stability an insulation resistance test.
0.05% maximum ice-point resistance shift following 1,000 hours
at 400 C (752 F). Enclosure Ratings
When installed properly, Rosemount Series 78 sensors are
Accuracy suitable for indoor and outdoor NEMA 4X and CSA Enclosure
TABLE 7. Series 78 Interchangeability complete installation information.
Standard Series 78 IEC-751 Class B Temperature
0.80 C (1.44 F) -100 C (-148 F) Physical Specifications
0.30 C (0.54 F) 0 C (32 F)
0.80 C (1.44 F) 100 C (212 F) Sheath Material
1.80 C (3.24 F) 300 C (572 F)
2.30 C (4.14 F) 400 C (752 F)
316 SST
Series 78 with IEC-751 Class A Option Temperature
Lead Wires
0.35 C (0.63 F) -100 C (-148 F)
0.15 C (0.27 F) 0 C (32 F) Teflon-insulated, nickel-coated, 22-gauge stranded copper wire.
0.35 C (0.63 F) 100 C (212 F)
0.75 C (1.35 F) 300 C (572 F) Identification Data
0.95 C (1.71 F) 400 C (752 F) The model and serial numbers and up to six lines of permanent
tagging information are etched on each sensor. Stainless steel
Maximum Hysteresis tags are available upon request.
Single- and dual-element, standard: 0.04% of range.
Single-element, high temperature: 0.1% of range. Weight
Capsule sensors: 5 oz
Time Constant General purpose and spring-loaded sensors: 9 oz
4 seconds maximum required to reach 63.2% sensor response in
water flowing at 3 ft/s (0.91 m/s), 9.5 seconds for single-element
high-temperature sensors.
Self Heating
18 mW minimum power dissipation required to cause a 1 C (1.8
F) temperature measurement error in water flowing at 3 ft/s, 25
mW for single-element high temperature sensors.
Insulation Resistance
500 106 ohms minimum insulation resistance when measured at
500 V dc at room temperature [20 C (68 F)]. Single element
high-temperature sensors are measured at 100V dc.
Environmental
Humidity Limits
Lead seal is capable of withstanding 100%
relative humidity.
-18
Product Data Sheet
00813-0100-2654, Rev DA
Ordering Information

0078 Platinum Wire-Wound Temperature Sensors and Sensor Assemblies
Code Sensor Type Temperature
Single Element Temperature Sensors -200 to 500 C (-328 to 932 F)
01(2)(3) Capsule style
31(5) Bayonet spring-loaded style (available in (X) lengths of 1 to 21-in, increments of 1-in.)
Single Element High Temperature Sensors 0 to 600 C (32 to 1112 F)
03(2) Capsule style (available in (X) lengths of 3 to 24-in, increments of 1-in.)
13 General-purpose style (available in (X) lengths of 3 to 24-in, increments of 1/2-in.)
23(4) Spring-loaded style (available in (X) lengths of 3 to 24-in, increments of 1/2-in.)
Dual-element Temperature Sensors -200 to 500 C (-328 to 932 F)
05(2) Capsule style
00 0.0 in.
60 6.0 in.
010 1.0-in. 130 13.0-in. 250 25.0-in.
015 1.5-in. 135 13.5-in. 260 26.0-in.
020 2.0-in. 140 14.0-in. 270 27.0-in.
025 2.5-in. 145 14.5-in. 280 28.0-in.
030 3.0-in. 150 15.0-in. 290 29.0-in.
035 3.5-in. 155 15.5-in. 300 30.0-in.
040(7) 4.0-in. 160 16.0-in. 310 31.0-in.
045 4.5-in. 165 16.5-in. 320 32.0-in.
050 5.0-in. 170 17.0-in. 330 33.0-in.
055 5.5-in. 175 17.5-in. 340 34.0-in.
060(7) 6.0-in. 180 18.0-in. 350 35.0-in.
065 6.5-in. 185 18.5-in. 360 36.0-in.
070 7.0-in. 190 19.0-in. 370 37.0-in.
075 7.5-in. 195 19.5-in. 380 38.0-in.
080 8.0-in. 200 20.0-in. 390 39.0-in.
085 8.5-in. 205 20.5-in. 400 40.0-in.
090(7) 9.0-in. 210 21.0-in. 410 41.0-in.
095 9.5-in. 215 21.5-in. 420 42.0-in.
100 10.0-in. 220 22.0-in. 430 43.0-in.
105 10.5-in. 225 22.5-in. 440 44.0-in.
110 11.0-in. 230 23.0-in. 450 45.0-in.
115 11.5-in. 235 23.5-in. 460 46.0-in.
120 12.0-in. 240 24.0-in. 470 47.0-in.
125 12.5-in. 245 24.5-in. 480(8) 48.0-in.
-19
Product Data Sheet
00813-0100-2654, Rev DA
Code Options
Sensor
A(9) IEC 751 Class A Sensor
Calibration
(2) Capsule style available in 1-in. increments only. See Mounting Adapters for Series 58, 68, 78, and 183 on page -50.
(3) Must be used with Sensor Lead Wire Termination code N and is not available with assembly option XA or with approval option codes E1, E5, E6, or E7.
(4) Spring loaded sensors must be installed in a thermowell assembly to meet the requirements of explosion-proof approval option code E6.
(5) This option is not available with Sensor Lead Wire Termination codes R, P or W or approval code E1, E6, and E7.
(7) Standard configuration with best delivery
(8) Additional lengths are available up to 68-in., increments of 1-in.
(9) The IEC 751 Class A option is not available with high-temperature sensors.
(10) SAA Flameproof approvals only applicable if installed with a Rosemount 248, 244E, 644, 3144P or 3244MV transmitter.
(11) CENELEC / ATEX Flameproof approvals only applicable if installed with a Rosemount 144, 248, 244E, 644, 3144P or 3244MV transmitter.

Number
0078 N 21 N 00 N 045 E5
-20
Product Data Sheet
00813-0100-2654, Rev DA
13 General-purpose style (available in (X) lengths of 3 to 24-in., increments of 1/2-in.)
23 Spring-loaded style (available in (X) lengths of 3 to 24-in., increments of 1/2-in.)
00 0.0 in.
60 6.0 in.
A Type 316 SST(5) J Hastelloy C (with 304 SST Flange, if flange style is ordered)
B Type 304 SST L Hastelloy B (with 304 SST Flange, if flange style is ordered)
U(7) L T(8) U(7) L T(8) U(7) L T(8)
-21
Product Data Sheet
00813-0100-2654, Rev DA

1
3
3
1
T32 Threaded /2-14 ANPT Straight
3
T36 Threaded 1-11.5 ANPT Straight
T38 Threaded 3/4-14 ANPT Straight
1
3
3
3
W48 Welded /4-in. pipe Straight
W50 Welded 1-in. pipe Straight
F10 Flanged 2-in., Class 150 Straight
F66 Flanged 11/2-in., Class 150 Straight
3
Code Options
Sensor
A(11) IEC 751 Class A sensor
-22
Product Data Sheet
00813-0100-2654, Rev DA
Calibration
Thermowell Options
XA(3)(17) Assemble connection head or transmitter to a sensor assembly (Teflon (PTFE) paste where appropriate, fully wired.)
(2) Not available with Sensor Lead Wire Termination codes R, P or W.
(3) Not available with Approval codes E1, E6, or E7.
(6) Available only with straight stem flanged thermowells.

(9) Straight or Tapered stem only.
(10) F88 to F08 cannot be used with 0-in. (T) length. F08 cannot be used with 0- or 1/2-in. (T) length
(12) SAA Flameproof approvals only applicable if installed with a Rosemount 248, 244E, 644, 3144 or 3244MV transmitter.
(13) CENELEC / ATEX Flameproof approvals only applicable if installed with a Rosemount 144, 248, 244E, 644, 3144 or 3244MV transmitter.

Number
0078 N 21 A 30 A 075 T22 E5
-23
Product Data Sheet
00813-0100-2654, Rev DA
SERIES 68Q SANITARY PLATINUM RTD SPECIFICATIONS

Rosemount Series 68Q sanitary RTD temperature sensors
measure from 50 to 200 C (58 to 392 F). Series 68Q sensors Performance
are available in Tri-Clamp endcap designs in immersion lengths
from 2.5 to 9.5 inches. Table 12 shows the interchangeability of Temperature Range
the Series 68Q sensor. 50 to 200 C (58 to 392 F)
Accuracy Maximum Hysteresis

0.05% of operating temperature range
TABLE 12. Series 68Q Interchangeability (IEC 751 Class B)
0.55 C (0.99 F) at 50 C (58 F)
Stability
0.30 C (0.54 F) at 0 C (32 F)
0.80 C (1.44 F) at 100 C (212 F) 0.04% maximum ice-point resistance shift following 1,000 hours
1.30 C (2.34 F) at 200 C (392 F) at maximum specified temperature 392 F (200 C).
Construction Response Time

Series 68Q sensors conform to 3-A Sanitary Standards and Less than 3.5 seconds required to reach 63.2% sensor response
feature product contact surfaces designed for CIP cleaning. The in water flowing at 3 ft/s (0.91 m/s). Meets PMO specification
response times of Series 68Q sensors meet the
Grade A Pasteurized Milk Ordinance (PMO) specification for Insulation Resistance
thermometric response of an indicating thermometer on a pipeline. 500 106 ohms minimum insulation resistance when measured at
Series 68Q sensors are offered in a Tri-Clamp sanitary endcap 100 V dc at room temperature
configuration. The sensor capsule is welded into the 316 SST
sanitary endcap/stem assembly. The product contact of this Surface Finish
assembly is polished to a finish that exceeds No. 4 minimum finish 32RA standard finish on product contact surfaces. Meets 3-A
as required by the 3A Sanitary Council Standard #74-02. requirements
Platinum Element and Lead Wire Configurations Environmental

Single-element temperature sensors have four lead wires and may
be used in 2-, 3-, and 4-wire signal conditioning systems. Humidity Limits
Dual-element sensors have six lead wires and may be used in 2-
and 3-wire signal conditioning systems. Lead seal is capable of withstanding 100% relative humidity
Quality Assurance
Each sensor is subjected to a resistance accuracy test at 0 C
Physical Specifications
Sheath Material
316 SST
Lead Wire
Teflon insulated, nickel-coated, 24-gauge stranded copper wire
Identification Data
The model and serial numbers and up to six lines of permanent
tags are available upon request
Weight
0.6 to 2.0 lb (0.3 to 0.9 kg)
-24
Product Data Sheet
00813-0100-2654, Rev DA
Dimensional Drawings
FIGURE 10. 68Q Sanitary Sensor and Polypropylene Connection Head Dimensional Drawings
68Q Sanitary Sensor with Tri-Clamp Endcap
3.00 (76) R 1.5 (6.35)

Tri-Clamp
Endcap
Stem 0.5 (13) 0.250 (6.35)
0.84 (21)
14 ANPT R 0.250 (6.35) R 0.250 (6.35)
Immersion length must be at least 1-in. greater than stem length. U = R + 1.5-in.
14 ANPT 35
2.90 (74)
1.63 (41) 0.80 (20)
1.175 (30)
3/418 ANPT
1.225 (31)
1.05 (27)
-25
Product Data Sheet
00813-0100-2654, Rev DA
TABLE 13. Series 68Q Sanitary Platinum RTD Sensor Assemblies

0068Q Series 68Q Sanitary RTD Temperature Sensors
W Polypropylene Connection Head, Six Terminals
11 Single -50 to 200 C (-58 to 392 F)
15 Dual -50 to 200 C (-58 to 392 F)
Code Immersion Length (U) (in.)
U025 2.5
U030 3.0
U035 3.5
U040(1) 4.0
U045 4.5
U050(1) 5.0
U055 5.5
U060 6.0
U065 6.5
U070 7.0
U075 7.5
U080 8.0
U085 8.5
U090 9.0
U095 9.5
Code Endcap Type O.D. Tube Size (inches)
L100 Tri-Clamp 1.00
L150(1) Tri-Clamp 1.50
L250 Tri-Clamp 2.50
L300 Tri-Clamp 3.00
Code Additional Options
Calibration Options
V1-V7 Choose from option code VCallendar-van Dusen Constants. See Option Code V Callendar-van Dusen Constants. Option codes V3, V4, and
V7 are not available with Series 68Q sensors.
R20 Electropolishing of wetted surfaces
Ordering Example
Typical Endcap Type, Tube
Model Model Lead Wire Termination Sensor Type Immersion Length Size Additional Options
Number
0068Q N 11 U050 L150 V2
-26
Product Data Sheet
00813-0100-2654, Rev DA
SERIES 58C PLATINUM RTD Stability

Rosemount Series 58C sensors are available in 0.035% maximum ice-point resistance shift following 1,000 hours
12-, 24-, 36-, and 48-inch (X) lengths and may be shortened to any at maximum specified temperature (200 C).
desired length with an ordinary tubing cutter. This cut-to-fit feature
eliminates the need to stock a large selection of sensors in many Insulation Resistance
specific lengths. Table 14 shows the interchangeability of the 500 106 ohms minimum insulation resistance when measured at
Series 58C Sensor. 50 V dc at room temperature.
TABLE 14. Series 58C Interchangeability (IEC 751 Class B) Environmental Specifications
0.55 C (0.99 F) at 50 C (58 F)
0.30 C (0.54 F) at 0 C (32 F) Humidity Limits
0.80 C (1.44 F) at 100 C (212 F)
No permanent rear seal is installed
1.30 C (2.34 F) at 200 C (392 F)
Quality Assurance
Specifications Each sensor is subjected to a resistance accuracy test at 0 C and
an insulation resistance test
Performance Specifications
Temperature Range
50 to 200 C (58 to 392 F) Sheath Material
316 SST
Maximum Hysteresis
0.09% of operating temperature range. Lead Wires
Teflon-insulated, nickel-coated, 24-gauge stranded copper wire
Series 58C Sensor
Do not cut all the way through the sensor sheath when cutting the sensor to length. Damage to the sensor wires could result. To prevent damage to the sensor
wires, score the sheath considerably with a tubing cutter and gently break off the excess.
0.25 0.002 (6.35 0.13) Diameter

4 Lead Wires 6 (152) Long
X Length 0.25 (6)
Sensors-0021A
0.6 (15) Max. Sensing Element
Nylon Sleeve
Do Not Cut or Bend Sheath within 2 (51)
Option Code SNN Spring-Loaded Fitting Option Codes C01, C02, Swagelok Compression Fitting
303 SST. 1/214 ANPT 316 SST. 1/214 ANPT
for 0.25 (6)

for 0.25 (6) Diameter Sensors
Diameter Sensors
Sensors-0020A, B
2.51 1.75
(64) Max. (44) Max.
-27
Product Data Sheet
00813-0100-2654, Rev DA
TABLE 15. Series 58C Cut-to-Fit RTD Sensors

0058C Platinum Resistance Temperature Sensor (50 to 200 C (58 to 392 F))
W Polypropylene Connection Head
Code Sensor Length (X) in inches
1200 12
2400 24
3600 36
4800 48
Code Mounting Adapter
NNN None
C01(1) One-compression fitting 1/214 ANPT
C02 (1)
Two-compression fittings 1/214 ANPT
SNN Spring-loaded fitting 1/214 ANPT
(1) The only difference between C01 and C02 is that the C01 includes one fitting while the C02 option includes two fittings.
Ordering Example
Typical Model Lead Wire Mounting
Number Model Termination Sensor Length Adapter
0058C R 1200 SNN
TABLE 16. Series 58C Spare Parts List

(specify spare part number separately when ordering mounting
adapters)
Mounting Adapters Option Code Spare Part Number

1
Compression fitting /214 ANPT C01 and C02 C07961-0008
Spring loaded fitting 1/214 ANPT SNN 00058-0010-0001
-28
Product Data Sheet
00813-0100-2654, Rev DA
SERIES 183 THERMOCOUPLE Specifications

Rosemount Series 183 Thermocouple sensors measure from
180 to 1150 C (292 to 2102 F). Performance Specifications
The thermoelectric current relationship in a thermocouple is
Construction standardized and defined by ASTM E-230. All Series 183
The Series 183 Thermocouples are manufactured using ISA Type Thermocouples conform to these standards with special limits of
J, K, E, or T wire with special limits of error accuracy. The error accuracy. The particular characteristics of each ISA type
junction of these wires is fusion-welded to form a pure joint, to thermocouple are outlined in Table 21.
maintain the integrity of the circuit, and to ensure the highest
accuracy. Grounded junctions are available for improved response Physical
time and good thermal contact with protection from the
environment. The ungrounded and isolated junctions provide Sheath Material
electrical isolation from the sensor sheath (see Figure 11). 304 SST for types J, E, and T (used at temperatures up to 871 C).
Rosemount thermocouples are encased in a protective metal Inconel for type K (used at temperatures up to 1150 C).
sheath. The sheath material is 304 SST for types J, E, and T, used
at temperatures up to 871 C and Inconel for type K, used at Lead Wires
temperatures up to 1150 C. Metallic oxide insulation is compacted Thermocouple, internal16 AWG solid wire (max), 18 AWG solid
into the sheath to mechanically support and electrically insulate wire (min.). External lead wires20 AWG wire, Teflon insulated.
the thermocouple wire. See Table 21 for more information on the Color coded per lead wire configuration schematic shown in Figure
different types of thermocouples. 12.
FIGURE 11. Series 183 Junction Configurations Identification Data

Single, Grounded Dual, Grounded, Unisolated tagging information are etched on each sensor. Stainless steel
+ +
+
Weight
Capsule sensors: 5 ounces. General-purpose and spring-loaded
sensors: 9 ounces.
Single, Ungrounded Dual, Ungrounded, Unisolated

+
+
+ 100 V dc at room temperature.

Enclosure Ratings
Dual, Ungrounded, Isolated
suitable for indoor and outdoor
NEMA 4X and CSA Enclosure Type 4X installations. See
+ Hazardous Area Approvals for complete installation information.
+
FIGURE 12. Series 183 Lead Wire Configurations
Type J Type E
+ White + Purple
Red Red
Type K Type T
+ Yellow + Blue
Red Red
-29
Product Data Sheet
00813-0100-2654, Rev DA
TABLE 17. Series 183 Thermocouple Sensor Assemblies WITHOUT Thermowell

0183 Thermocouple Temperature Sensors and Sensor Assemblies
N Sensor only with 6-in. Teflon -insulated, 22-gauge lead wires (12-in. lead wires for dual thermocouples)
Code Sensor Type Junction
Capsule Sensor(2)(3)
01(2) Single Grounded
02 Dual Grounded
03 Single Ungrounded
04 Dual, Unisolated Ungrounded
05 Dual, Isolated Ungrounded
General Purpose Sensors
11 Single Grounded
12 Dual Grounded
Spring-Loaded Sensors(4)
21 Single Grounded
22 Dual Grounded
Bayonet Spring-Loaded Sensors(5)(6)
31 Single Grounded
32 Dual Grounded
Code Thermocouple Type Temperature Range
J2 J 0 to 760 C (32 to 1400 F)
K2 K 0 to 1150 C (32 to 2102 F)
E2 E 0 to 871 C (32 to 1600F)
T2 T 180 to 371 C (292 to 700 F)
J2 J 0 to 760 C (32 to 1400 F)
00 0.0 in.
60 6.0 in.
-30
Product Data Sheet
00813-0100-2654, Rev DA
020 2.0-in. 140 14.0-in. 260 26.0-in.
025 2.5-in. 145 14.5-in. 270 27.0-in.
030 3.0-in. 150(8) 15.0-in. 280 28.0-in.
035 3.5-in. 155 15.5-in. 290 29.0-in.
040(8) 4.0-in. 160 16.0-in. 300 30.0-in.
045 4.5-in. 165 16.5-in. 310 31.0-in.
050 5.0-in. 170 17.0-in. 320 32.0-in.
055 5.5-in. 175 17.5-in. 330 33.0-in.
060(8) 6.0-in. 180(8) 18.0-in. 340 34.0-in.
065 6.5-in. 185 18.5-in. 350 35.0-in.
070 7.0-in. 190 19.0-in. 360 36.0-in.
075 7.5-in. 195 19.5-in. 370 37.0-in.
080 8.0-in. 200 20.0-in. 380 38.0-in.
085 8.5-in. 205 20.5-in. 390 39.0-in.
090(8) 9.0-in. 210 21.0-in. 400 40.0-in.
095 9.5-in. 215 21.5-in. 410 41.0-in.
100 10.0-in. 220 22.0-in. 420 42.0-in.
105 10.5-in. 225 22.5-in. 430 43.0-in.
110 11.0-in. 230 23.0-in. 440 44.0-in.
115 11.5-in. 235 23.5-in. 450 45.0-in.
120(8) 12.0-in. 240 24.0-in. 460 46.0-in.
125 12.5-in. 245 15.5-in. 470 47.0-in.
130 13.0-in. 250 25.0-in. 480 48.0-in.
135 13.5-in.
Code Options
Assembly Options
XA(11) Assemble connection head or transmitter to a sensor assembly (hand tight, Teflon (PTFE) paste where appropriate, fully wired.)
(2) This option must be used with Sensor Lead Wire Termination code N and is not available with assembly options XA.
(3) Cannot be used with approval option codes E1, E5, E6, or E7. See Mounting Adapters for Series 58, 68, 78, and 183 on page -50.
(4) Spring-loaded sensors must be installed in a thermowell assembly to meet the requirement option code E6.
(5) This option is not available with explosion-proof approval option code E6.
(6) Bayonet spring-loaded style is available to 45-inches but is not available with Sensor Lead Wire Termination codes R, P, or W.

Model Model Termination Sensor Type ISA Type Type Length Code Length Options
Number
0183 N 11 J2 N 00 N 045 E5
-31
Product Data Sheet
00813-0100-2654, Rev DA
TABLE 19. Series 183 Thermocouple Sensor Assemblies WITH Thermowell

General-Purpose Sensors
11 Single Grounded
12 Dual Grounded
15 Dual, Isolated
Spring-Loaded Sensors
21 Single Grounded
22 Dual Grounded
31 Single Grounded
32 Dual Grounded
J2 J 0 to 760 C (32 to 1400 F)
K2 K 0 to 1150 C (32 to 2102 F)
E2 E 0 to 871 C (32 to 1600F)
T2 T 180 to 371 C (292 to 700 F)
00 0.0 in.
30 3.0 in.
60 6.0 in.
-32
Product Data Sheet
00813-0100-2654, Rev DA

U(7) L T(8) U(7) L T(8) U(7) L T(8)
085 8.5-in. 12.0-in. 2.0-in.
T20(5) Threaded 1/2-14 ANPT Stepped
3/4-14 ANPT
T22(5) Threaded Stepped
3/4-14 ANPT
T34 Threaded Straight
1/2-14 ANPT
T44 Threaded Tapered
3
3/4-in. pipe
W42 Welded Tapered
3/4-in. pipe
W48 Welded Straight
-33
Product Data Sheet
00813-0100-2654, Rev DA

3
Code Options
Thermowell Options
R01 Full penetration weld
Assembly Options
(2) This option is not available with explosion-proof approval option codes E1, E5, E6, or E7.
(3) Bayonet spring-loaded style available to 45 inches. Codes 31 - 35 are not available with Sensor Lead Wire Termination codes R or P.

(9) Straight or Tapered stem thermowells only.
(10) Cannot be used with 0-in. (T) length. F08 cannot be used with 0- or 1/2-in. (T) length

Typical Lead Wire Sensor Extension Extension Material Immersion Mounting Additional
Model Model Termination Type ISA Type Type Length Code Length Style Options
Number
0183 N 21 J2 A 30 A 075 T22 E5
-34
Product Data Sheet
00813-0100-2654, Rev DA
Comparison of Thermocouples
80
Type E
60
Type K
Millivolts (approx.)
Type J
40
Type T
20
SENSORS_VOL1_01A
0
32 1000 2000
Degrees Farenheit
Thermocouple Conditions for Use

Type J Maximum operating temperature of 760 C (1400 F). Used with or without protective tubing where deficiency of free oxygen
Iron / Constantan exists. Protective tube not essential, but desirable for cleanliness and longer service.
Type K Suitable for extended use in temperature reaching 1150 C (2102 F). Use of metal or ceramic protective tube desirable,
Chromel / Alumel especially in reducing atmospheres. in oxidizing atmospheres, protective tubing necessary only to promote cleanliness and
longer service.
Type E Suitable for use at temperature p to 900 C (1652 F) in vacuum r inert, mildly oxidizing or reducing atmosphere. Not subject to
Chromel / Constantan corrosion at cryogenic temperatures. Has highest EMF output per degree of all commonly used thermocouples.
Type T Operating temperature range of 180 to 371 C (292 to 700 F). Use in either oxidizing or reducing atmospheres. Protective
Copper /Constantan tubing necessary only to promote cleanliness and longer service. Stable at lower temperature. Superior for a wide variety of uses
in cryogenic temperatures.
TABLE 21. Characteristics of Series 183 Thermocouple Types

ISA Temperature Range
Thermocouple Thermocouple Wire
Types Alloys C F Limits of Error (Interchangeability)
J Iron/Constantan 0 to 760 32 to 1400 1.1 C or 0.4% of measured temperature, whichever is greater
K Chromel/Alumel 0 to 1150 32 to 2102 1.1 C or 0.4% of measured temperature, whichever is greater
E Chromel/Constantan 0 to 871 32 to 1600 1.0 C or 0.4% of measured temperature, whichever is greater
T Copper/Constantan 180 to 0 292 to 32 1.0 C or 1.5% of measured temperature, whichever is greater
0 to 371 32 to 700 0.5 C or 0.4% of measured temperature, whichever is greater
-35
Product Data Sheet
00813-0100-2654, Rev DA
Calibration
CALIBRATION OPTIONS Note that this is a modification of the fourth-order CVD equation
where = 0 for temperatures greater than 0 C. Since this
Sensor calibration may be required for input to quality systems, or modified equation is a second-order degree equation, at least
for control system enhancement. More frequently, it is used to
three distinct temperature values are needed in order to curve fit
improve the overall temperature measurement performance by
the behavior of the RTD. For the temperature range from 0 to 100
matching the sensor to a temperature transmitter. C only these two end points are used, and an approximation is
Transmitter-Sensor matching is available for RTD sensors used
made to render the constants.
with Rosemount 644, 3144P, and 3244MV temperature
Once the sensor-specific constants are entered, the transmitter
transmitters where the inherent stability and repeatability of the
RTD technology is well established. uses them to generate a custom curve to best describe the
relationship between resistance and temperature for the particular
sensor and transmitter system. Matching a Series 68 or 78 RTD
Transmitter-Sensor Matching sensor to a 644, 3144P, and 3244MV transmitter typically results in
Using Callendar-Van Dusen Constants a 3- or 4-fold improvement in temperature measurement accuracy
for the total system. This substantial system accuracy
Significant temperature measurement accuracy improvement can
be attained using a temperature sensor that is matched to a improvement is realized as a result of the transmitters ability to
use the sensors actual resistance-vs.-temperature curve instead
temperature transmitter. This matching process entails teaching
of an ideal curve.
the temperature transmitter the relationship between resistance
and temperature for a specific RTD sensor. This relationship, An example of the benefits of using the sensor matching capability
approximated by the Callendar-Van Dusen equation, described as: of a Rosemount 3144P Temperature transmitter along with a
matched Series 68 RTD sensor are shown in Typical
Rt = Ro + Ro[t (0.01t 1)(0.01t) (0.01t 1)(0.01t)3], Transmitter-Sensor Matching Uncertainty Improvements.
where:
Calibration Uncertainty
Rt = Resistance (ohms) at Temperature t (C)
Calibration uncertainties of the lab are equal to or better than 1/10
Ro = Sensor-Specific Constant (Resistance at t = 0 C)
IEC 751 Class B interchangeability:
=Sensor-Specific Constant
=Sensor-Specific Constant Uncertainty = 0.03 + 0.0005 t
=Sensor-Specific Constant (0 at t > 0 C, 0.11 at t < 0C)
t = absolute value of temperature in C
The exact values for R0, , , , known as Callendar-Van Dusen
(CVD) constants are specific to each RTD sensor, and are
established by testing each individual sensor at various
temperatures.
The calibration temperature values using the CVD equation are
divided into two major temperature areas: above 0 C and below 0
C. The calibration for the temperature range between 0 and 660
C is obtained from the following formula:
t t
R t = R 0 1 + t --------- --------- 1
100 100

-36
Product Data Sheet
00813-0100-2654, Rev DA
TYPICAL TRANSMITTER-SENSOR MATCHING UNCERTAINTY IMPROVEMENTS

Transmitter: 3144 (has built-in sensor matching Sensor Interchangeability Total Calibrated Sensor
capabilities), span of 1 to 200 C, accuracy = 0.1 C) Temperature Error Uncertainty(1)
Sensor: Series 68 RTD C F C F C F
Callendar van Dusen Option: V2 0 32 0.30 0.54 0.10 0.18
Process Temperature: 150 C 50 122 0.55 0.99 0.17 0.31
100 212 0.80 1.44 0.22 0.40
150 302 1.05 1.89 0.18 0.32
200 392 1.30 2.34 0.16 0.29
(1) Includes calibration uncertainties of the lab, hysteresis, and repeatability.
System Uncertainty Comparison at 150 C:

Standard 68 Sensor
Rosemount 3144: 0.10 C
1.0 C Standard Series 68 RTD: 1.05 C
1.05 C
Total System(1): 1.05 C
0.75 C
68 Sensor with V2 Option
0.5 C
Standard Series 68 RTD: 0.18 C
0.22 C
Standard With Sensor
Matching
(1) Calculated using RSS statistical method:
SystemAccuracy = ( TransmitterAccuracy )2 + ( SensorAccuracy ) 2
Sensor Characterization
(Calibration) Schedules Option Code V
Series 68, 68Q, and 78 RTD sensors can be ordered with an For applications requiring the increased accuracy obtainable
option (V1, V2,...V7, see Option Code V Callendar-van Dusen through a matched sensor and transmitter, order the appropriate
Constants), that provides Callendar-Van Dusen constants that are V option (seeOption Code V Callendar-van Dusen Constants).
shipped with the sensor. When you order this option, the values of To ensure optimal performance, select a V option such that the
all four sensor-specific constants are physically attached to each sensors range of actual operation is between the minimum and
sensor with a wire-on tag. Rosemount 644, 3144P, and 3244MV maximum calibration points.
have a unique, built-in sensor matching capability. To use this The accuracy (uncertainty) of different calibration points varies
capability, the four sensor-specific constants are programmed into because each calibration schedule has specific hysteresis and
the 644, 3144P, and 3244MV at the factory by ordering a C2 repeatability characteristics. For example, the accuracy of
option on the transmitter, or easily entered and changed in the calibration points at 100 C for options V1 and V2 differs because
field using a HART Communicator or AMS. When these values are of the two different temperature ranges.
entered into a Rosemount 644, 3144P, and 3244MV, the sensor
and transmitter become matched.
NOTE
Each V option is specific to a particular temperature range for a
An RTD ordered with the V option is shipped with CVD constants
given sensor type (see Option Code V Callendar-van Dusen
only; it does not include calibration tables.
Constants). As with option code X8Q4, the accuracies associated
with each option code represent worst-case conditions when the
sensor is used over the entire temperature range.
-37
Product Data Sheet
00813-0100-2654, Rev DA
OPTION CODE V CALLENDAR-VAN DUSEN CONSTANTS
Total Uncertainty(2) of Calibrated Sensor
Option Calibration Uncertainty(1) of Series 78 Series 78 High

Code Temperature Range Points Calibration Lab Series 68 Standard Temperature
C F C F C F C F C F C F
V1(3) 0 to 100 32 to 212 0 32 0.03 0.05 0.06 0.11 0.06 0.11 0.06 0.11
100 212 0.08 0.14 0.10 0.18 0.10 0.18 0.10 0.18
V2(3) 0 to 200 32 to 392 0 32 0.03 0.05 0.10 0.18 0.09 0.16 0.10 0.18
100 212 0.08 0.14 0.22 0.40 0.15 0.27 0.23 0.41
200 392 0.13 0.23 0.16 0.29 0.15 0.27 0.16 0.29
V3(3) 0 to 400 32 to 752 0 32 0.03 0.05 0.20 0.29 0.16 0.29 0.20 0.29
200 392 0.13 0.23 0.42 0.76 0.29 0.52 0.44 0.79
400 752 0.23 0.41 0.30 0.54 0.28 0.50 0.30 0.54
V4(3)(4) 0 to 600 32 to 1112 0 32 0.03 0.05 NA NA NA NA NA NA
200 392 0.13 0.23 NA NA NA NA NA NA
400 752 0.23 0.41 NA NA NA NA NA NA
V5(3) 50 to 100 58 to 212 0 32 0.03 0.05 0.08 0.14 0.06 0.11 0.09 0.16
100 212 0.08 0.14 0.10 0.18 0.10 0.18 0.10 0.18
V6(3) 50 to 100 58 to 392 50 58 0.06 0.10 0.14 0.25 0.11 0.20 0.14 0.25
0 32 0.03 0.05 0.20 0.36 0.14 v0.25 0.21 0.38
100 212 0.08 0.14 0.26 0.47 0.18 0.32 0.27 0.49
200 392 0.13 0.23 0.18 0.32 0.16 0.29 0.17 0.3
V7(3) 50 to 400 58 to 752 50 58 0.06 0.10 0.23 0.41 0.19 0.34 0.23 0.41
0 32 0.03 0.05 0.31 0.56 0.22 0.40 0.32 0.58
200 392 0.13 0.23 0.46 0.83 0.31 0.56 0.48 0.86
400 752 0.23 0.41 0.32 0.58 0.29 0.52 0.32 0.58
(1) Includes only the uncertainly of the lab.
(2) Includes the uncertainty of the lab, hysteresis, and repeatability.
(3) Uncertainties are valid for option code X8Q4 when ordered with the corresponding temperature range. The largest error shown in each temperature range
is the worst case error for all points not shown in that range.
(4) Only available with Series 78 High Temperature Sensors 10-in. or longer.
Specify Sensor Model Number with V Option Example
Sensor Model 0068 N 11 N 00 N 120 V2
FIGURE 13. Typical Sensor Ordered with Option Code V
Sensors-0004B
-38
Product Data Sheet
00813-0100-2654, Rev DA
Option Code X8Q4

The X8Q4 option calibrates the sensor to a customer-specified FIGURE 14. Graph of a Typical Two-point Trim
temperature range. The X8Q4 report includes the Callendar-Van
Dusen (CVD) constants (Ro, , , ), a resistance-versus- A two-point trim
temperature table in one-degree increments, and a graph which shifts the ideal curve
Resistance ()
includes the maximum errors due to the uncertainty of the up or down, and
calibration equipment, hysteresis, and repeatability. The values in changes the slop
the tables are calculated using Callendar-Van Dusen based on the two
methodology. Two of the values on this table could be used to characterized
perform a two-point trim. The X8Q4 option also provides the CVD points.
constants on a stainless steel tag attached to the sensor. Temperature (C)
See Figure 16.
Option X8Q4: Sensor Calibrated to a Customer-Specified Temperature Range

When you order an RTD with the X8Q4 option, you must specify a temperature range over which the sensor is to be calibrated. Before
specifying the range, take careful note of the sensor temperature limits.
Ordering Example:
Typical Lead Wire Sensor Extension Extension Thermowell Immersion Additional

Model Model Termination Type Type Length Material Length Options
Number
0068 N 11 N 00 N 045 X8Q4
X8X9Q4
If X8Q4 and X9Q4 are both required, do not repeat the Q4 code in the model string. Include the following instead:
Calibrate from 10 to 120 C
Option Code X9Q4

The X9Q4 option calibrates the sensor at a single FIGURE 15. Graph of a Typical One-point Trim
customer-specified point. A calibration certificate with the
resistance value at this point is supplied. This value could be used
to perform a one-point trim on the transmitter.All characterizations
are traceable to the National Institute of Standards and Technology
(NIST). The calibration table is dated and marked with the sensor
Resistance ()
series and serial number.
Sensors-0000_04A
See Figure 17.
NOTE
The X9Q4 option can be ordered and used in conjunction with the Temperature (C)
X8Q4 option.
A one-point trim shifts the ideal curve up or down based on the
single characterized point.
Option X9Q4: Sensor Calibrated to a Customer-Specified Single Point

When you order an RTD with theX9Q4 option, you must specify a single temperature point at which the sensor is to be calibrated. Before
specifying the point, take careful note of the sensor temperature limits.
Ordering Example:

Number
0068 N 11 N 00 N 045 X9Q4
If X8Q4 and X9Q4 are both required, do not repeat the Q4 code in the model string. Include the following instead: X8X9Q4
Calibrate at 50 C
-39
Product Data Sheet
00813-0100-2654, Rev DA
FIGURE 16. Example of Report Provided with X8Q4 Option
-40
Product Data Sheet
00813-0100-2654, Rev DA
-41
Product Data Sheet
00813-0100-2654, Rev DA
-42
Product Data Sheet
00813-0100-2654, Rev DA
-43
Product Data Sheet
00813-0100-2654, Rev DA
-44
Product Data Sheet
00813-0100-2654, Rev DA
-45
Product Data Sheet
00813-0100-2654, Rev DA
-46
Product Data Sheet
00813-0100-2654, Rev DA
TABLE 22. Option Code X9Q4 Calibration Uncertainties for the Series 68 and 78 Standard and High Temperature
Temperature Uncertainty of Calibration Lab(1) Total Uncertainty of Calibrated Sensor(2)
C F C F C F
50 58 0.06 0.10 0.07 0.13
0 32 0.03 0.05 0.06 0.11
100 212 0.08 0.14 0.09 0.16
200 392 0.13 0.23 0.14 0.25
400 752 0.23 0.41 0.24 0.43
(1) Includes only the uncertainty of the lab.
(2) Includes uncertainty of the lab and repeatability.
TABLE 23. Resistance vs. Temperature

IEC 751
Platinum 100, = 0.00385 RTD
F Ohms F Ohms F Ohms C Ohms C Ohms C Ohms
330 18.04 210 138.08 690 235.15 200 18.52 90 134.71 380 240.18
320 20.44 220 140.19 700 237.09 190 22.83 100 138.51 390 243.64
310 22.83 230 142.29 710 239.02 180 27.10 110 142.29 400 247.09
300 25.20 240 144.39 720 240.95 170 31.34 120 146.07 410 250.53
290 27.57 250 146.49 730 242.87 160 35.54 130 149.83 420 253.96
280 29.93 260 148.58 740 244.79 150 39.72 140 153.58 430 257.38
270 32.27 270 150.67 750 246.71 140 43.88 150 157.33 440 260.78
260 34.61 280 152.75 760 248.62 130 48.00 160 161.05 450 264.18
250 36.94 290 154.83 770 250.53 120 52.11 170 164.77 460 267.56
240 39.26 300 156.91 780 252.44 110 56.19 180 168.48 470 270.93
230 41.57 310 158.98 790 254.34 100 60.26 190 172.17 480 274.29
220 43.88 320 161.05 800 256.24 90 64.30 200 175.86 490 277.64
210 46.17 330 163.12 810 258.14 80 68.33 210 179.53 500 280.98
200 48.46 340 165.18 820 260.03 70 72.33 220 183.17 510 284.30
190 50.74 350 167.24 840 263.80 60 76.33 230 186.84 520 287.62
180 53.02 360 169.30 850 265.68 50 80.31 240 190.47 530 290.92
170 55.29 370 171.35 860 267.56 40 84.27 250 194.10 540 294.21
160 57.55 380 173.40 870 269.44 30 88.22 260 197.71 550 297.49
150 59.81 390 175.45 880 271.31 20 92.16 270 201.31 560 300.74
140 62.06 400 177.49 890 273.17 10 96.09 280 204.90 570 304.01
130 64.30 410 179.53 900 275.04 0 100.00 290 208.48 580 307.25
120 66.54 420 181.56 910 276.90 10 103.90 300 212.05 590 310.49
110 68.77 430 183.59 920 278.75 20 107.79 310 215.61 600 313.71
100 71.00 380 173.40 930 280.61 30 111.67 320 219.15 610 316.92
90 73.22 390 175.45 940 282.46 40 115.54 330 222.68 620 320.12
80 75.44 400 177.49 950 284.30 50 119.40 340 226.21 630 323.30
70 77.66 410 179.53 960 286.14 60 123.24 350 229.72 640 326.48
60 79.86 420 181.56 970 287.98 70 127.08 360 233.21 650 329.64
50 82.07 430 183.59 980 289.82 80 130.90 370 236.70 660 332.79
40 84.27 450 187.65 990 291.65
30 86.47 460 189.67 1000 293.48
20 88.66 470 191.68 1010 295.30
10 90.85 480 193.70 1020 297.12
10 93.03 490 195.71 1030 298.94
20 95.21 500 197.71 1040 300.75
30 97.39 510 199.71 1050 302.56 Note
40 99.57 520 201.71 1060 304.37
50 101.74 530 203.71 1070 306.17 To covert from C to F: {1.8 X (C)] + 32 = F
60 106.07 540 205.70 1080 307.97 Example: (1.8 X 100) + 32 = 212 F
70 108.23 550 207.69 1090 309.77
80 110.38 560 209.67 1100 311.56
90 112.53 570 211.66 1110 313.35 To convert from F to C: 0.556 [(F) 32] = 100 F
100 114.68 580 213.63 1120 315.14 Example: 0.556 (212 32) = 100 C
110 116.83 590 215.61 1130 316.92
120 118.97 600 217.58 1140 318.70
130 121.11 610 219.55 1150 320.47
140 123.24 620 221.51 1160 322.24
150 125.37 630 223.47 1170 324.01
160 127.50 640 225.42 1180 325.77
170 129.62 650 227.38 1190 327.53
180 131.74 660 229.33 1200 329.29
190 133.86 670 231.27 1210 331.04
200 135.97 680 233.21
-47
Product Data Sheet
00813-0100-2654, Rev DA
Mounting Accessories
EXTENSION FITTING ASSEMBLIES FIGURE 19. 3144 Transmitter Housing Temperature Rise
versus Extension Length for a Test Installation
Extension fitting assemblies are available in
a coupling and nipple assembly
a union and nipple assembly 60
FIGURE 18. Extension Fitting 50
40
HOUSING
Length (E) (Nominal) Coupling and Nipple RISE ABOVE 30
Assembly AMBIENT (C) 815 C Oven Temperature
20
Sensors-0036A
3044-0123A
540 C Oven
Temperature
10
0.53 (13) Max. Thread Engagement (14 ANPT Ref.)
250 C Oven Temperature
0
3 4 5 6 7 8 9
Union and Nipple N LENGTH (in.)
Assembly
Example
The rated ambient temperature specification is 85 C. If the
TABLE 24. Extension maximum ambient temperature is 40 C and the process
temperature to be measured is 540 C, the maximum allowable
Coupling and Nipple, SST Union and Nipple, SST housing temperature rise is the rated temperature specification
Nom. Nom.
limit minus the existing ambient temperature (85 40), or 45 C.
Length (E) Length (E) As shown in Figure 19, an extension (E) dimension of 3.0-in (76
Model Number (inches) Model Number (Inches) mm) will result in a housing temperature rise of 30 C. An E
7903540250 2.5 7903550250 2.5 dimension of 3-in. would therefore be the minimum recommended
7903540300 3.0(1) 7903550300 3.0(1) length, and would provide a safety factor of about 15 C. A longer
7903540350 3.5 7903550350 3.5 E dimension, such as 6-in. (152 mm), would be desirable in order
7903540400 4.0 7903550400 4.0 to reduce errors caused by transmitter temperature effect,
7903540450 4.5 7903550450 4.5 although in that case the transmitter would probably require extra
79035-0500 5.0 7903550500 5.0 support. If a thermowell with lagging is used, the E dimension
7903540550 5.5 7903550550 5.5 may be reduced by the length of the lagging.
7903540600 6.0(1) 7903550600 6.0(1)
7903540650 6.5 7903550650 6.5 FLAT COVER CONNECTION HEAD
7903540700 7.0 7903550700 7.0
The Flat Cover Connection Head (P/N 00079-0325-xxxx) is for
7903540750 7.5 7903550750 7.5
general-purpose and spring-loaded sensors. The terminal block
7903540800 8.0 7903550800 8.0
has six terminals for either single- or dual-element sensors.
7903540850 8.5 7903550850 8.5
7903540900 9.0 7903550900 9.0
(1) Standard configuration with best delivery. Also available for

EXTENDED COVER CONNECTION HEAD
emergency requirements. Consult factory for information. The Extended Cover Connection Head (P/N 00079-0324-xxxx)
provides the additional space required by sensors that have
Choosing an Extension and a bayonet connectors. This model can also be used with
Thermowell has six terminals for either single- or dual-element sensors.
Aside from ambient temperature variations, the heat from the
process is transferred from the thermowell to the transmitter Specifications
housing. If the process temperature is near or beyond specification
limits, consider the use of additional thermowell lagging, an
Sensor Connection
extension nipple, or a remote mounting configuration to isolate the 1
transmitter from the excessive temperatures. Use Figure 19 and /214 ANPT mounting thread. Screw terminals for lead wire
the example below to determine an adequate thermowell connections
extension length.
-48
Product Data Sheet
00813-0100-2654, Rev DA
Electrical Connection TABLE 25. Connection Head
3/414 ANPT conduit
Model Description
Materials of Construction 007903252003 Six Terminals with Flat Cover,

Unapproved, Unpainted
Housing: Lowcopper aluminum alloy
O-ring seal: Silicone rubber 007903242003 Six Terminals with Extended Cover,
Terminals: Nickelplated brass
007903250002 Six Terminals with Flat Cover, FM
Approved, Unpainted
Temperature Limits 007903240002 Six Terminals with Extended Cover,
Head Type Unapproved With E5 option With E6 option FM Approved, Unpainted
Painted 100 to 100 C 50 to 85 C 50 to 85 C 007903250003 Six Terminals with Flat Cover, CSA
148 to 212 F 58 to 185 F 58 to 185 F Approved, Unpainted
Unpainted 100 to 200 C 50 to 85 C 50 to 200 C 007903240003 Six Terminals with Extended Cover,
148 to 392 F 58 to 185 F 58 to 392 CSA Approved, Unpainted
007903252005 Six Terminals with Flat Cover,
Enclosure Ratings Unapproved, Painted
When installed properly, painted connection heads are suitable for 007903242005 Six Terminals with Extended Cover,
Unapproved, Painted
indoor and outdoor NEMA 4X and CSA Enclosure Type 4X
installations. When installed properly, unpainted connection heads Approved, Painted
are suitable for NEMA 4 and CSA Enclosure Type 4 installations. 007903240004 Six Terminals with Extended Cover,
See Hazardous Area Approvals for complete installation FM Approved, Painted
information 007903250005 Six Terminals with Flat Cover, CSA
Approved, Painted
Weight 007903240005 Six Terminals with Extended Cover,
Extended cover type: 2 lb 8 oz CSA Approved, Painted
Flat cover type: 1 lb 9 oz C537510301 Six Terminals, No Approval Options,
White Polypropylene
POLYPROPYLENE CONNECTION HEAD Connection Head Dimensional Drawings

The polypropylene connection head (P/N C53751-0301) is
Flat Cover Extended Cover Terminal View
designed for use with sanitary sensors. It meets the requirements
of NEMA 4X, is FDA-compliant, and is resistant to attack by acids,
alkalies, and organic solvents. 3.5 5.5 1/214 ANPT
(89) (140)
Specifications 4.9
(124)
Sensor Connection
Sensors-0035A
1/214 ANPT mounting thread. Screw terminals for lead wire
connections
3
/414 ANPT
Electrical Connection Chain Terminal Block (6 terminals)
3
/414 ANPT conduit
Polypropylene
Temperature Limits
73 to 104 C (100 to 220 F)
Sensors-3751A02A, 3751B02A
Weight 35 2.90 (74)
0.5 lb 1.63 (41) 0.80 (20)
Materials of Construction
Housing: White polypropylene polymer 1.175 (30)
3/418 ANPT
O-ring seal: Silicone rubber
Terminals: Nickelplated brass
1.41 (36)
1.05 (27)
-49
Product Data Sheet
00813-0100-2654, Rev DA
MOUNTING ADAPTERS FOR SERIES 58, 68, 78, AND 183

M5M7, Sensor Compression Fittings, 316 SST
For adjustable sensor length.
Fitting Diameter
For low pressure applications
(100 psig maximum).
Fits -inch diameter sensors.
Available with 1/827 (M5), 18 (M6), and 14 (M7) ANPT
process threads.
Not available on spring-loaded sensors.
Sensors-0025A
Sensor Process Thread
Length
TABLE 26. Compression Fittings, 316 SST

(for attachment to the stem of the capsule)
Model Number Option Code Sensor Process Thread Fitting Diameter Length
in. mm in. mm
C07961-0005 M5 1/827 ANPT 0.25 6.35 1.31 33.27
C07961-0006 M6 1/418 ANPT 0.25 6.35 1.5 38.1
C07961-0008 M7 1/214 ANPT 0.25 6.35 1.75 44.45
-50
Product Data Sheet
00813-0100-2654, Rev DA
LEAD WIRE EXTENSIONS, CONNECTORS, AND SEALS

The following options are available on most Series 68 and 78 sensors. They are not available for use on Series 58C, 68Q, and 183 sensors or
with SAA or CENELEC/ISSeP Flameproof approval (Option Codes E7 or E1).
(Capsule Sensor Only)

Twisted Lead WIre Extension
(Option Codes A1 A8)
(Capsule Sensor with Standard Adapter)
Shielded Cable Lead Wire Extension

(Option Codes B1 B8)
Armored Cable Lead Wire Extension

(Option Codes C1 C8)
Armored Cable
Mating Plug with Lead
Wire Extension
(Option Codes L1 L8) Armored Cable Lead Wire Extension with
Electrical Plug
(Option Codes D1 D8)
4-Pin Connector
(Option Codes H1 H8) Bayonet Connector
(Option Code F1)
Moisture-Proof Seal Assembly for
Armored Cable (Option Code J1)
Sensors-0009A05A
3244MV Transmitter Armored Cable Lead Wire Extension (Option Codes C1 C8)
A1A8, Twisted Lead Wire Extension

Lead wire connections are silver brazed and
individually insulated by shrinkable Teflon tubes Option Code Y Length (ft) Option Code Y Length (ft)
Withstands 95 percent relative humidity A1 11/2 A5 24
200 C (392 F) maximum temperature A2 3 A6 50
A3 6 A7 75
Available with single or dual-element sensors
A4 12 A8 100
22-Gauge Teflon (PTFE) Lead Wire

Teflon Sensor
Sensors-0027A
6 (152) [Ref.]
Y
Not available for use with Series 68Q Sanitary RTDs and 183 thermocouples or with SAA or CENELEC/ISSeP flameproof approval
(option codes E7 or E1)
-51
Product Data Sheet
00813-0100-2654, Rev DA
B1B8, Shielded Cable Lead Wire Extension

Copper shielded cable prevents electrical noise distortions to
sensor signal output Option Code Y Length (ft) Option Code Y Length (ft)
Withstands 95 percent relative humidity B1 11/2 B5 24
200 C (392 F) maximum temperature B2 3 B6 50
B3 6 B7 75
B4 12 B8 100
Shielded Cable Teflon Jacket Rubber Seal

0.375 (10) Diameter
22-Gauge Teflon-Insulated Wires 0.25 (6) [Approx.] Sensor
Sensors-0028A
Y 2.75 (70) [max.]
Not available for 58C, 68Q, and 183 sensors or with SAA or CENELEC/ISSeP flameproof approval (option codes E7 or E1)
C1C8, Armored Cable Lead Wire Extension

Provides lead wire protection
in heavy duty environments. Option Code Y Length (ft) Option Code Y Length (ft)
Withstands 95 percent relative humidity C1 11/2 C5 24
200 C (392 F) maximum temperature C2 3 C6 50
C3 6 C7 75
C4 12 C8 100
22-Gauge Teflon-Insulated Wire

Armor Cable 0.34 (8.64) I.D. 0.375 (10) Diameter 0.445 (11)
Sensor
Sensors-0030A
6.0
Y 2.75 (70) [Max.]
(152)
D1D8, ARMORED CABLE LEAD WIRE EXTENSION WITH ELECTRICAL PLUG

Provides lead wire protection in
heavy-duty environments Option Code Y Length (ft) Option Code Y Length (ft)
Provides quick-disconnect capability D1 11/2 D5 24
Withstands 95 percent relative humidity D2 3 D6 50
D3 6 D7 75
D4 12 D8 100
Mates with Option Codes L1L8

Armor Cable 0.25 (6) 0.375 (10) Diameter
Sensor
Sensors-0029A
Y 2.75 (70) [Max.]

-52
Product Data Sheet
00813-0100-2654, Rev DA
L1L8, ARMORED CABLE MATING PLUG WITH LEAD WIRE EXTENSION
Completes quick-disconnect capability for armored cable
Option Code Y Length (ft) Option Code Y Length (ft)
Withstands 95 percent relative humidity L1 11/2 L5 24
Twisted lead wire extension for lowest cost installation L2 3 L6 50
L3 6 L7 75
L4 12 L8 100
22-Gauge Teflon Lead Wire Mates with Option Codes D1D8
Sensors-0031A
Y
F1, 4-PIN BAYONET CONNECTOR

Provides quick-disconnect capability
Withstands 100 percent relative humidity with connector mate
Available for capsule and general purpose with 4-wire lead
wire configuration only
Receptance Shell and Pin 0.652 (17) Mates with Option Codes H1H8
Finish Are Nickel Plate Dia. Max. 0.375 (10) Diameter
Sensors-0032A
Wiring Schematic Sensor
A 2.0 (51)
B
4-Wire 3.0 (76)
C
D 150 C Max. for Series 68 and 78
Not available for 58C, 68Q, and 183 sensors, or with FM or CSA explosion-proof, or with SAA or CENELEC/ISSeP flameproof approval
(option codes E5, E6, E7, or E1)
H1H8, 4-PIN CONNECTOR MATING PLUG WITH LEAD WIRE EXTENSION

Completes the quick-disconnect capability of connector
Option Code Y Length (ft) Option Code Y Length (ft)
Provides twisted lead wire extension for H1 11/2 H5 24
remote installations H2 3 H6 50
Withstands 100 percent relative humidity H3 6 H7 75
with connector mate H4 12 H8 100
F1 connector is required if H1H8 lead wire extension is used
22-Gauge Teflon
4-Pin Connector (Mates with Option Code F1)
Lead Wire
Sensors-0033A
Y
(option codes E5, E6, E7, or E1)
-53
Product Data Sheet
00813-0100-2654, Rev DA
J1, MOISTURE-PROOF SEAL ASSEMBLY FOR ARMORED CABLE

Prevents moisture migration through armored cable
For use in humid environments but not for direct liquid
immersion
Non-disconnectable type assembly with armored cable
and sensor
Nipple, 304 SST, 1/214 ANPT 1.12 (28.45) Long
Moisture-Proof Seal (J1)

Compression Fitting Sensor
ensors-0034A
Armored Cable Lead Wire
(Specify Option Codes C1C8)
J1
(option codes E5, E6, E7, or E1).
Moisture-proof seal assembly must be ordered with armored cable lead wire extension (option codes C1 C8)
THERMOWELLS
To simplify ordering, the previous Series 79, 80, and 81 thermowell Construction
offerings are all included in the new Series 91 thermowell option. All thermowell bodies with an overall length less than 42-in. are
machined from solid bar stock to ensure water-tightness. Flange
Materials mounts are welded to the thermowell body. Standard construction
Rosemount Thermowells are supplied in most materials required provides immersion lengths (U) from 2 to 48 inches with overall
for industrial applications. Standard materials are 316 SST, 304 lengths (L) from 4 to 59 inches respectively. Thermowells with
SST, and C1018 carbon steel. For corrosive environments, special overall lengths larger than 42-in. will be a 3-piece welded
materials such as Monel, Hastelloy, and Inconel 600 are construction. Consult the factory for more information on welded
available. Consult factory for other material availability. 3-piece construction thermowells.
Strength (Pressure and Flow Vibration) Identification Data

The strength of a thermowell depends on several parameters that The part number is etched on each thermowell. Additional tagging
relate thermowell construction to the installation environment. For for specific customer requirements is available.
most industrial applications, standard Rosemount thermowells
provide the necessary strength if the material, style, and length are Installation
correct for the application. The proper selection of a thermowell For dimensional drawings of Thread Mounted, Weld Mounted, and
depends on fluid type, temperature, pressure, and fluid velocity. It Flange Mounted Thermowells, refer to Figure 20, 22, and 24.
is important to note that most thermowell failures are caused by
vibration that is induced by fluid flow. If static pressure strength is a
major consideration, refer to Table 27 for standard material ratings
for a 1/2-inch tip. Tapered thermowells are offered for additional
strength.
Strength Calculation
Rosemount Inc. has the ability to perform thermowell frequency
calculations to verify that the thermowell dimensions you provide
are appropriate for your specific application. To take advantage of
this calculation, fill out and return the Configuration Data Sheet
on page -69.
TABLE 27. Thermowell Material Rating

Process Rating(1) (psi) at Temperature (F)
Material Recommended Usage 0 F 300 F 500 F 700 F 900 F 1100 F 1300 F
304 SST Good resistance to oxidation 5600 4800 4700 4600 3400 2400 780
316 SST Good resistance to corrosion. Better resistance to 5600 5400 5300 5200 4400 3200 1250
chemical attack than 304 SST
Carbon Steel For non-corrosive service 3700 3700 3700 3650 2000
(1) In case of an explosion, the integrity of the thermowell is maintained to the specified pressures.
-54
Product Data Sheet
00813-0100-2654, Rev DA
TABLE 28. Series 91 Thermowells
Model Description
0091 Series 0091 Thermowells
Code Thermowell Material Code Thermowell Material Code Thermowell Material
A Type 316 SST G Monel R Nickel 200
B Type 304 SST H Inconel 600 T Titanium
C Carbon Steel J Hastelloy C (304 SST Flange, if U(2) 316 SST with tantalum sheath
flange style is ordered)
D 316L SST L Hastelloy B (304 SST Flange, if V 310 SST
E 304L SST M 304 SST with Teflon coating W 321 SST
F Alloy 20 P Chrome Molybdenum F22 Z Chrome Molybdenum F11
Code Length (U) in inches(1) Code Length (U) in inches(1) Code Length (U) in inches(1)
(2)
015 1.5 130 13.0 260 26.0
020 2.0 135 13.5 270 27.0
025 2.5 140 14.0 280 28.0
030 3.0 145 14.5 290 29.0
035 3.5 150 15.0 300 30.0
040 4.0 155 15.5 310 31.0
045 4.5 160 16.0 320 32.0
050 5.0 165 16.5 330 33.0
055 5.5 170 17.0 340 34.0
060 6.0 175 17.5 350 35.0
065 6.5 180 18.0 360 36.0
070 7.0 185 18.5 370 37.0
075 7.5 190 19.0 380 38.0
080 8.0 195 19.5 390 39.0
085 8.5 200 20.0 400 40.0
090 9.0 205 20.5 410 41.0
095 9.5 210 21.0 420 42.0
100 10.0 215 21.5 430 43.0
105 10.5 220 22.0 440 44.0
110 11.0 225 22.5 450 45.0
115 11.5 230 23.0 460 46.0
120 12.0 240 24.0 470 47.0
125 12.5 250 25.0 480 48.0
Code Thermowell Mounting Style Stem Style Tip A (in.) Root B (in.)
T20 Thread, 1/214 ANPT Stepped 0.50 0.63
T24 Thread, 111.5 ANPT Stepped 0.50 0.88
T26 Thread, 3/414 ANPT Tapered 0.63 0.88
T28 Thread, 111.5 ANPT Tapered 0.63 1.06
T30 Thread, 11/211.5 ANPT Tapered 0.75 1.50
T32 Thread, 1/214 ANPT Straight 0.50 0.50
T36 Thread, 111.5 ANPT Straight 0.75 0.75
W38 Weld, 3/4-in. pipe Stepped 0.50 0.75
W40 Weld, 1-in. pipe Stepped 0.50 0.88
W42 Weld, 3/4-in. pipe Tapered 0.63 0.88
W44 Weld, 1-inch Pipe, Tapered 0.75 1.00
W46 Weld, 11/4-inch Pipe Tapered 0.75 1.25
W48 Weld, 3/4-inch Pipe Straight 0.75 0.75
W50 Weld, 1-inch Pipe Straight 0.75 0.75
F10 Flange, F = 2-inch, Class 150 Straight 0.75 0.75
-55
Product Data Sheet
00813-0100-2654, Rev DA
F52 Flange, F = 1-inch, Class 150 Stepped 0.50 0.75

F58 Flange, F = 1-inch, Class 150 Tapered 0.75 1.00
F88(3) Flange, F = 1-inch, Class 600 Stepped 0.50 0.75
F94(3) Flange, F = 1-inch, Class 600 Tapered 0.75 1.00
F02(3) Flange, F = 1-inch, Class 600 Straight 0.75 0.75
Q02 Sanitary, 1-in.,Tri-Clamp Stepped 0.50 0.75
Q04 Sanitary, 11/2-in., Tri-Clamp Stepped 0.50 0.75
Q06 Sanitary, T2-in., ri-Clamp Stepped 0.50 0.75
Q20 Sanitary, 3/4-in., Tri-Clamp Straight 0.44 0.44
Q22 Sanitary, 1-in.,Tri-Clamp Straight 0.50 0.50
Q26 Sanitary, 2-in., Tri-Clamp Straight 0.50 0.50
Thermowell Lagging Thermowell Lagging Thermowell Lagging
Code Length (T) in. Code Length (T) in. Code Length (T) in.
T000 0.0 T035 3.5 T070 7.0
T005 0.5 T040 4.0 T075 7.5
T010 1.0 T045 4.5 T080 8.0
T015 1.5 T050 5.0 T085 8.5
T020 2.0 T055 5.5 T090 9.0
T025 2.5 T060 6.0 T095 9.5
T030 3.0 T065 6.5
Code Instrument Connection Thread
P 1/214 NPSM
D 1/214 ANPT for CSA
-56
Product Data Sheet
00813-0100-2654, Rev DA

Thermowell Options
R01(5) Thermowell special external pressure testing
R14(8) Thermowell special surface finish (12 Ra Max) (Maximum (U) length = 22.5 in.)
R16(3)(6)(7) Ring joint flange (Not available with 0-in. (T) length)
(1) Thermowells with an overall lengths (U + T + 1.75-in.) of 42-in. or less are machined from solid bar stock. Thermowells with an overall length larger
than 42-in. will be constructed using a welded 3-piece design and are available only with a stepped stem style.
(2) Available in straight stem only
(3) Not available with 0-in. (T) length.
(4) Not available with 0- or 1/2-in. (T) length.
(5) Maximum (U) length = 42.0-in.
(8) Maximum (U) length = 22.5 inches.
Ordering Example
Typical Model Immersion Lagging
Number Model Material Length Mounting Style Length Connection Thread Additional Options
0091 A 030 F52 T040 P R01
R05
R07
-57
Product Data Sheet
00813-0100-2654, Rev DA
FIGURE 20. Thread Mounted Thermowells
Straight
Wrench and
Lagging Extension, Nom. Thread U
T
Allowance
1.75 (44)
14 NPSM* A Tip Diameter
Sensors-0010A
Inside Diameter 0.26 (7)
P Process
H 0.875 Mounting Thread
(22) Max.
L 0.25 (6)
Nominal
Thread (P) Hex Size Inches (H)

0.5 0.75 ANPT 1.125
111.5 ANPT 1.375
Tapered
Wrench and
Lagging Extension, Nom. T Thread
Allowance U
14 NPSM* 1.75 (44) Root Diameter B
A Tip Diameter
Sensors-0012A
P Process Inside Diameter 0.26 (7)
H 0.875
(22) Max. Mounting Thread
L 0.25 (6)
Nominal

0.5 0.75 ANPT 1.125
111.5 ANPT 1.375
* 1/214 ANPT threads are available
-58
Product Data Sheet
00813-0100-2654, Rev DA
FIGURE 21. Thread Mounted Thermowells (continued)
Stepped
Wrench and
Thread
Lagging Extension, Nom. T Allowance U
1.75 (44)
14 NPSM* 2.5 (64)
B Root A Tip Diameter
Diameter
Sensors-0011A
H 0.875 P Process Mounting
(22) Max. Thread
L
0.25 (6)
Nominal
Stepped, For Thermowells with Overall Length Greater than 42-in. (3-Piece Construction)
T 1.75 (44) U
14 NPSM*
2.5 (64)
Pipe
0.26 (7) Nominal
Sensors-0051A
H
Welds 0.25 (6)

0.5 0.75 ANPT 1.125
111.5 ANPT 1.375
-59
Product Data Sheet
00813-0100-2654, Rev DA
FIGURE 22. Weld Mounted Thermowells
Straight
1.75
T U
(44)
Sensors-0015A
0.875 (22) Max.

S Socket Weld Diameter
L 0.25 (6) Nominal
Pipe Size Socket Size (S) Diameter

0.75-in. 1.050 0.010
1-in. 1.315 0.010
Tapered
T 1.75 U
(44)
Root Diameter B
Sensors-0017A
0.875 (22)
L 0.25 (6) Nominal

0.75-in. 1.050 0.010
1-in. 1.315 0.010
-60
Product Data Sheet
00813-0100-2654, Rev DA
FIGURE 23. Weld Mounted Thermowells (continued)
Stepped
1.75
T (44) U
14 A Tip Diameter
NPSM* 2.5 (64)
Sensors-0016B
0.875 (22) Max. B Root Diameter Inside Diameter 0.26 (7)
0.25 (6)
L Nominal
14 U
T 1.75 (44) 2.5 (64)

Pipe
0.26 (7) Nominal
Sensors-0052A
0.25 (6)
Welds
L

0.75-in. 1.050 0.010
1-in. 1.315 0.010
-61
Product Data Sheet
00813-0100-2654, Rev DA
FIGURE 24. Flange Mounted Thermowells
Straight
G 1.7
T U
5 Flange Mount
1.25 (32) Diameter
14 A Tip Diameter
NPSM*
Sensors-0013A
0.875
(22)
Max. H
F L 0.25 (6) Nominal
E
Tapered
G
1.75
1.25 (32) Diameter T (44) U
14 Flange
NPSM* Mount A Tip Diameter
0.875 Inside Diameter 0.26 (7)

R Root Diameter
(22) Max.
Sensors-0047A
H
E
Class 150 Class 600

Size (in.) O.D. (E) Circle (F) # of holes thickness Size (in.) O.D. (E) Circle (F) # of holes thickness
and dia. (G) (in.) (H) and dia. (G) (in.) (H)
1.0 4.25 3.12 four-0.625 0.5625 1.0 4.88 3.5 four-0.75 0.94
1.5 5.0 3.88 four-0.625 0.6875 1.5 6.12 4.5 four-0.88 1.13
2.0 6.0 4.75 four-0.75 0.75 2.0 6.5 5.0 eight-0.75 1.25
3.0 7.5 6.00 four-0.75 0.94 Class 900 and 1500
Class 300 1.5 7.0 4.88 four-1.12 1.5
1.0 4.88 3.5 four-0.75 0.69 Class 2500
1.5 6.12 4.5 four-0.88 0.81 1.5 8.0 5.75 four-1.25 2.0
2.0 6.5 5.0 eight-0.75 0.88

-62
Product Data Sheet
00813-0100-2654, Rev DA
FIGURE 25. Flange Mounted Thermowells (continued)
Stepped
G 1.75
T (44) U
Flange
1.25 (32) Diameter 14 A Tip
Mount
NPSM* 2.5 Diameter
Sensors-0014A
R Root
(22) Max.
Diameter
H
F 0.25 (6) Nominal
L
E
1.75
T (44.5)
G
1.25 (32) Diameter
U
Flange
Weld Weld
14 Pipe 2.5 (64)
NPSM*
0.26 (7) Nominal

F 0.25 (7) Nominal
Welds
Sensors-0053A
E
Class 150 Class 600

1.0 4.25 3.12 four-0.625 0.5625 1.0 4.88 3.5 four-0.75 0.94
1.5 5.0 3.88 four-0.625 0.6875 1.5 6.12 4.5 four-0.88 1.13
2.0 6.0 4.75 four-0.75 0.75 2.0 6.5 5.0 eight-0.75 1.25
3.0 7.5 6.00 four-0.75 0.94 Class 900 and 1500
Class 300 1.5 7.0 4.88 four-1.12 1.5
1.0 4.88 3.5 four-0.75 0.69 Class 2500
1.5 6.12 4.5 four-0.88 0.81 1.5 8.0 5.75 four-1.25 2.0
2.0 6.5 5.0 eight-0.75 0.88

-63
Product Data Sheet
00813-0100-2654, Rev DA
Hazardous Area Approvals

SENSORS SENSOR AND TRANSMITTER
Factory Mutual (FM) Approvals ASSEMBLIES
E5 Explosion Proof for Class I, Division 1, Groups B, C, and D. CENELEC/ATEX Approvals
Dust-Ignition Proof for Class II/III, Division 1, Groups E, F, E1 CENELEC/ATEXExplosion- proof
and G. Suitable for indoor and outdoor (NEMA 4X)
Certificate Number: KEMA99ATEX8715
hazardous locations. Install in accordance with Rosemount
ATEX Marking: II 2 G
drawing 00068-0013. EEx d IIC T6 ( 40C = Tamb = +65C)
Rosemount Series 68 and 78 RTD and Series 184
Canadian Standards Association (CSA) Approvals
thermocouple temperature sensors with spring-loaded or
E6 Explosion Proof for Class I, Division 1, Groups B, C, and D. general purpose style sensors are approved only for direct
Dust-Ignition Proof for Class II/III, Division 1, Groups E, F, mount to the Rosemount 3144P, 3244MV, 644, 244E, 144H,
and G. Suitable for Class I, Division 2, Groups A, B, C, and and 248.
D. Suitable for indoor and outdoor (CSA Enclosure Type 4X)
To ensure approval compliance, specify the E1 option on
both the sensor and the transmitter at the time of ordering.
drawing 00068-0033.
To ensure approval compliance install sensors in exact
accordance with the specified installation drawings (see NOTE
Figure 27). Rosemount series 68 and 78 RTD and Series 183 Thermocouple
Temperature Sensors can be supplied as a replacement part with
the E1 option for installation in an existing temperature
CONNECTION HEADS measurement assembly.
Factory Mutual (FM) Approvals
E5 Explosion Proof for Class I, Division 1, Groups B, C, and D.
Dust-Ignition Proof for Class II/III, Division 1, Groups E, F, Standard Association of Australia (SAA)
and G. Painted models are suitable for indoor and outdoor Flameproof Approval
(NEMA 4X) hazardous locations. Unpainted models are E7 Ex d IIC T6 (Tamb = 20 to 60 C)
suitable for indoor and outdoor (NEMA 4) hazardous Rosemount Series 68 and 78 RTD and Series 183
locations. When used with temperature sensors, connection thermocouple temperature sensors with spring-loaded or
heads must be installed in accordance with Rosemount general purpose style sensor adapters are approved for
drawing 00068-0013. direct mount to the Rosemount 144, 244E, 644, 3144 and
3244MV Smart Temperature Transmitters.
Canadian Standards Association (CSA) Approvals To ensure approval compliance, specify the E7 option on
E6 Explosion Proof for Class I, Division 1, Groups C, and D. both the sensor and the transmitter at the time of ordering,
Dust-Ignition Proof for Class and install in exact accordance with Rosemount drawing
II/III, Division 1, Groups E, F, and G. Suitable for Class I, 03144-0225 (see Figure 29).
Division 2, Groups A, B, C, and D.
Painted models are suitable for indoor and outdoor (CSA
Enclosure Type 4X) hazardous locations. Unpainted models
are suitable for indoor and outdoor (CSA Enclosure Type 4)
hazardous locations. When used with temperature sensors,
connection heads must be installed in accordance with
Rosemount drawing 00068-0033.
To ensure approval compliance, install connection heads in
exact accordance with the specified installation drawings
(see Figure 27).
-64
Product Data Sheet
00813-0100-2654, Rev DA
Factory Mutual (FM) Explosion-Proof

FIGURE 26. Installation Drawing 00068-0013, Rev. AC
NOTE
For Hand-Tight Assembly Option XA: End-User (installer) must unscrew threaded joints, then reassemble and tighten all joints per installation
drawing 00068-0013.
-65
Product Data Sheet
00813-0100-2654, Rev DA
Canadian Standards Association (CSA) Explosion-Proof

FIGURE 27. Installation Drawing 00068-0033, Rev. AA
NOTE
drawing 00068-0033.
-66
Product Data Sheet
00813-0100-2654, Rev DA
CENELEC Flameproof
FIGURE 28. Installation Drawing 03144-0324, Rev. AB
-67
Product Data Sheet
00813-0100-2654, Rev DA
Standard Association of Australia (SAA) Flameproof

FIGURE 29. Drawing 03144-0225, Rev. A
-68
Product Data Sheet
00813-0100-2654, Rev DA
Configuration Data Sheet

Calculations conducted per ASME/ANSI PTC 19.3 but with Strouhal number varying with Reynolds number.
Company Information
Requesting Company: Phone: Fax:

Contact Tag Number
End Customer Date of Request:
Thermowell Information (Information for either (a), (b), or (c) required)
a) Rosemount Thermowell Part Number (example 0091A030FS2T040PR01):

b) Rosemount Sensor Model Number (example 0078R21C30A120F54):
c) Generic Thermowell Information:
Thermowell Material: Mounting Stem
Style Style
Stem Style: Straight U A
Stepped
Threaded Straight
Tapered
D
Mounting Threaded
Style: T
Welded
U
Flanged Z A
If flanged, ANSI/ASME Welded
SENSORS_0010B, 0016B, 0047B

Stepped
specify:
DIN D
B T
Size: Class:
Thermowell Bore Diameter (D):
U
Tip Diameter (A):
A
Tip Thickness (T):
Length from Tip to Support (U): Flanged Tapered

Root Diameter (B): D
B
(same as (A) for straight thermometers)
T
Length of Tip Diameter (Z):
(stepped thermowells only)
Service: Liquid Gas Steam Fluid Description:

Operating Fluid Flow Rate; Maximum:
Operating Fluid Flow Rate Units:
gal/s gal/min gal/hr l/s l/min l/hr ft/s
ft3/min ft3/hr bbl/hr impgal/s impgal/min impgal/hr m/s
m3/min m3/hr shton/hr lb/hr kg/s kg/hr other:
Operating Max. Fluid Pressure: Gauge
Absolute
Viscosity: kg/m s (Pas)
Centipoise
Operating Fluid Specific F Operating Fluid Density: m3/kg
Temperature: C ft3/lbm
Specific Volume: at process conditions
at standard conditions (STP)
Process Pipe Size:

Pipe Schedule:
For Rosemount Internal Use Only
Rosemount Order/Quotation # Line Item # Ship Set # ID #

Customer Order/Item # Salesperson:
Cont. Admin. Tech. Specialist:
-69
Product Data Sheet
00813-0100-2654, Rev DA
Rosemount and the Rosemount logotype are registered trademarks of Rosemount Inc.
Teflon is a registered trademark of E.I. du Pont de Nemours & Co.
Hastelloy is a registered trademark of Haynes International.
Monel and Inconel is a registered trademark of International Nickel Co.
All other marks are the property of their respective owners.
Emerson Process Management
Rosemount Inc. Emerson Process Management Emerson Process Management Asia

8200 Market Boulevard Temperature GmbH Pacific Private Limited
Chanhassen, MN 55317 USA Frankenstrasse 21 1 Pandan Crescent
T (U.S.) 1-800-999-9307 63791 Karlstein Singapore 128461
T (International) (952) 906-8888 Germany T (65) 6777 8211
F (952) 949-7001 T 49 (6188) 992 0 F (65) 6777 0947
F 49 (6188) 992 112 AP.RMT-Specialist@emersonprocess.com
www.rosemount.com
00813-0100-2654}
2003 Rosemount Inc. All rights reserved.
Mounting and
Installation Advice
00809-0301-2654
Rev. AA, September 2001
Resistance Thermometers
and Thermocouple Assemblies
Product
Manual
Mounting and Installation Advice
for Resistance Thermometers and
Thermocouple Assemblies
NOTICE
Read this manual before working with the product. For personal and system safety, and
for optimum product performance, make sure you thoroughly understand the contents
before installing, using, or maintaining this product.
For further details please contact your local Rosemount representative.
! CAUTION
The products described in this document are NOT designed for nuclear-qualified applica-
tions. Using non-nuclear qualified products in applications that require nuclear-qualified
hardware or products may cause inaccurate readings.
For information on Rosemount nuclear-qualified products, contact your local Rosemount
Sales Representative.
Cover Photo: Product Overview Temperature Sensors and Transmitters
2
Table of Contents
SECTION 1 Description and Measuring Principle .................................................... 5

Temperature Measurement Structure ................................................................................................... 5
with Resistance Methods of Connection ............................................................................ 7
Areas of Application ................................................................................. 8
Thermometers
SECTION 2 Description and Measurement Principle ............................................... 9

Temperature Measurement Installation of Protective Tubes ........................................................... 10
with Thermocouples Leads and Connections .......................................................................... 10
Areas of Application ............................................................................... 11
SECTION 3 Rules and Regulations ........................................................................... 13

Assembly of Housing Operating Stress .............................................................................. 13
Starting Torques for Screw-in Type Threads ................................ 13
Assembly of Housing with Flange Mounting ................................ 13
Installation of Ceramic
Housing in Plants at Operating Temperature .............................. 14
Connection of Transmitter .............................................................. 14
APPENDIX Appendix I
Limit Tolerances of the Basic Values ............................................. 15
Appendix II
Limit Tolerances for Thermocouples .............................................. 15
3
Rosemount Mounting and Installation Advice for Resistance Thermometers and Thermocouple
4
Section
1 Temperature Measurement
with Resistance Thermometers
Description and Measuring Principle ......................................... page 5
Structure ......................................................................................... page 5
Methods of Connection ................................................................ page 7
Areas of Application ..................................................................... page 8
DESCRIPTION AND Temperature measurement with resistance thermometers is based on

MEASURING PRINCIPLE the property possessed by all conductors and semiconductors, namely
that their resistance varies as a function of temperature. This property
is more or less pronounced, depending on the particular material. The
relative change in the resistance as a function of temperature (dR/dt)
is known as the temperature coefficient, the value of which is usually
not constant over the range of temperature of interest, but is itself a
function of temperature. The result is that the mathematical relation-
ship between resistance and temperature takes the form of a high-
order polynomial.
Figure 1 shows the change in resistance as a function of temperature

for a Pt 100 resistance thermometer.
Figure 1:
Pt 100 characteristic curve
STRUCTURE The resistance temperature detector is made up of a platinum coil

wound on a suitable support. The wire coil is either fused into glass or
embedded in ceramic. To meet todays requirements for more compact
dimensions and higher resistance values, extremely thin platinum
layers are applied to a ceramic substrate instead of wires (see Fig. 2).
5
Figure 2:
Glass wire-wound, ceramic wire-wound
and thin-film resistance thermometers
To protect them against mechanical damage (pressure or flowing liquid)

these measuring elements are usually installed into suitable protective
tubes (measuring inserts). This also ensures easy replacement without
the need to replace the complete fitting. As resistance thermometers
are contact-making temperature sensors (i.e. the sensor has to reach
the temperature of the medium in which measurement is to be per-
formed) the housing has to be adapted to the application (see Fig. 3).
Figure 3:
Resistance thermometer modules
6
METHODS When using resistance thermometers for temperature measurement, the
OF CONNECTION fact that the measurement result is influenced by the resistance of the
selected lead wire must be taken into account.
Three circuit types are commonly used: 2-wire, 3-wire and 4-wire
circuits.
The most accurate measurements are obtained with the 4-wire circuit,
as in this case the measurement is not affected by lead wire resistance
or environment temperature of lead wires (see Fig. 4).
The 3-wire circuit is normally used for eliminating the lead wire
resistance (Wheatstone bridge).
In the case of the 2-wire circuit the lead wire resistance is fully mea-
sured by the measuring bridge. By the use of modern control equip-
ment the influence of the lead wire resistance at 2-wire circuit can be
compensated by a line compensation resistor, which is independent of
temperature.
Figure 4:
Methods of connection
7
AREAS OF APPLICATION Resistance thermometers can be used over a temperature range of

-220 C to +600 C.
Their advantages are:

High temperature ranges
Resistance to vibration
High immunity to electrical interference
Long-term stability
Robust design
High accuracy
Resistance thermometers are used in the following industries:

Chemical industries
Petrochemical industries
Pharmaceutical industries
Power generation
Mechanical engineering
Food & beverage
Mining
8
Section
2 Temperature Measurement
with Thermocouples
Description and Measuring Principle ......................................... page 9
Installation of Protective Tubes ................................................ page 10
Leads and Connections .............................................................. page 10
Areas of Application ................................................................... page 11
DESCRIPTION AND A thermocouple consists of two electrical conductors of different mate-

MEASUREMENT rials connected to one another at one end (measuring junction). The
PRINCIPLE two free ends build a compensation point resp reference junction. The
thermocouple can be extended by using an extension or a compensa-
ting cable. The extension or compensating cables are connected to a
measuring instrument, e.g. a galvanometer or electronic measuring
unit (see Fig. 5).
Figure 5
The thermoelectric voltage appearing at the reference junction depends

on the thermocouple wire material and on the temperature difference
between the measuring junction and the reference junction. For tem-
perature measurement, the temperature of the reference junction must
be kept constant (e.g. 0 C) or must be well known, to make a apprio-
priate correction in mV (see Fig. 6).
Figure 6
9
Extension cables are manufactured of the same material as the corres-

ponding thermocouple, e.g. Cu-CuNi, Fe-CuNi. Compensating cables
are manufactured of special materials.
Up to 200 C compensating cables supply the same thermoelectric volt-

age as the thermocouples to which they are connected. The thermo-
electric voltages of the thermocouples are laid down in so-called basic
value series.
e.g. PtRh30%-PtRh6% Type B

Fe-CuNi Type J
NiCr-NiAl Type K
PtRh87/13%-Pt Type R
PtRh90/10%-Pt Type S
and others in DIN IEC 584-1
and Fe-CuNi Type L

Cu-CuNi Type U
These thermocouples are not more available
for use in new plants (thermoelectric voltage
according to DIN 43710). Basic value tables
are available on request only at manufacturer
site.
The compensating cable for a thermocouple must be made of a mate-

rial to suit the particular type of thermocouple, so compensating leads
are colour-coded. For standardized compensating cable the regulations
contained in DIN EN 60584 apply.
Maximum temperatures indicated by manufacturer have to be considered.
Most thermocouples are supplied ready for operation, that is in a pro-

tective mounting to prevent damage to the thermocouple by mechanical
forces or chemical attack.
INSTALLATION OF The protective tubes of thermocouples must be adapted to the particular

PROTECTIVE TUBES operating conditions. Precious metal thermocouples are always protec-
ted with a ceramic tube, even if the unit has a metallic protective
mounting.
At high temperatures the protective tubes should be installed vertically,

where possible, i.e. suspended, to avoid damage deflection to the protec-
tive tube and thermocouple through bending. If specific conditions on
site make a horizontal installation unavoidable, long protective tubes
have to be suitably supported.
LEADS AND When laying and connecting extension resp. compensating cables, care
CONNECTIONS must be taken to connect the positive pole of the thermocouple to the
positive terminal of the indicating instrument. If extension cables or
compensating cable are used, care must be taken not to interchange
positive and negative conductors. To prevent errors, the positive and
negative leads bear a corresponding marking.
10
All connections must be absolutely clean and firmly tightened. The
corresponding positive and negative terminals should have the same
temperature potential.
The compensating cables between the thermocouple and the indica-

ting instrument should comply with the requirements for insulated
leads in power systems (VDE 0250) . In exceptional cases, the regula-
tions for insulated leads in telecommunications systems (VDE 0810)
may be applied.
AREAS OF APPLICATION In the negative temperature range, thermocouples can be used down
to -200 C. For temperatures above 1000 C thermocouples made of
platinum and a platinum/rhodium alloy are used.
Advantages of thermocouples are:

Very high temperature ranges
Fast response
Compact design
Extremely high resistance to vibration
Long term stability
Robust design.
Thermocouples are used in the following and other industries:

Chemical industries
Pharmaceutical industries
Power generation
Mechanical engineering
Food & beverage
Mining
Iron and steel
Ceramics and glass
11
12
Section
3 Assembly of Housing
Rules and Regulations ......................................................... page 13, 14
RULES AND For assembly of housing following instructions are to be considered.

REGULATIONS
VDE/VDI 3511
Technical temperature measurement/instruction
VDE/VDI 3512
Set-up for temperature measurements
AD instruction leaflets (1)

Working group pressure vessels
TRB technical directions for tank

construction (1)
Vd TV regulations (1)
Operating stress
The stresses, indicated in the drawing, apply to the supplied housing.
The load data, included in the standards for every type, are valid for
housing according to DIN 43763 and DIN 43772.
Starting torques for screw-in type threads

Applicable to screw-in type threads of housing according to DIN
43763 and DIN 43772 as well as comparable housing according to
customers specification.
G 3 8, G 50 Nm
G 100 Nm
Above starting torques are to be used as well for coupling rings with
similar threads.
(1)
To be considered in case of weld-in type protective tubes. Material, weld and pressure test according to operating conditions
13
Assembly of housing with flange mounting

The seal is to be selected according to the requirements. During insertion
of the seal, a good support is necessary. Fastening screws are to be
tightened evenly and crosswise.
Installation of ceramic housing in plants at operating

temperature
Temperature of the plant:
1600 C insertion speed: 12 cm/min
1200 C insertion speed: 1020 cm/min
Connection of transmitters
When connecting transmitter, the installation-, connection- and test
instructions of the manufacturers are to be considered.
14
Appendix
A Appendix I and Appendix II
APPENDIX I
Limit tolerances of the basic values according to DIN IEC 751 and DIN 43760
Basic values Limit tolerances
according to according to according to according to
DIN IEC 751 DIN 43760 DIN IEC 751 DIN 43760
Platinum RTD- Nickel RTD- Platinum RTD-elements Nickel RTD-
elements elements elements
Class A Class B
Ohm Ohm/K Ohm Ohm/K Ohm corresp. C
C Ohm corresp. C Ohm corresp. C
-200 18.49 0.44 0.24 0.55 0.56 1.3
-100 60.25 0.41 0.14 0.35 0.32 0.8
-60 69.5 0.47 - 1.0 2.1
0 100.00 0.39 100.0 0.55 0.06 0.15 0.12 0.3 0.2 0.4
100 138.50 0.38 161.8 0.69 0.13 0.35 0.30 0.8 0.8 1.1
200 175.84 0.37 240.7 0.90 0.20 0.55 0.48 1.3 1.6 1.8
250 289.2 1.04 2.3 2.1
300 212.02 0.35 0.27 0.75 0.64 1.8
400 247.04 0.34 0.33 0.95 0.79 2.3
500 280.90 0.33 0.38 1.15 0.93 2.8
600 313.59 0.33 0.43 1.35 1.06 3.3
700 345.13 0.31 1.17 3.8
800 375.71 0.30 1.28 4.3
850 390.26 0.29 1.34 4.6
APPENDIX II
Limit tolerances for thermocouples according DIN IEC 584-2
Class 1 2 3(2)
(1)
Limit tolerances 0.5 C or 0.004 x |t| 1 C or 0.0075 x |t| 1C or 0.015 x |t|
() Limit tolerances apply to following temperature ranges
Typ T -40 C up to 350 C -40 C up to 350 C -200 C up to 40 C
(1)
Limit tolerances 1.5 C or 0.004 x |t| 2.5 C or 0.0075 x |t| 2.5 C or 0.015 x |t|
Typ E -40 C up to 800 C -40 C up to 900 C -200 C up to 40 C
Typ J -40 C up to 750 C -40 C up to 750 C ---
Typ K -40 C up to 1000 C -40 C up to 1200 C -200 C up to 40 C
(1)
Limit tolerances 1.0 C or 1.5 C or 0.0025 x |t| 4 C or 0.005 x |t|
[1+(t-1100) x 003] C
Type R and S 0 C up to 1600 C 0 C up to 1600 C ---
Type B --- 600 C up to 1700 C 600 C up to 1700 C
(1)
Limit tolerances for thermocouples are indicated in degrees centigrade or as percentage of the measured temperature in degrees centigrade. Whichever value is greater applies.
(2)
Thermocouples and thermocouple wires are usually supplied with limit tolerances according to the table above valid for temperature range above of -40 C. The thermocouple limit
tolerances of same material at temperatures below -40 C may be exceeded as stated for tolerance class 3 according to DIN IEC 584-2. Thermocouples requested by purchaser
with limit tolerances according to classes 1, 2 or 3 may be obtained by special material selection.
|t| = Temperature in degrees Centigrade
15
This document is available electronically at www.fisher-rosemount.com
Fisher-Rosemount satisfies all obligations coming

from legislation to harmonise product requirements
in the European Union.
Rosemount Temperature GmbH Fisher-Rosemount Ltd.

Frankenstrae 21 Heath Place
63791 Karlstein Bognor Regis, PO22 SH6,
Germany England
Phone +49 (6188) 992-0 Phone +44 (1243) 863-121
Fax +49 (6188) 992-286 Fax +44 (1243) 867-554
Internet www.fisher-rosemount.de/rtemp Internet www.rosemount.com
MFM25-2654.A01 1.09.01 Rev. AA VD/Kroeber Printed in Germany

Technical alterations reserved
1/4 3 (DN 6 80)
jamesbury
STANDARD PORT 600
CWP BRASS BALL VALVES
Jamesbury Series 300 general purpose ball valves
feature bubble tight shut-off and are used in hot and
cold water, compressed air, natural and bottled gas,
and low pressure steam applications.
FEATURES
Body and cap forged from high strength MS58 brass
Bulletin B103-4
for a durable compact design.
Brass ball and stem are plated to resist wear and
corrosion. Series 361T and 362T valves feature a 3/4" male hose
thread.The hose end includes a cap with lace retainer.

Internal entry system for positive retention.
Available in 1/2" and 3/4" (DN 15 and 20) sizes. Series
Large port for high flow capacity. 361T has female NPT, and 362T is made for joining
Proven polymeric sealing with no metal to metal with solder. Excellent valve for utility services such as
contact for reliable shut-off. water and HVAC. The hose connection is great for
Adjustable packing gland with reinforced PTFE washdown and drain.
stem seals.
CLOSED POSITION
Solder End Series 341T and 346T are available in 1/2" 2" Upstream
(DN 15 50) sizes. Series 346T Features 316 stainless Sealed
steel ball and stem.
Air Power
Supply Device
Downstream vent
to atmosphere
Series 371T vent valves provide automatic downstream

venting when in the closed position. A slide locking
handle is standard on the 371T. Valves conform to issue 10/2002
OSHA 1910.147 lock/tagout requirements.The 1/2" 1"
(DN 15 25) valves can be cycled during an emergency
Threaded Series 351T and 356T are the most economic from the open to the closed position without interfer-
choice for general purpose ball valves from Jamesbury. ence from mechanical stops. Other size valves may be
Sizes range from 1/4" 3" (DN 6 80). Series 356T locked in either open or closed position.
features 316 stainless steel ball and stem which is
ideal for saturated steam service to 150 psi (10.34 bar).
M E T S O A U T O M AT I O N
VALVE-BODY RATINGS Valve Seat Ratings

This is the maximum working pressure of the valve body Temperature C
only. The seat rating and solder joint rating determine the 0 50 100 150 200 250
practical pressure limitation in actual service. Working 700
pressure rating is 600 psi (41.37 bar) at -20F to +100F Series 351T, 356T, 362T
Maximum Differential Pressure, bar

600
Maximum Differential Pressure, psi

(-29C to 38C). 0F (-18C) solder end valves. 40
500
Solder Joint Ratings
Series 341T, 346T, 361T 30
Based on ANSI B16.18 and B16.22 400
Working Maximum Working
Joining Temperature Pressure psi (bar) 300 20
Material 1/2 1 1-1/4 2
F C (DN 15 25) (DN 30 50) Series 371T
200
100 38 200 (13.8) 175 (12.1)
50-50
150 66 150 (100.3) 125 (8.6) 10
Tin-Lead 100
200 93 100 (6.9) 90 (6.5)
Solder
250 121 85 (5.9) 75 (5.2)
0
100 38 400 (27.6) 400 (27.6) -100 0 100 200 300 400 500
95-5 Temperature F
150 66 400 (27.6) 350 (24.1)
Tin-Antimony
200 93 300 (20.7) 250 (17.2)
Solder
250 121 200 (13.8) 175 (12.1)
Dimensions - Inches (mm) and Weights
E Port Dia.
B
A Location of vent series 371T only
These valves are available with a wide range of handles. For Automated Brass Valves refer to Bulletin B103-2. Valves
Round Handles, Extension Handles, Locking devices and feature Jamesbury VPVL double opposed compact piston
Memory Stops. To view valve handle accessories, please actuators.
refer to Bulletin B103-6.
-2-
1 / 4 3 ( D N 8 8 0 ) S TA N D A R D P O R T 6 0 0 C W P B R A S S B A L L VA LV E S
Series 341T / 346T (Solder-End)

Valve Approx. Dimensions inches Approx. Valve Approx. Dimensions (mm) Approx.
Size Weight Size Weight
A B E H J A B E H J
inches lb DN kg
1/2 2.07 0.94 0.39 3.94 1.65 0.4 15 52.6 23.9 9.91 100.1 41.9 .18
3/4 2.64 1.32 0.59 3.94 1.73 0.6 20 67.1 33.5 15.0 100.1 43.9 .27
1 3.27 1.63 0.79 4.72 2.07 1.0 25 83.1 41.4 20.1 119.9 52.6 .45
1-1/4 3.74 1.87 0.98 4.72 2.24 1.4 30 95.0 47.5 24.9 119.9 56.9 .63
1-1/2 4.41 2.20 1.26 6.22 3.03 2.1 40 112.0 55.9 32.0 158.0 77.0 .94
2 5.37 2.70 1.57 6.22 3.29 3.5 50 136.4 68.6 39.9 158.0 83.6 1.6
Series 351T / 356T / 371T (Threaded-End)

Valve Approx. Dimensions inches Approx. Valve Approx. Dimensions mm Approx.
A B E H J A B E H J
inches lb DN kg
1/4 1.78 0.89 0.31 3.94 1.50 0.3 6 45.2 22.6 7.9 100.1 38.1 .14
3/8 1.81 0.91 0.34 3.94 1.50 0.3 10 46.0 23.1 8.7 100.1 38.1 .14
1/2 2.22 1.11 0.41 3.94 1.65 0.4 15 56.4 28.2 10.4 100.1 41.9 .18
3/4 2.41 1.20 0.59 3.94 1.73 0.5 20 61.2 30.5 15.0 100.1 43.9 .23
1 2.97 1.48 0.78 4.75 2.09 1.2 25 75.4 37.6 19.8 120.7 53.1 .54
1-1/4 3.34 1.67 1.00 4.75 2.24 1.5 30 84.8 42.4 25.4 120.7 56.9 .68
1-1/2 3.75 1.88 1.25 6.25 3.03 2.2 40 95.3 47.8 31.8 158.8 77.0 .99
2 4.28 2.14 1.56 6.25 3.29 3.3 50 108.7 54.4 39.6 158.8 83.6 1.5
2-1/2 5.28 2.64 1.89 6.25 3.52 5.3 65 134.1 67.1 48.0 158.8 89.4 2.4
3 6.38 3.19 2.52 10.04 5.20 10.6 80 162.1 81.0 64.0 255.0 132.1 4.8
Series 361T

A B E H J A B E H J
inches lb DN kg
1/2 2.45 1.06 0.39 3.94 1.65 0.4 15 62.2 26.9 9.9 100.1 41.9 .18
3/4 2.56 1.20 0.59 3.94 1.73 0.5 20 65.0 30.5 15.0 100.1 43.9 .23
Series 362T

A B E H J A B E H J
inches lb DN kg
1/2 2.33 0.94 0.39 3.94 1.65 0.4 15 59.2 23.9 9.9 100.1 41.9 .18
3/4 2.68 1.32 0.59 3.94 1.73 0.6 20 68.1 33.5 15.0 100.1 43.9 .23
-3-
M E T S O A U T O M AT I O N
Bill of Materials and Parts List

Part Name Materials of Construction
Body Forged Brass++
Ball* Chrome-Plated Brass
Seats Virgin PTFE
Stem* Nickel-Plated Brass
Stem Seal Virgin PTFE (PTFE & Viton 3 Size)
Handle Vinyl-Coated Steel
Handle Nut Carbon Steel
Packing Nut Carbon Steel
Stem Thrust Washer Carbon-Filled PTFE
Cap & Seal+ Brass & EPDM
* Series 356T and 346T feature 316 stainless steel ball and stem material.
+ For Series 361T & 362T valves. Cap & seal not shown.
++Attention: The state of California has determined lead and lead
compounds are known to cause cancer, birth defects and reproductive
harm. The state of California prohibits the use of brass valves for
drinking water service.
HOW TO ORDER
To order a valve series, first indicate the size then follow with the series. Example: 1/ 2" (DN 15) valve series 351T is specified 1/2 351T.
Installation Instructions, Maintenance and Operation

IMO's (Installation, Maintenance, and Operating instructions) or AMI's (Assembly, Mounting, and Installation instructions)
are shipped with the products. Additional copies of these instructions are available. Call your local Metso Automation
Distributor, or visit our web site.
Metso Automation, Field Systems Division
Europe, Levytie 6, P.O.Box 310, 00811 Helsinki, Finland. Tel. int. +358 20 483 150. Fax int. +358 20 483 151
Europe (UK), 8 Pipers Wood Industrial Park, Waterlooville, Hampshire PO7 7XU UK. Tel. int. +44 (0)23 9223 8500. Fax int. +44 (0)23 9223-8510
North America, 44 Bowditch Drive, P.O.Box 8044, Shrewsbury, Massachusetts, 01545-8044 USA. Tel. int. +1 508 852 0200. Fax int. +1 508 852 8172
Latin America, Av. Central, 181- Chracas Reunidas, 12238-430, So Jose dos Campos. Tel. int. +55 12 335 3500. Fax int. +55 12 335 3535
Asia Pacific, 501 Orchard Road, #05-09 Wheelock Place, 238880 Singapore. Tel. int. +65 735 5200. Fax int. +65 735 2955
www.jamesbury.com
B103-4-10/02 2002 Metso Automation Printed in U.S.A.-M-J

E2
Temperature Products New!

Model ADJ 3 and 5 Adjustable Angle MADE IN USA
Industrial Bimetallic Thermometers

U.S. Gauge offers 3 and 5 STEM DIAMETER: .25 standard up to 42 stem; .375
heavy duty, industrial standard over 42 stem
bimetallic thermometers CONNECTION: 1/2-14 NPT
with a versatile case and EXTERNAL RESET: Easy to calibrate by inserting 1/16 hex
stem that can be wrench into reset opening
adjusted to almost any CONSTRUCTION: 304 stainless steel external parts and
angle for easy viewing. welded construction; corrosion resistant to most chemicals
The head can be rotated HERMETIC SEAL: Per ASME B40.3, dustproof and
360 and the stem leakproof
positioning moves over 180. HARNESS: All stainless steel brackets with screws that
These thermometers are rugged and loosen to allow 360 rotation of head and 180 adjustment
preferred by the process, offshore, power, of stem position
pharmaceutical, and chemical industries. BELLOWS: Heavy-duty flexible stainless steel, hermetically
The union connection is 1/2-14 NPT, sealed at case and connection; protects mechanism that
transfers temperature
but others are available. The thermometers
DIAL: True anti-parallax dial, easy to read from any angle,
may be silicone filled for additional vibration minimizes reading errors; anodized aluminum with large
dampening. A variety of lens materials are black numbers and graduations
available including acrylic, polycarbonate, LENS: Glass
shatterproof and tempered glass. Standard
BIMETALLIC COIL: Helix coil is silicone coated on ranges
stem diameter, up to 42 long, is .25. below 500F for vibration dampening and to maximize heat
Other available stem sizes are .24 (6 mm), transfer and response time
.32 (8 mm), and .375 (9.52 mm). ACCURACY: 1% full span per ASME B40.3 Grade A;
adjustment of the angle between case and stem may affect
accuracy up to 0.5% of span (ASME B40.3)
A OVER TEMPERATURE LIMITS: Up to 250F, 100%; 250 to
550F, 50%; 550 to 1000F, continuous use up to 800F,
intermittent use over 800F
2.37
(60.2)
.625
1/2-14 NPT (15.88)
STANDARD
STEM LENGTHS
INCHES 2.5 (63.5) MODEL UNIT A B
4 (101.6)
(MM) 6 (152.4) inches 2.43 3.19
9 (228.6) ADJ-3
.25 mm 61.72 80.95
12 (304.8)
(6.35) 15 (381.0) inches 2.66 5.04
18 (457.2) ADJ-5
24 (609.6) mm 67.56 128.02

Tel: (215) 355-6900 Tel: (215) 355-6900 Tel: (727) 536-7831
Fax: (215) 354-1802 Fax: (215) 354-1800 Fax: (727) 539-6882
E3
Temperature Products
Model ADJ 3 and 5 Adjustable Angle
Industrial Bimetallic Thermometers
SPEC NUMBER SELECTION CHART
Model ADJ-3 3 Dial Size

2-1/2 Stem 4 Stem 6 Stem 9 Stem 12 Stem
Length Length Length Length Length
Temperature
Connection Range* Spec No. Spec No. Spec No. Spec No. Spec No.
1/2-14 NPT 0 to 200 FC 415002 415008 415014 415020 415026
0 to 250 FC 415003 415009 415015 415021 415027
50 to 300 FC 415004 415010 415016 415022 415028
50 to 400 FC 415005 415011 415017 415023 415029
50 to 550 FC 415006 415012 415018 415024 415030
200 to 1000 FC 415007 415013 415019 415025 415031
Model ADJ-5 5 Dial Size

2-1/2 Stem 4 Stem 6 Stem 9 Stem 12 Stem
Length Length Length Length Length
Temperature
Connection Range* Spec No. Spec No. Spec No. Spec No. Spec No.
1/2-14 NPT 25 to 125 FC 415038 415045
0 to 200 FC 415032 415039 415046 415052 415058
0 to 250 FC 415033 415040 415047 415053 415059
50 to 300 FC 415034 415041 415048 415054 415060
50 to 400 FC 415035 415042 415049 415055 415061
50 to 550 FC 415036 415043 415050 415056 415062
200 to 1000 FC 415037 415044 415051 415057 415063
* All dials are dual scale, Fahrenheit outer scale, Celsius inner scale

Tel: (215) 355-6900 Tel: (215) 355-6900 Tel: (727) 536-7831
Fax: (215) 354-1802 Fax: (215) 354-1800 Fax: (727) 539-6882
Check Valve Doctor
In-Line Check Valves

DFT
Check Valve Doctor
DFT in-line check valves began over 50 years ago with a customers need
for a small metal-seated check valve that could be installed in any position
while providing tight shut-off. The Basic-Check valve was developed to
satisfy that need. Over the following decades, other customers needs led
to the development of the DLC, Excalibur, GLC, PDC, SCV and WLC
styles of in-line silent check valves. Each of these DFT in-line check valves
addresses the particular needs of a modern day customer.
DFTs objective is to solve check valve problems and prevent check valve
failures. DFT has learned by listening to customers like you that each indus-
try has special needs that can exceed other check valve designs. We spe-
cialize in providing in-line check valves that meet customer requirements as
opposed to simply meeting line size. In some cases, minor modifications to
our valves have solved customer problems by improving performance and
extending service life. The Check Valve Doctor continues to grow from
satisfying these needs and solving problems.
DFT silent check valves are known around the world as the valve to use to
prevent or eliminate water hammer problems. Whatever your size, pres-
sure or piping configurations, DFT has a check valve for you.
Thank you for considering DFT for your check valve requirements.
Table Of Contents
ITEM PAGE ITEM PAGE ITEM PAGE
Applications ..............................27 Introduction.................................2 SCV ...........................................6
Basic-Check.............................18 Materials...................................26 Selection Chart ............................5
Codes and Standards ................24 Material Limitations ...................25 Technical Information .................29
DLC ..........................................8 Ordering Information ................30 Vacuum Breakers .......................20
Excalibur .................................12 PDC .......................................16 Valve Data Sheet .......................31
Features ......................................4 Pressure-Temperature Warranty ..................................30
Flange Dimensions.....................28 Ratings .....................................25 Water Hammer ...........................3
GLC ........................................14 Restrictor Check ........................22 WLC (Wafer Check) .................10
Basic-Check, Excalibur, DLC, GLC, PDC, WLC are registered trademarks of DFT Inc.
dft@dft-valves.com
2 610-363-8903
www.dft-valves.com
Water Hammer
is the generation and effect of high pressure shock waves (transients) in relatively incompressible
fluids. Water hammer is caused by the shock waves that are generated when a liquid is stopped
abruptly in a pipe by an object such as a valve disc. Symptoms include noise, vibration and
hammering pipe sounds which can result in flange breakage, equipment damage, ruptured piping
and damage to pipe supports. Whenever incompressible fluids exist in a piping system, the
potential exists for water hammer. The risks of water hammer developing are particularly high when
the velocity of the fluid is high, there is a large mass of fluid moving and/or when there are large
elevation changes within the piping systems. Since the swing check must rely on gravity and/or fluid
flow to help it close, flow reversal must occur before closure begins. When the swing check finally
closes, it abruptly stops the flow and causes a pressure surge resulting in shock waves. These shock
waves continue until the energy generated from this sudden action dissipates. Figure 1 shows
typical pressure curves after closure of a check valve.
These high pressure waves act against the piping and the valve, exerting very high forces. This
causes severe stress on the metal and vibrations in the system. If the system is not designed to
withstand these high transient forces, the pipe could rupture and/or other components in the system,
such as pumps and valves, could possibly be damaged. These problems can be eliminated or
greatly minimized by installing a spring assisted silent check valve. Silent check valves do not rely
on gravity or fluid flow for their closure. Instead as the forward velocity of the fluid slows, the spring
assist on the valve starts to close the disc. Due to the spring assist and the relatively short distance
the disc must travel, by the time the forward velocity has decreased to zero, the valve disc has
reached the seat and the valve is closed. With reverse flow eliminated, the forces necessary to
produce water hammer on both the upstream and downstream sides of the valves are substantially
eliminated as shown on the right side of Figure 1.
dft@dft-valves.com
610-363-8903 3
www.dft-valves.com
Features
Designed to prevent Water Hammer.

The spring-assisted, in-line design featured in all DFT check valves insures that as the
forward flow in a pipeline decreases the disc begins moving closer to the seat. By the time
the flow stops, the disc is closed against the seat preventing flow reversal. This prevents the
valve from slamming closed causing Water Hammer and the resultant noise and damage
to piping systems from occurring.
Designed to open at 0.5 psi differential pressure and fully open at 1.0 psi differential
pressure.
Can be installed in ANY position.

Including vertical with flow up or down. (Special springs may be required)
MSS SP 126-2000 Steel In-line Spring-Assisted Center Guided Check Valves Standard
DFT carbon steel, stainless steel and alloy valves meet this standard. (Does not apply to the
Basic-Check , Restrictor Check or Vacuum Breaker)
Meet or exceed MSS SP-61 leakage requirements.

Metal-to-metal seating is standard in all DFT in-line check valves. Cast iron valves
meet AWWA seat leakage requirements.
Available with soft seats for bubble-tight shutoff.
Dual guided stems.

The stem is guided upstream and downstream to guard against vibrations and insure
proper disc seating. (Does not apply to the Basic-Check, DLC, Restrictor Check, SCV or
Vacuum Breaker)
Custom sizing available.

The following DFT check valves can be sized to the appropriate flow conditions: Excalibur,
GLC and WLC.
Pulse-Damping Design.
The DFT Model PDC is specifically designed for use on the discharge of reciprocating air
or gas compressors. The design includes a pulse-damping chamber to protect against
premature seat wear due to chattering.
Liquids, gas or steam.

All DFT in-line check valves provide positive shutoff for applications involving liquids, gas or
steam and can be used in most industries including oil and gas, petrochemical, pulp and
paper, textiles, food and beverage and commercial construction. Applications include
chemical lines, fluid injection, condensate recovery, steam, nitrogen, pump and compressor
discharge, chiller and boiler feed systems. Cast Iron valves are recommended for liquid
services only.
Maintenance and Installation guides.

Available for all DFT in-line check valves.
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Valve Selection Chart
Basic- Restrictor Vacuum
DLC Excalibur GLC PDC SCV WLC
Check Check Breaker
PAGE 18 8 12 14 16 22 6 20 10
SIZE 1/4 TO 3/4 TO 2 TO 24 1 TO 2 TO 1/4 TO 1/2 TO 1 TO 4 1 TO
2-1/2 3 24 12 2-1/2 3 10
ENDS
NPT X X X(1) X
SW X(1)
FLG X X X X
BW X
FLG/BW X
Victaulic X
Wafer X
ANSI
125 X X
150 X X X X X
250 X X
300 X X X X X
600 X X X X
900 X X X X
1500 X X X X
2500 X X
750 CWP X
3600 CWP X
OTHER X(2) X(3) X(2) X(2) X(3)
MATERIALS BODY /TRIM

Cast Iron X(4) X(4)
WCB/316 SS X X X X
316SS/316SS X(5) X X X X X(5) X X(5) X
Other Alloys X X X
OPTIONS
Soft Seat X X X X X X X X
X-750 Spring X X(6) X X X X X(6) X X
1. NPT x SW available.
2. CWP RATING BSS, BSA, BSE, BSSV, Restrictor Check: 450 to 2500 CWP depending on size;
BSSH6, BSSV6: 450 to 6000 CWP depending on size.
BSSH7: 800 to 6000 CWP depending on size.
3. API 2000 and 5000 ARE AVAILABLE. Contact DFT for sizes.
4. TRIM MATERIAL: BRONZE OR 316 SS
5. BODY & SEAT: BSE, BSS, BSSV. Restrictor Check: 303SS, BSA: 416SS, BSSH6, BSSH7, BSSV6: 316SS
6. Inconel X-750 spring is standard.
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SCV
Features:
1/2 to 3 Line size

750 & 3600 CWP
NPT & SW ends
316 Stainless Steel Construction
Inconel X-750 spring
Meets NACE MR-01-75
Spring-assisted silent closing
Zelon body O ring
Horizontal or vertical installation
Body guided disc
Tight shut-off - lapped disc & seat
Simplified construction - 5 parts
Easy maintenance
Versatile
OPTIONS:
- 316 SS Springs
- Body seal weld
- Soft seat
- Alloy 20 body & seat
- Hastelloy C body & seat
- NPT x socket weld ends
The DFT Model SCV is a corrosion resistant, dependable, ver-

satile and economical spring-assisted, in-line check valve for a
wide range of applications. Whether the fluid is liquid, gas or
steam, the SCV provides tight shut-off and protects other
equipment in the system from water hammer. Its 316 stainless
steel construction insures a long service life.
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SCV
750 CWP/500 WSP
1/2 3/4 1 1 1/4 1 1/2 2 3
A 2.68 3 3.32 3.87 4.75 5 6.75
B (dia.) 1.62 2.13 2.54 3.06 3.44 4.4 6.19
Weight 1.1 1.5 1.9 3.9 4.7 7.7 18.8
CV 7 13 22 39 54 93 180
Cracking 0.4 0.3 0.3 0.3 0.2 0.2 0.3
Pressure (psi)
3600 CWP
1/2 3/4 1 2
A 3.16 3 3.75 6.38
B 1.88 2.33 2.75 4.06
B
Weight 1.5 3 4.5 12.0
CV 6.0 11 19 65
Cracking 0.5 0.4 0.4 0.3
Pressure (psi)
Notes: All dimensions are in inches. Weights are in pounds. A
750 CWP MATERIALS OF CONSTRUCTION 3600 CWP MATERIALS OF CONSTRUCTION

Body A351 CF8M A351 CF8M
Seat (1) A351 CF8M A351 CF8M
Disc A240 316 A240 316
Spring Inconel X-750 Inconel X-750
O ring Zelon (470F max.) Zelon (400F max.) (2)
Notes: 1. Soft seats are available for bubble-tight shutoff. See below. 2. Buna-N CO2 resistant O ring
Body seal and soft seat material are the same unless otherwise requested. is available upon request.
3. Maximum temperature for Buna-N.
PRESSURE TEMPERATURE RATING (PSIG) 4. Maximum temperature for Viton and
Zelon w/3600CWP SCV.
Temp. (deg.F) 750 CWP 3600 CWP 5. Maximum temperature for Zelon
-20 to 100 750 3600 w/750CWP SCV.
200 630 3095 6. Buna-N and Viton are not suitable for
steam service.
250 (3) 600 2945 7. Maximum valve temperature rating is
300 570 2795 limited by the body seal & seat material
selected.
400 (4) 525 2570 8. 750CWP is rated to 470F.
470 (5) 510
BODY O RING/SOFT SEAT MATERIALS (6) (7) SPRINGS

MATERIALS BUNA-N VITON ZELON(8) 316SS INCONEL X-750
TEMP. F -70 TO 250 -40 TO 400 37 TO 400 -460 TO 450 -460 TO 700
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DLC
Features:
ANSI Face-to-Face dimensions
3/4 to 3 Line size
ANSI 150 and 300
316 Stainless Steel Construction
BODY
SPRING Raised Face Flanged ends
Inconel X-750 spring
DISC Electron beam welded body
Meets B16.34 - 1988
Meets NACE MR-01-75
ELECTRON
BEAM WELD
Body guided disc
Simplified construction - 3 parts
Versatile
OPTIONS:
- 316 SS Springs
- Body Materials
- Alloy 20

- Hastelloy C
The DFT Model DLC is a corrosion resistant,

dependable, versatile and economical spring
assisted, in-line check valve for a wide range of
applications. Whether the fluid is liquid, gas or
steam, the DLC provides tight shut-off and protects
other equipment in the system from water hammer.
Its 316 stainless steel construction insures a long
service life.
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DLC
Class 150 RF
3/4 1 1 1/2 2 3
A 4.62 5.00 6.50 8.00 9.50
B 3.88 4.25 5.00 6.00 7.50
Weight 4.5 6.0 11.7 19.1 39.2
CV 13 22 54 93 180
Cracking .3 .3 .2 .2 .3
Pressure
(psi) B
Class 300 RF
3/4 1 1 1/2 2 3
A 7.00 8.50 9.50 10.50 12.50
B 4.62 4.88 6.12 6.50 8.25 A
Weight 7.2 9.9 18.5 24.3 50.5
CV 13 22 54 93 180
Cracking .3 .3 .2 .2 .3
Pressure
(psi)
Notes: All dimensions are in inches. Weights are in pounds.
MATERIALS OF CONSTRUCTION PRESSURE TEMPERATURE RATING (PSIG)

Body A351 CF8M Temp. (deg.F) Class 150 Class 300
Seat A351 CF8M 460 to 100 275 720
Spring Inconel X-750 200 235 620
Disc 316 SS 250 225 590
300 215 560
400 195 515
470 175 490
500 170 480
600 140 450
700 110 430
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WLC
BODY GUARD Features:
Wafer design
Lightweight
SPRING Edge guided (1 & 1-1/2)
DISC
Center guided (2 to 10)
Dual guided stem (2 to 10)
Protected spring
ANSI 150 to 2500
O-RING - 1 to 10 Line Size
SEAT
- WCB & 316 SS bodies
RETAINING - 316 SS trim
RING 1 and 1-1/2 WLC - Ends:
- Wafer RF
- Wafer RTJ
BUSHING - MSS-SP 61 seat leakage
SPRING - API 594 Face-to-Face dimension:
- Class 600 RF
- Class 900/1500 RF
OPTIONS:
- Inconel X-750 Spring
- Soft Seat
- Custom Sizing
- Body Materials:
- Alloy20, Inconel 625, Titanium
- Stellited trim (600F+)
- Weld Neck Flanges to meet B16.10
Face-to-Face dimensions
BODY STEM/DISC ASSY. SEAT ANSI 125 & 250
2 and larger WLC - 2 to 10 Line Size
- Cast Iron body
- Bronze or 316 SS trim
The DFT Model WLC Wafer style Silent Check Valve is
- Ends:
a lightweight, spring-assisted, center guided, in-line
- Wafer FF
check valve that provides reliable, low maintenance
- AWWA seat leakage
service for a wide range of fluids and pressure/
- FM approval:
temperature combinations. The joint between the seat
- 2 to 10 CI. 125 w/Bronze trim
ring and body is sealed by the flange gasket upon
OPTIONS:
installation preventing any leakage through the joint
- Soft seat
when the valve is in service.
Consult page 25 for Pressure/Temperature ratings and page 26 for materials of construction.
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WLC
Class 150 RF(1) Class 300 RF(1) Class 150/300 RF 150 RF

1* 11/2* 1* 11/2* 2* 21/2* 3* 4* 5* 6* 8* 10*
A 2 21/2 2 21/2 25/8 27/8 31/8 4 45/8 51/2 61/2 81/4
B 25/8 31/4 27/8 33/4 43/8 51/8 53/4 71/8 81/2 97/8 121/8 175/8
Weight 2 4 3 6 4 10 12 20 35 41 86 138
CV 19 36 13 36 57 95 140 265 360 506 860 1355
B A
Class 600 RF(1)
1 11/2 2 3 4 6
A 23/8 27/8 23/8 27/8 31/8 53/8
B 27/8 33/4 41/4 53/4 71/2 103/8
Weight 21/2 8 5 11 21 68
CV 19 23 53 133 234 441
Class 900/1500 RF(1)

1 11/2 2 3 4 6
A 23/8 27/8 23/4 31/4 4 61/4
B 31/8 37/8 51/2 63/4 81/8 111/4
Weight 4 8 14 21 38 100
CV 19 23 48 113 211 370
Class 1500 RTJ(2) 1500 RF(2) 2500 RTJ(2)

1 11/2 2* 3 4* 6 10 10 1 2* 3
A 23/8 27/8 31/8 31/4 41/8 61/4 9 3/4 93/4 23/8 213/16 33/8
B 31/8 37/8 51/2 63/4 81/4 111/4 171/16 17 31/8 53/4 71/2
Weight 4 7 14 21 38 100 430 430 4.1 17 33
CV 19 23 48 113 211 370 755 755 19 35 80
Class 125/250 Cast Iron FF

2* 21/2* 3* 4* 5* 6*
A 25/8 27/8 31/8 4 43/4 51/2
B 41/4 5 53/4 7 83/8 93/4
Weight 6 7 12 18 27 42
CV 66 88 130 228 350 520
Class 125 Cast Iron FF Class 250 Cast Iron FF

8* 10* 8* 10*
A 61/2 81/4 A 61/2 81/4
B 133/8 16 B 133/8 16
Weight 85 129 Weight 86 137
CV 900 1450 CV 900 1450
All dimensions are in inches. Weights are in pounds.
*Does not meet API 594 face-to-face dimension.
o
Notes: 1. Size 1 and 1-1/2 have Buna-N (-70 to 250 F) body O ring seals. Contact DFT for other materials.
o
2. All sizes have Buna-N (-70 to 250 F) body O ring seals except 10 C l.1500 RTJ/RF have spiral wound body
seals. Contact DFT for other materials.
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Excalibur
Features:
ANSI B16.10 Face-to-Face dimensions

2 to 24 Line size
ANSI 150 to 1500
WCB & 316 SS bodies
316 SS trim
Ends:
- RF Flanged
- RTJ
Center guided
Dual guided stem
Tight shut-off
Two piece body
Protected spring
Body gaskets (See Page 26)
Easy maintenance
Versatile
OPTIONS:
SEAT - Soft seat
- Custom sizing
- Digester trim
- Body Materials:
- Alloy 20
- Monel
(1)
- Ends :
- Butt weld
- Flanged x Butt weld
- Victaulic
The DFT Excalibur Silent Check Valve is a spring-assisted, center guided, in-line, check valve that
provides reliable, low maintenance service for a wide range of fluids and pressure/temperature
combinations. The valve consists of a body, gasket, seat, spring, disc with stem and guide bushing.
Excalibur check valves are available in a wide range of sizes and pressure ratings and in a variety of
metals to meet most check valve requirements.
(1) Consult DFT for availability
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Excalibur
Class 150 RF*

2 21/2 3 4 6 8 10 12 16 24
A 8 81/2 91/2 11 /2 14 191/2
1 241/2 27 /2 34
1 51
B 6 7 71/2 9 11 131/2 16 19 231/2 32
Weight 22 30 37 64 114 207 317 457 830 1851
CV 65 105 155 265 685 1050 1650 2400 5200 11300
Class 300 RF*

2 21/2 3 4 6 8 10 12 14 20
A 101/2 111/2 121/2 14 171/2 21 241/2 28 33 40
B 61/2 71/2 81/4 10 121/2 15 171/2 201/2 23 301/2
Weight 29 42 52 92 177 285 456 696 725 2375
CV 65 105 155 265 685 1050 1650 2400 3600 7850
Class 600 RF*

2 3 4 6 8 10 12
A 111/2 14 17 22 26 31 33
B 61/2 81/4 103/4 14 161/2 20 22
Weight 35 69 138 300 481 981 1320
CV 65 155 265 584 985 1650 2400
Class 900 RF*

2 3 4 6 8 10
A 141/2 15 18 24 29 33
B 81/2 91/2 111/2 15 181/2 211/2
Weight 81 155 176 780 1250 1650
CV 51 138 242 512 777 1449
Class 1500 RF* A
2 3 4 6 8
A 141/2 181/2 211/2 27 /4 323/4
3
B 81/2 101/2 121/4 151/2 19

Weight 81 158 267 780 1270
CV 51 109 187 512 777 B
* For other sizes, consult factory.
Note: All dimensions are in inches. Weights are in pounds.
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GLC
Features:
Short Face-to-Face dimensions

One piece body
Center guided
Dual guided stem
BODY Horizontal or vertical installation
Protected spring
BUSHING
Easy maintenance
SPRING Versatile
ANSI 150 To 2500
DISC
- 1 to 24 Line size
STEM - WCB & 316 SS Bodies
- 316 SS trim
SEAT
- RF Flanged Ends
- MSS-SP61 seat leakage
(1)
O-RING
(some valves)
OPTIONS:
- Soft seat
- Custom sizing
- Body Materials
Full Face Seat (2) - Alloy 20
(some valves)
- Digester trim
(3)
- RTJ Ends
ANSI 125 & 250
- 2-1/2 to 24 Line size (CI.125)
The DFT Model GLC Silent Check Valve is a spring-assisted,
center guided, in-line, flanged check valve that provides - 2-1/2 to 8 Line size (CI.250)
reliable, low maintenance service for a wide range of fluids - Cast Iron Body
and pressure/temperature combinations. The valve consists - Bronze or 316 SS trim
of a body, seat, spring, disc with stem and guide bushing. - Ends:
Some valves have body or gasket seals. The DFT GLC check - FF Flanged
valve has the advantage of minimum pressure loss with silent, - AWWA seat leakage
non-slam operation. - OPTIONS:
(1) Consult Page 15 for valves with Body O ring seals. - Soft seat
(2) Consult Page 15 for valves with Full Face seats
(3) Contact DFT for availability
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GLC
Class 150 RF
1 11/2 2* 3* 4 5 6 8 10 12 14 16 18 20 24
A 41/2 53/4 61/4 71/2 81/2 91/2 10 12 14 18 21 221/2 24 24 28
B 41/4 5 6 71/2 9 10 11 131/2 16 19 21 231/2 25 271/2 32
Weight 7 13 17 33 55 72 93 172 266 387 456 700 753 1292 1571
CV 17 35 63 148 260 415 620 1030 1630 2370 3500 5100 6400 7700 11100
Class 300 RF
1 11/2 2 21/2 3 4 5 6 8 10 12* 14* 16* 20 24
A 43/4 6 61/2 71/4 77/8 91/8 103/8 11 13 153/8 191/2 23 24 24 28
B 47/8 61/8 61/2 71/2 81/4 10 11 121/2 15 171/2 201/2 23 251/2 301/2 36
Weight 9 17 23 41 46 71 89 139 232 335 550 724 898 1357 2420
CV 19 35 63 100 148 267 415 620 933 1704 2370 2781 5100 7700 10510
Class 600 RF
1 11/2 2* 3* 4 6 8* 10* 12 16*
A 51/4 65/8 71/4 85/8 101/8 123/8 145/8 171/8 211/4 26
B 47/8 61/8 61/2 81/4 103/4 14 161/2 20 22 27
Weight 11 19 25 57 115 175 332 450 840 1093
CV 17 35 63 125 237 549 933 1620 2272 5100
Class 900 RF
11/2* 2* 21/2 3 6* 8* 10*
A 73/8 81/4 9 91/8 13 151/4 175/8
B 7 81/2 95/8 91/2 15 181/2 211/2
Weight 30 56 78 87 264 396 539
CV 26 46 81 114 549 851 1499 Class
B
Class 1500 RF 2500 RF
11/2* 2* 21/2 3 4* 6* 8* 12* 2* 3*
A 73/8 81/4 9 97/8 113/8 151/8 171/2 441/2 91/4 14
B 7 81/2 95/8 101/2 121/4 151/2 19 261/2 91/4 12
Weight 30 56 78 110 164 405 670 2550 77 218
CV 26 46 81 114 192 441 742 1689 32 77 A
Class 125 Cast Iron FF
21/2 3 4 5 6 8 10 12 14 16 18 20 24
A 51/2 6 71/4 81/2 93/4 121/2 151/2 141/4 153/4 175/8 183/4 205/8 24
B 7 71/2 9 10 11 131/2 16 19 21 231/2 25 271/2 32
Weight 24 29 42 52 73 126 205 306 380 501 724 890 1220
CV 110 155 278 435 625 1115 1770 2500 3400 4400 5600 6900 10000
Class 250 Cast Iron FF
21/2 3 4 5 6 8
A 51/2 6 71/4 81/2 93/4 121/2
B 71/2 81/4 10 11 121/2 15
Weight 30 36 59 78 103 179
CV 110 155 278 435 625 1115
Note: All dimensions are in inches. Weights are in pounds.
*Full Face seat valves with Buna-N (-70 to 250F) body O ring seal. Contact DFT for other materials. SPLIT FACE SEAT
Valves without body O ring seals have a Split Face design.
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PDC
Features:
Pulse damped design

Modulating air or gas applications:
- discharge of reciprocating
air/gas compressors
- self sizing - accommodates varying
BODY flows without chattering
BUSHING Mediums:
SPRING
- air
- gas
DISC ANSI B16-10 Face-to-Face dimensions
One piece body
ORIFICE Spring-assisted silent closing
PLUG 2 to 12 Line size
SEAL ANSI 150 to 1500
SPRING
RETAINER
RING WCB, 316 SS & LCC body
GUIDE 316 SS trim
RING
316 SS spring (450F max)
DISC
SPRING
GUIDE Ends:
BALL - RF Flanged
CHECK - RTJ
Center guided
Tight shut-off
Protected spring
FULL FACE SEAT
SEAT(1) O-RING (2)
Easy maintenance
(some valves) NUT (some valves) Versatile
OPTIONS:
US Patent #4,766,929 #4,693,270 - Soft seat
- Inconel X-750 Spring (500F max
due to nonmetallic components)
- Monel trim
The DFT Model PDC Silent Check Valve is specially designed for use on the discharge side of
reciprocating air or gas compressors. It includes a pulse damping chamber to maintain the disc in
the open position during the momentary reductions in flow associated with each cycle of a
reciprocating compressor and to protect against premature seat wear.
(1) Consult Page 17 for valves with Full Face Seat.
(2) Consult Page 17 for valves with Body O ring seals.
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PDC
Class 150 RF
2 3 4 6 8*
A 8 91/2 111/2 14 191/2
B 6 71/2 9 11 131/2
Weight 20 40 64 94 158
CV 62 148 255 660 1005
Class 300 RF
2 3 4 6 8* 10* 12
A 101/2 121/2 14 171/2 21 241/2 28
B 61/2 81/4 10 121/2 15 171/2 201/2
Weight 27 50 82 149 293 452 673
CV 62 148 255 660 1005 1580 2300
Class 600 RF
2* 3* 4* 6* 8* A
A 111/2 14 17 22 26
B 61/2 81/4 103/4 14 161/2
Weight 35 58 117 272 450
CV 62 142 255 660 1005
B
Class 900 RF
2* 3* 4* 6*
A 141/2 15 18 24
B 81/2 91/2 111/2 15
Weight 65 84 144 322
CV 55 118 224 567
Class 1500 RF
2* 3*
A 141/2 181/2
B 81/2 101/2
Weight 65 171
CV 55 118 SPLIT FACE SEAT
Note:
1. All dimensions are in inches. Weights are in pounds.
2. Maximum operating temperature is 4500F with the 316 SS spring. 5000F with the Inconel X-750 spring due
to nonmetallic components.
*Full Face seat valves with Buna-N (-70 to 250F) body O ring seal. Contact DFT for other materials.
Valves without body O ring seals have a Split Face design.
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Basic-Check
Features:
1/4 to 2-1/2 Line size
450 to 6000 CWP
Threaded ends
Stainless Steel Construction
B Tight shut-off - lapped disc & seat
Easy Maintenance
Versatile
OPTIONS:
A - Inconel 750 Spring
The DFT Basic-Check valve is a versatile all-purpose, -Soft seat
spring-assisted, in-line check valve that provides
reliable, low maintenance service for a wide range of
liquids and gases at various pressure/temperature
combinations. The valve consists of a guard cage,
spring, valve disc, retaining ring and seat. It can be
combined with pipe fittings such as reducing couplings,
drain elbows, etc. to form a complete check valve unit
ideally suited for a broad range of pipeline
applications or incorporated into machinery for OEM
applications. The metal-to-metal sealing area of the Use with reducing coupling.
Basic-Check valves disc and seat is precision lapped,
providing very tight shut-off of both gas and liquid. If
bubble-tight shut-off is required, resilient soft seats are
available.
MATERIALS OF CONSTRUCTION
Retaining
Model Seat Disc Guard Spring Ring
Basic-Checks BSS 303 SS 316 SS 316 SS(1) 316 SS 316 SS

BSA 416 SS 316 SS 316 SS 316 SS 316 SS Drain elbow is another
BSE 303 SS 316 SS 17-4 SS Inconel 316 SS standard fitting with which
DFT Basic-Check Units are
High Pressure BSSH6 316 SS 316 SS 316 SS 316 SS 316 SS
used.
Basic-Checks BSSH7 316 SS 17-7 SS 316 SS 316 SS 316 SS
(1) 1/4, 3/8 and 1/2 BSS units have a 303 SS guard
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Basic-Check
TECHNICAL INFORMATION
BASIC CHECK VALVE CRACKING

PRESSURE* Approx.
Line Size Outside Net WT.
Inlet Thread CV Friction Loss (Inches of Each
(FNPT) (MNPT) (Feet of Pipe) (PSI) Water) (In lbs.)
A B
1/4 1 5.8 7 .60 (1) 16.7 .38

3/8 1 5.8 7 .60 (1) 16.7 .38
1/2 1 5.8 7 .60 (1) 16.7 .38
3/4 1-1/2 13.2 6 .45 12.5 .88
1 2 23.1 7 .38 10.5 1.25
1-1/4 2-1/2 36 12.5 .20 5.5 2.25
1-1/2 3 57.4 11 .14 3.9 3.75
2 4 90 16 .15 4.3 7.00
2-1/2 4 90 16 .15 4.3 7.00
(1) Light spring available: Cracking Pressure = . 18 PSI (5.0 inches of water)
*Cracking pressure for vertical flow will be slightly different: upward flow, slightly higher;
downward flow, slightly less.
Not recommended for use on discharge of reciprocating compressors.
Sat. Steam Adjusted

Pressure Tempera- Rating as
COLD, NON-SHOCK PRESSURE RATING (2)
(PSIG) ture Percent of
Ref. (3) (Deg. F.) Cold Rating
1/4
Size 3/8 3/4 1 1-1/4 1-1/2 2 2-1/2 -3 200 86%
15 250 82%
1/2 52 300 78%
BSS BSA 232 400 71%
Basic-Check BSE 2500 2000 1500 850 700 450 450 407 450 69%
High-Pressure BSSH6 6000 5500 3000 1100 900 450 450 665 500 66%
1526 600 62%
Basic-Check BSSH7 6000 6000 6000 4000 2700 800 800 3075 700 60%
All stainless steel construction is suitable for cryogenic service. For pressure rating at elevated temperatures for standard metal-
seated valves, reduce above rating per chart at right.
Maximum valve temperature rating is limited by soft seal (if any) and spring materials in chart below. For ratings of soft seals
using some other elastomers, consult factory.
(2) Contingent on service ratings of matching pipe and fittings.
(3) Saturated steam pressure is given for reference only; pressure limit of valve is the adjusted rating at the given temperature.
MAXIMUM OPERATING TEMPERATURES OF MATERIALS

SEAL (4) SPRING
MATERIALS BUNA-N VITON ZELON 316 SS INCONEL
X-750
TEMP. F -70 to 250 -40 to 400 37 to 400 -460 TO 450 -460 TO 700
(4) Buna-N and Viton are not suitable for steam service.
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Vacuum Breaker
Features:
1 to 4 size
450 to 6000 CWP
Threaded O.D. (MNPT)
Unthreaded inlet bore
Easy maintenance
Versatile
OPTIONS:
- Inconel 750 Spring
-Soft seat
DFT Vacuum Breakers provide effective protection

against collapse of pressure vessels, tanks and rolls.
They prevent condensate back-up when equipment is
shut down or inlet steam is reduced by modulating con-
trol valves. In piping systems, DFT Vacuum Breakers are
used to break siphons, prevent pipe collapse during
transient pressure drops, and to provide addition of air
on the downstream side of check valves to dampen
water hammer.
Two DFT Vacuum Breakers
used in a dry can.
Retaining
Vacuum BSSV 303 SS 316 SS 316 SS(1) 316 SS 316 SS

Breakers BSSV6 316 SS 316 SS 316 SS 316 SS 316 SS
(1) 1 has a 303 SS guard
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Vacuum Breaker
VACUUM BREAKER VALVE CRACKING

Approx.
PRESSURE* Net WT.
Nominal Size Unthreaded Friction Loss (Inches of Each
(MNPT) Inlet Bore CV (Feet of Pipe) (PSI) Water) (In lbs.)
A B
1 9/16 5.8 7 .60 (1) 16.7 .38
1-1/2 7/8 13.2 6 .45 12.5 .88
2 1-3/32 23.1 7 .38 10.5 1.25
2-1/2 1-1/2 36 12.5 .20 5.5 2.25
3 1-23/32 57.4 11 .14 3.9 3.75
4 2-7/32 90 16 .15 4.3 7.00
(1) Light spring available: Cracking Pressure = . 18 PSI (5.0 inches of water)
*Cracking pressure for vertical flow will be slightly different: upward flow, slightly higher;
downward flow, slightly less.
COLD, NON-SHOCK PRESSURE RATING (2) Sat. Steam Adjusted

Ref. (3) (Deg. F.) Cold Rating
Size 1 1-1/2 2 2-1/2 3 4 -3 200 86%

15 250 82%
Vacuum BSSV 2500 2000 1500 850 700 450 52 300 78%
Breaker BSSV6 6000 5500 3000 1100 900 450 232 400 71%
407 450 69%
665 500 66%
1526 600 62%
3075 700 60%

SEAL (4) SPRING
X-750
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Restrictor Check
Features:
Higher cracking pressures
(2 to 40 psi)
1/4 to 2-1/2 Line size
450 to 2500 CWP
Threaded ends
B
Easy maintenance
Versatile
A OPTIONS:
-Soft seat
The DFT Restrictor Check Valve (RCV) is a versatile,

all-purpose, spring-assisted, in-line check valve for
applications that require higher cracking pressures to
open the check valve than those offered by other DFT
check valves. Cracking pressures are available from 2
to 40 psi. Like the Basic-Check valve, the Restrictor
Check provides reliable, low maintenance service for a
wide range of fluids and gases at various pressure/
temperature combinations. The valve consists of a
guard cage, spring, valve disc, retaining ring and seat.
It can be combined with pipe fittings such as couplings,
drain elbows, etc. (not provided by DFT) to form a com-
plete check valve unit ideally suited for a broad range
of applications. The RCV should not be considered a
substitute for a Pressure Relief Valve.
Typical Installation
Retaining
Restrictor Checks 303 SS 316 SS 316 SS 302 SS 316 SS
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Restrictor Check
RESTRICTOR CHECK VALVE CRACKING

PRESSURE Approx.
Line Size Outside
Inlet Thread Friction Loss (PSI) Net WT.
(FNPT) (MNPT) (Feet of Pipe) ( 10%) Each
A B (In lbs.)
1/4 1 7 3.3 to 20.4 .38

3/8 1 7 3.3 to 20.4 .38
1/2 1 7 3.3 to 20.4 .38
3/4 1-1/2 6 3.4 to 15.5 .88
1 2 7 4.2 to 40.7 1.25
1-1/4 2-1/2 12.5 1.8 to 18.8 2.25
1-1/2 3 11 2.4 to 19.1 3.75
2 4 16 1.7 to 9.4 7.00
2-1/2 4 16 1.7 to 9.4 7.00
Not recommended for use on discharge of reciprocating compressors.
COLD, NON-SHOCK PRESSURE RATING (1) Sat. Steam Adjusted

1/4 Ref. (2) (Deg. F.) Cold Rating
Size 3/8 3/4 1 1-1/4 1-1/2 2 2-1/2
-3 200 86%
1/2 15 250 82%
52 300 78%
Restrictor Check 2500 2000 1500 850 700 450 450 232 400 71%
407 450 69%
665 500 66%
1526 600 62%
3075 700 60%

SEAL (3) SPRING
X-750
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Codes and Standards
Basic- DLC Excalibur GLC PDC Restrictor SCV Vacuum WLC
Check Check Breaker
ANSI
B1.1 X X X
B1.20.1 X X X X
B16.5 X X X X X
B16.10 X X X
B16.20 X X X X
B16.25 X X
B16.34 X X X X X(1) X
MSS
SP-6 X X X X
SP-25 X X X X X X X X X
SP-61 X X X(2) X X X(2)
SP-125 X(7) X(7)
SP-126 X X X(6) X X X(6)
ASTM
A126CLASS B X X
A216GR WCB X X X X
A351GR CF8M X X X X X X
API
594 X(3)
FM X(4)
NACE
MR-01-75 X X(5) X(5) X(5) X X(5)
ANSI B1.1 Unified Inch Screw Threads Form #C & S

ANSI B1.20.1 Pipe Threads, General Purpose
1. Complies with B16.34 except for
ANSI 16.5 Pipe Flanges & Flanged Fittings. markings. 2 3600 CWP does not
ANSI 16.10 Face to Face & End to End Dimensions of Valves meet B16.34.
ANSI 16.20 Ring-Joint Gaskets & Grooves for Steel Pipe Flanges 2. Class 125 and 250 Cast Iron
ANSI 16.25 Buttwelding Ends valves are leak tested in
ANSI 16.34 Valves - Flanged, Threaded & Welding Ends accordance with AWWA.
3. ANSI Class 600 RF and
900/1500 RF valves meet face to
MSS SP-6 Standard finishes for contact faces of pipe flanges and
connecting end flanges of valves & fittings face dimensional only.
4. WLC with Cast Iron body (A126
MSS SP-25 Standard marking system for valves, fittings, flanges and unions CLASS B), and Bronze Trim in
MSS SP-61 Pressure testing of steel valves ANSI Class 125 only.
MSS SP-125 Grey Iron & Ductile Iron In-Line Check Valves 5. Meets this requirement when
MSS SP-126 Steel In-Line Spring-Assisted Center Guided Check Valves furnished with an Inconel X-750
spring.
ASTM A126 CLASS B Grey Iron Castings 6. Except Cast Iron Valves
ASTM A216 GR WCB Carbon Steel Castings 7. Cast Iron Valves only.
ASTM A315 GR CF8M Austenitic Steel Castings Victaulic is a registered trademark of Victaulic Company
of America
Teflon and Viton are registered trademarks of E.I. Dupont
API 594 Wafer & Wafer-Lug Check Valves Company
Inconel and Monel are registered trademarks of
International Nickle Co., Inc.
FM Factory Mutual System Hastelloy is a registered trademark of Haynes
International Inc.
Rulon is a registered trademark of Dixon Industries
NACE MR-01-75 Sulfide stress cracking resistant metallic materials for oilfield Corporation
equipment
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Pressure/Temperature
PRESSURE-TEMPERATURE RATINGS FOR WCB1 (PSIG)
TEMP. (deg. F) CLASS
150 300 600 900 1500 2500
20 285 740 1480 2220 3705 6170
100 285 740 1480 2220 3705 6170
200 260 675 1350 2025 3375 5625
250(2) 245 665 1330 1995 3325 5545
300 230 655 1315 1970 3280 5470
400(3) 200 635 1270 1900 3170 5280
450(4) 185 615 1235 1845 3080 5135
470(5) 175 610 1220 1825 3045 5075
500 170 600 1200 1795 2995 4990
600 140 550 1095 1640 2735 4560
650 125 535 1075 1610 2685 4475
700(6) 110 535 1065 1600 2665 4440
750 95 505 1010 1510 2520 4200
800 80 410 825 1235 2060 3430
PRESSURE-TEMPERATURE RATINGS FOR CF8M1 (PSIG)

TEMP. (deg. F) CLASS
150 300 600 900 1500 2500
462 275 720 1440 2160 3600 6000
100 275 720 1440 2160 3600 6000
200 235 620 1240 1860 3095 5160
250(2) 225 590 1180 1770 2945 4910
300 215 560 1120 1680 2795 4660
400(3) 195 515 1025 1540 2570 4280
450(4) 180 495 990 1485 2480 4130
470(5) 175 490 975 1465 2440 4070
500 170 480 955 1435 2390 3980
600 140 450 900 1355 2255 3760
650 125 445 890 1330 2220 3700
700(6) 110 430 870 1305 2170 3620
750 95 425 855 1280 2135 3560
800 80 420 845 1265 2110 3520
850 65 420 835 1255 2090 3480
900 50 415 830 1245 2075 3460
950 35 385 775 1160 1930 3220
1000 20 350 700 1050 1750 2915
1050(7) 20 345 685 1030 1720 2865
1100(7) 20 305 610 915 1525 2545
Notes:
1. Pressure/temperature ratings in accordance with ASME/ANSI B16.34-1996. 5. Maximum temperature for Zelon with 750CWP SCV.
2. Maximum temperature for Buna-N. 6. Maximum temperature for Inconel X-750 spring.
3. Maximum temperature for Viton & Zelon w/3600CWP SCV. 7. Butt weld end valves only. Flanged ratings terminate
4. Maximum temperature for 316 SS spring. at 1000o F.
PRESSURE TEMPERATURE RATING FOR CAST IRON (PSIG)

Class 125 Class 250
Temp. (deg. F) 2 to 12 14 + 2 to 12 14 +
0 to 150o 200 psig 150 psig 400 psig 300 psig
200o (MAX.) 190 psig 135 psig 370 psig 280 psig
Notes: Buna-N soft seat available for bubble tight shutoff. 316 stainless steel trim recommended for temperatures from 180o F to 200o F.
MAXIMUM OPERATING TEMPERATURES OF MATERIALS (8)

SEAL (9) SPRING
MATERIALS BUNA-N VITON ZELON 316 SS INCONEL HASTELLOYC
X-750
TEMP. F -70 to 250 F -40 to 400 F 37 to 400 F -460 to 450 F -460 to 700 F -460 to 1000 F
Note: 8. Maximum valve temperature rating is limited by seal and spring materials shown above.
9. Buna-N and Viton are not suitable for steam service.
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Standard Materials
EXCALIBUR, GLC AND WLC*
COMPONENT CARBON STEEL BODY STAINLESS STEEL BODY
Body A216 Grade WCB A351 CF8M
Disc/stem assy A351 CF8M/A479 316 A351 CF8M/A479 316
Spring (2) A313 316 A313 316
Bushing A 479 316 A479 316
Bolting (3) A193-B7 (Stud) & A194-2H (Nut)
Cl.150 & 300 Durlon8500 Flexible Graphite
Gasketing (3)
Cl.600+ 316 Spiral wound with Flexible Graphite Filler
*1 & 1-1/2 WLC; Cl 150 to 1500 - 316 SS trim except 17-7 disk in Cl 900+.
Some valves contain body seals (O ring or gasket). Consult DFT for material selection.
Notes: 1. Soft seats are available for bubble-tight shutoff. See page 25.
2. Inconel X-750 spring is available.
3. Excalibur only. Contact DFT for stainless steel or other bolting materials.
PDC
COMPONENT CARBON STEEL BODY STAINLESS STEEL BODY
Body A216 Grade WCB A351 CF8M
Disc A351 CF8M A351 CF8M
Spring (5) A313 316 (450 F max.) A313 316 (450 F max.)
Spring for ball check Inconel X-750 Inconel X-750
Disc guide A479 316 A479 316
Bushing Rulon (6) Rulon (6)
Seal ring Teflon/Hastelloy C276(6) Teflon/Hastelloy C276(6)
Spring retainer - ball check A479 316 A479 316
Guide ring Teflon (6) Teflon (6)
Ball check Teflon (6) Teflon (6)
Orifice Plug A479 316 A479 316
PDC temperature rating is limited by the body seal material (pg. 17), spring material and nonmetallic components.
Notes: 4. Soft seats are available for bubble-tight shutoff. See page 25.
5. Inconel X-750 spring is available.
6. 500 F maximum.
CAST IRON GLC AND WLC

COMPONENT CAST IRON BODY/BRONZE TRIM CAST IRON BODY/316 TRIM (7)
Body A126 Class B Cast Iron A126 Class B Cast Iron

Disc/stem assy B584 836 - Bronze A351 CF8M
Seat (8) B584 836 - Bronze A351 CF8M
Spring A313 T302 A351 CF8M
Bushing B584 836 - Bronze A351 CF8M
Notes: 7. 316 stainless steel trim recommended for temperatures from 180 F to 200 F.
8. Buna-N soft seat available for bubble-tight shutoff.
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Applications
Chemical Processing Power Generation
Process Lines Steam Lines
Boiler Feed & Discharge Water Lines
Steam Lines Cooling Towers
Condensate Lines Evaporators
Water Treatment Vacuum System
Nitrogen Purge (Fly Ash System)
Pump Discharge Boiler Feed & Discharge
Cooling Towers Pump Discharge
Compressor Discharge Compressor Discharge
Evaporators
Mineral Dewatering Food, Beverage & Drug
Cryogenics Boiler Feed & Discharge
Vacuum Lines & Breakers Cookers
Metering Pumps Evaporators
Refrigeration (Hot Gas Defrost)
Petroleum Production & Refining Metering Pumps
Crude & Refined Product Lines Chemical Lines
Boiler Feed & Discharge Steam Lines
Steam Lines Condensate Lines
Condensate Lines Vacuum Lines & Breakers
Water Treatment Pump Discharge
Pump Discharge Compressor Discharge
Cooling Towers Autoclaves
Compressor Discharge
Evaporators Mining
Generator Inlet & Discharge Mine Dewatering
Vacuum Lines & Breakers Boiler Feed & Discharge
Pulp & Paper Primary Metals

Steam Lines Hydraulic Lines
(Digester & Paper Machines) Steam Lines
Chemical Lines Condensate Lines
Boiler Feed & Discharge Pump Discharge
Condensate Lines Compressor Discharge
Water Treatment Water Lines
Pump Discharge Water Treatment
Metering Pumps Evaporators
Generator Inlet & Discharge Extrusion Equipment
Chemical Lines
Textiles Presses - Water Inlet & Outlet
Chemical Dye Lines
Boiler Feed & Discharge Building Maintenance
Pump Discharge Steam Lines
Compressor Discharge Condensate Lines
Metering Pumps Pump Discharge
Steam Lines Compressor Discharge
Condensate Lines Water Lines
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Flange Dimensions
ANSI Nominal Outside Outside Minimum Diameter Diameter Number Diameter
Class Pipe Diameter Diameter Thickness of Bolt of Bolt of Bolts of Bolts
Size of Flange of Raised of Flange Circle Holes
O Flange C A ANSI B16.5
R
3/4 3.88 1.69 0.50 2.75 0.62 4 0.50
RAISED FACE
1 4.25 2.00 0.56 3.12 0.62 4 0.50
1.5 5.00 2.88 0.69 3.88 0.62 4 0.50
2 6.00 3.62 0.75 4.75 0.75 4 0.62
3 7.50 5.00 0.94 6.00 0.75 4 0.62
4 9.00 6.19 0.94 7.50 0.75 8 0.62
150 6 11.00 8.50 1.00 9.50 0.88 8 0.75
8 13.50 10.62 1.12 11.75 0.88 8 0.75
10 16.00 12.75 1.19 14.25 1.00 12 0.87
12 19.00 15.00 1.25 17.00 1.00 12 0.87
14 21.00 16.25 1.38 18.75 1.12 12 1.00
16 23.50 18.50 1.44 21.25 1.12 16 1.00 Class 150 and 300
18 25.00 21.00 1.56 22.75 1.25 16 1.12
20 27.50 23.00 1.69 25.00 1.25 20 1.12
24 32.00 27.25 1.88 29.50 1.38 20 1.25
3/4 4.62 1.69 0.62 3.25 0.75 4 0.62
1 4.88 2.00 0.69 3.50 0.75 4 0.62
1.5 6.12 2.88 0.81 4.50 0.88 4 0.75
2 6.50 3.62 0.88 5.00 0.75 8 0.62
3 8.25 5.00 1.12 6.62 0.88 8 0.75
4 10.00 6.19 1.25 7.88 0.88 8 0.75
300 6 12.50 8.50 1.44 10.62 0.88 12 0.75
8 15.00 10.62 1.62 13.00 1.00 12 0.87
10 17.50 12.75 1.88 15.25 1.12 16 1.00
12 20.50 15.00 2.00 17.75 1.25 16 1.12 Class 600 - 1500
14 23.00 16.25 2.12 20.25 1.25 20 1.12
16 25.50 18.50 2.25 22.50 1.38 20 1.25
18 28.00 21.00 2.38 24.75 1.38 24 1.25
20 30.50 23.00 2.50 27.00 1.38 24 1.25
1 4.88 2.00 0.69 3.50 0.75 4 0.62 Notes:
1.5 6.12 2.88 0.88 4.50 0.88 4 0.75 Class 150 and 300 flanges have a
2 6.50 3.62 1.00 5.00 0.75 8 0.62 1/16 raised face which is included
3 8.25 5.00 1.25 6.62 0.88 8 0.75 in the C dimension.
4 10.75 6.19 1.50 8.50 1.00 8 0.87
600 6 14.00 8.50 1.88 11.50 1.12 12 1.00 Class 600 to 1500 have a 1/4 raised
8 16.50 10.62 2.19 13.75 1.25 12 1.12 face. The C dimension does not
10 20.00 12.75 2.50 17.00 1.38 16 1.25 include the 1/4 raised face.
12 22.00 15.00 2.62 19.25 1.38 20 1.25
14 23.75 16.25 2.75 20.75 1.50 20 1.37 DFTs standard flange finish is
16 27.00 18.50 3.00 23.75 1.62 20 1.50 125 - 250 Ra.
1.5 7.00 2.88 1.25 4.88 1.12 4 1.00
All dimensions are in inches.
2 8.50 3.62 1.50 6.50 1.00 8 0.87
3 9.50 5.00 1.50 7.50 1.00 8 0.87
4 11.50 6.19 1.75 9.25 1.25 8 1.12
900 6 15.00 8.50 2.19 12.50 1.25 12 1.12
8 18.50 10.62 2.50 15.50 1.50 12 1.37
10 21.50 12.75 2.75 18.50 1.50 16 1.37
1.5 7.00 2.88 1.25 4.88 1.12 4 1.00
2 8.50 3.62 1.50 6.50 1.00 8 0.87
3 10.50 5.00 1.88 8.00 1.25 8 1.12
1500 4 12.25 6.19 2.12 9.50 1.38 8 1.25
6 15.50 8.50 3.25 12.50 1.50 12 1.37
8 19.00 10.62 3.62 15.50 1.75 12 1.62
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Technical Information
CONVERSIONS
FLOW PRESSURE VOLUME
1 U.S. gpm = 34.28 BPD 1 in. of water = 0.0361 psi 1 ft.3 = 1728 in.3
1 U.S. gpm = 0.2273 m3/hr. 1 in. = 25.4 mm = 2.54 cm 1 ft.3 = 28.32 liters
1 U.S. gpm = 3.785 liters/min. 1 ft. = 0.3048 m 1 lb./ft.3 = 1728 lb/ft.3
1 U.S. gal = 0.1337 ft.3 2.31 feet of water = 1 psi 1 lb./ft3 = 16.02 kg/m3
1 lb./hr. = 0.4536 kg/hr. 1 Bar = 14.51 psia 1 U.S. gal. = 231 in.3
1 metric ton/hr. = 2205 lb./hr. 1 std atm = 14.696 psi 1 U.S. gal. = 0.8327 Imperial gal.
1 m3/hr. = 16.68 liters/min. 1 std atm = 1.0133 bar 1 barrell = 42 gallons
1 ft3/s = 448.8 U.S. gpm
Head (Feet) = Pressure (psi) 2.31 AREA
x
TEMPERATURE Specific Gravity 1 m2 = 10.76 ft2

o
F = 1.8(oC) + 32 1 m2 = 1550 in.2
o
C = oF - 32 Inches of Water Column = 1 in.3 = 16.39 cm3
1.8 Pressure (psi) x 27.72
1 Hg (mercury) = 0.49 psi
SCFM of Vacuum Breaker

SCFM (Air flow into tank/vessel) = GPM (Liquid flow out of tank)
7.5
CV
CV = the number of U.S. gallons of water at 60oF that will flow through the valve in one
minute when the pressure differential across the valve is one pound per square inch (1 psi).
RING JOINT GROOVE INFORMATION

ANSI CLASS
600 900 1500
Size RTJ Additional RTJ Additional RTJ Additional
Number(1) Length(2) Number(1) Length(2) Number(1) Length(2)
1 16 0
1.5 20 0 20 0 20 0
2 23 0.12 24 0.12 24 0.12
3 31 0.12 31 0.12 35 0.12
4 37 0.12 37 0.12 39 0.12
6 45 0.12 45 0.12 46 0.25
8 49 0.12 49 0.12 50 0.38
10 53 0.12 53 0.12
12 57 0.12
14 61 0.12
16 65 0.12
Notes: (1) The RTJ number can be used for the Excalibur, GLC, PDC and WLC.
(2) The ADDITIONAL LENGTH dimension only applies to valves that meet ANSI B16.10 face-to-face dimensions such as the
Excalibur and PDC. These dimensions can be used with the GLC but DO NOT apply to the WLC.
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Ordering Info
When ordering or requesting quotations on DFT check valves, please specify the following information
or complete the Valve Data Sheet on opposite page:
Nominal pipe size

Class (ANSI/API)
Model (Basic-Check Restrictor Check, Vacuum Breaker, DLC, Excalibur GLC, PDC, WLC, SCV)
Body material
Trim material
Spring material
Seating (Metal or soft seat - if soft seat specify material)
End connections (Inlet and outlet)
Product to be handled (Air, water, chlorine, crude oil, etc.)
Specific gravity of the product
Special characteristics of the product to be handled
(%, CO2, Sulfuric Acid H2S, etc.)
Operating pressure
Operating temperature
Flow rate (GPM for liquids and SCFM for gases)
Orientation (Horizontal, vertical flow up, vertical flow down)
Special requirements (NACE, C of C, CMTRs - body or trim, etc.)
Delivery requirements
Warranty
Each DFTInc. product is warranted against defects in material and workmanship for a period of one year after being
placed in service, but not exceeding 18 months after shipment, when these products are properly installed, maintained
and used within the service and temperature and pressure ranges for which they were designed and manufactured, and
provided they have not been subject to accident, negligence, alteration, abuse, misuse or the like. This warranty extends
to the first purchaser only. All defective material must be returned to the person from whom you purchased
the product, transportation prepaid, free of any liens or encumbrances and if found to be defective will be repaired free
of charge or replaced, at the warrantors or DFTs option.
FOR A COMPLETE UNDERSTANDING OF YOUR SOLE AND EXCLUSIVE LEGAL RIGHTS AND REMEDIES, AND THE
PROCEDURES TO BE FOLLOWED WITH RESPECT TO ANY CLAIMS, PLEASE REFER TO THE LIMITATION AND
DISCLAIMER OF WARRANTIES AND LIABILITIES, AVAILABLE ON REQUEST FROM DFT. THE EXPRESS WARRANTIES SET
FORTH IN THAT DOCUMENT AND THE OBLIGATIONS AND LIABILITIES OF DFT THEREUNDER ARE EXCLUSIVE AND ARE
EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION, THE
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, AND ALL OTHER OBLIGATIONS AND
LIABILITIES OF DFT. IT IS UNDERSTOOD THAT THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE
DESCRIPTION OF THE EXPRESS TERMS IN THE LIMITATION AND DISCLAIMER OF WARRANTIES AND LIABILITIES.
UNDER NO CIRCUMSTANCES SHALL DFT BE LIABLE FOR ANY CONSEQUENTIAL, INCIDENTAL, ECONOMICAL, DIRECT,
INDIRECT, GENERAL OR SPECIAL DAMAGES, EXPENSES OR LOSSES RELATING TO ANY BREACH OF WARRANTIES.
It is expressly understood and agreed that unless a statement is specifically identified in this brochure as a warranty, the
statements made herein relating to DFTs products are not express warranties, but are merely for informational, illustrative
and identification purposes only.
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TEL: (610) 363-8903 VALVE DATA SHEET
FAX: (610) 524-9242
dft@dft-valves.com NON-SLAM CHECK VALVE

P.O. BOX 566, EXTON, PA 19341-0566 www.dft-valves.com CHECK VALVE DOCTOR
Customer: Date: Page: of

Contact:
Phone: Fax: QUOTE NO.: ITEM NO.
email:
Quantity: *
Line Size: *
Class (ANSI/API):*
Model:
End Connections: *
GENERAL Material: Body*
INFORMATION Tr im *
Spring
Seating Metal Soft
Gaskets/O-ring
Bolting
Tag No: ____________ Brass ___ Stainless ___ Other: _________
Fluid State * Liquid Gas Steam
Fluid: *
Specific Gravity: *
FLUID Design Conditions: Pressure: Temp.:
DATA Operating Conditions: Flow* Pressure * Temper ature*
Units: (i.e. GPM,PSI,F, etc.) ________ _________ ___
Normal *
Maximum
Minimum
INSTALLATION Orientation: * Horizontal Vert. flow: Up Down
DATA Service Application:
Specification Nos.:
Cert. of Compliance: Yes No
CMTRs: Body Trim
Physicals Req.: Yes No
SPECIAL NACE Cert.: Yes No
REQUIREMENTS NDE: (Specify)
Drawings: Yes No
Packaging:
Other:
NOTES
DELIVERY: ____ wks. * Denotes Required

FORM 4-1-2 05/31/2002
31
Installation & Maintenance
Manual
For additional information call
800-206-4013
610-363-8903
Fax: 610-524-9242
email: dft@dft-valves.com
www.dft-valves.com
140 Sheree Blvd.

P.O. Box 566
Exton, PA 19341-0566
DFT DFT is considered the control valve of check
valves, the Check Valve Doctor.
DFT specializes in spring assisted In-Line
Check Valves that prevent Water Hammer Our check valve sizing program insures you
and reverse flow and insure long life if will know in advance what to expect from the
properly sized for the flow not the line size. check valve as opposed to after start up.
DFT customizes the internal components
DFT In-Line check valves are used in all
for optimal performance without changing
industries. They include chemical, food &
the line size.
beverage, mining, oil & gas, power, pulp &
paper, refining and steel.
DFT In-Line check valves do not rely on
gravity or reverse fluid flow to close. Instead
DFT In-Line check valves should provide
as the forward velocity of the fluid slows, the
trouble free service. Occasionally
spring assist starts to close the disc.
problems do arise or inspection is required.
This manual provides information for
Due to the spring assist and short travel
inspection and repairs of your DFT check
distance of the disc, by the time forward
valves should the need arise. No special
velocity has decreased to zero, the valve
tools are needed.
disc has reached the seat and the valve is
closed.
Check Valve Assistance
With reverse flow eliminated, the forces
necessary to produce water hammer on
both the upstream and downstream sides of Contact DFT at 800-206-4013 for
the valve are substantially eliminated. assistance, questions or the Authorized
DFT repair facility in your area .
DFTs objective is to solve and prevent
check valve problems and failures in critical DFT is available to review your check valve
service applications. All valves are sizing requirements and assist in selecting
manufactured at our facility in Exton, PA. the proper check valve.
Table of Contents
Item Page
Basic-Check 4
DLC 5
Excalibur 6
Full Face Seat Illustration Back Cover
GLC 8
Installation Information 3
PDC 10
Restrictor Check 4
SCV 12
Split Face Seat Illustration Back Cover
Trouble Shooting Guide 3
Vacuum Breaker 4
WLC 14
2
INSTALLATION PROCEDURES
All DFT In-Line check valves can be installed in the line in any orientation. The operation of the
DFT check valve is not affected by the position of the valve itself. The only requirement is that
the flow arrow on the body casting must be pointed in the direction of the flow. If the
DFT check valve is to be installed in an orientation with flow downward, that should be specified
when ordering. A stronger spring may be required to compensate for the weight of the disc and
any static head.
The operation of DFT In-Line check valves is not affected by its proximity to elbows, tees, control
valves etc. However, installing DFT In-Line check valves directly to the outlet of such devices
can result in decreased life due to the turbulence caused by the fitting. DFT recommends that
all DFT In-Line check valves be installed a minimum of five pipe diameters downstream of any
fitting that could cause turbulence.
Flange gaskets: ANSI non-metallic gaskets and spiral wound gaskets can be used with the DLC
and Excalibur in all pressure classes. GLC, PDC and WLC units can use non-metallic gaskets
for ANSI Class 150 and 300. Spiral wound gaskets can be used for all high pressure valves. An
illustration of end flange gaskets is shown on the back cover.
Check Valve Trouble Shooting Guide
Symptom Cause Solutions

Water hammer, loud noise, vibration, Slow closing check valve In-Line spring assisted check
ruptured piping, equipment damage valve.
Stem wear (pointed stem), elongated Low flow, pulsating flow, improper Custom sizing of the check
seat guide, bushing wear sizing valve internals.
PDC for reciprocating air or
gas mediums.
Excessive seat leakage Dirt, trash, foreign substance in Clean out the valve. Install
(Greater than MSS-SP61) the valve strainers if it is a reoccurring
problem.
Install a soft seat if bubble
tight shutoff is required.
Noise, clicking, tapping Low flow, pulsating flow, improper Custom sizing of the check
sizing valve internals.
gas mediums.
Reverse flow Slow closing check valve In-Line spring assisted check
valve.
Component breakage, valve failure Reciprocating compressor PDC for reciprocating air or
gas mediums.
Missing internals Valve not full open, pulsing flow, Custom sizing of the check
improper sizing valve internals.
gas mediums.
3
BASIC-CHECK /RESTRICTOR CHECK/ VACUUM BREAKER
MAINTENANCE PROCEDURES
DIS-ASSEMBLY:
1) Draw together the ends of the retaining

ring with pliers.
2) Lift the guard off the seat.
3) Seating surfaces may be cleaned using a

Flow soft cloth and appropriate solvent. Avoid
scratching the seating surface.
Basic-Check RE-ASSEMBLY:
1) Place retaining ring in groove of seat.
2) Place spring, small end first, onto guard

spring hub.
3) Position the disc over the spring and

between the four guard legs. Be sure the
valve disc is replaced with the seat side
against the seat bushing.
Flow
4) While holding the disc and spring in the
guard with one hand, compress the
Restrictor Check retaining ring with suitable pliers into the
seat groove with the other, then position
the disc/spring/guard over the seat with
the notches in the guard legs aligned with
the retaining ring and release the retaining
ring, locking the guard onto the seat.
5) Lift the disc to work the valve a couple of

times to check for free disc movement.
Flow 6) Re-install the valve.
Do not allow pipe thread sealants or tape to

be forced into the valve operating area or to
Vacuum Breaker become lodged on the valve seating
surface. Protect the valves from excessive
CAUTION: The Restrictor Check spring is heat from welding or brazing which may
under higher compression than the Basic- distort the seat bushing or damage the
Check and Vacuum Breaker units. Use spring.
caution when the units are disassembled.
4
DLC MAINTENANCE PROCEDURES
The DLC In-Line check valve has no user serviceable components inside. In operation, the
valves are designed to be fully automatic. On start-up, the flow forces the disc open. Continuing
flow holds the disc in an open position. Upon shut down, the spring returns the disc to the seat
prior to flow reversal, preventing backflow.
WARNING: If the system fluid is hazardous, take appropriate precautions. Make sure to bleed off
pressure from the line before removing the valve.
Flow
5
EXCALIBUR MAINTENANCE PROCEDURES
SOFT SEATING: For valves with an o-
ring soft seat, inspect the o-ring and
replace if cracked or excessively
deformed.
(Top Section)
5) Refacing:
A) METAL TO METAL SEATING A total
of .03 metal per surface has been
provided on the seat and disc to permit
refacing when necessary. It is
important that the facing remain
perpendicular to the axis of the parts.
The finish should be 32 Ra or better.
B) SOFT SEATING: The disc may be
refaced as outlined above. The seat
CAN NOT be refaced; if the o-ring
groove is damaged, replace the trim. It
is acceptable for the contact surface of
the seat to have small scratches
and/or pits, provided the groove is un-
Flow damaged.
SEAT
6) Remove the old gasket material and clean
HOUSING gasket surfaces on both sides of the seat
(Bottom ring and on both body sections.
section) 7) Soft Seat Replacement:
A) To replace the ring, pry it out of the
groove using a thin piece of metal (a
DIS-ASSEMBLY: .005" thick feeler gage works well)
1) Position the valve with the arrow on the taking care not to scratch the bottom
side facing downward on the floor or of the o-ring groove.
bench. B) Clean out the groove.
2) Unscrew the nuts holding the two parts of C) Lubricate a new o-ring with water
the body together and lift the top section of soluble lubricant such as dishwashing
the body from the bottom section. detergent or suitable lubricant
3) Lift the seat ring from the bottom section compatible with the process fluid.
of the body being careful not to damage D) To install the new o-ring, push one
the seating surface. Lift the disc/stem section of the o-ring into the groove
assembly from the body and remove the with your thumb or a soft roller, then
spring. push the section 180 opposite from
4) Inspection: the first into the groove. Continue by
Inspect the seating surfaces, bushing and pushing in the o-ring at points 90 to
seat guide for wear. The seat and disc the original sections. Finally, push the
may be lapped with a suitable fine grade rest of the ring into the groove.
lapping compound. Remove any scale E) Rub the o-ring in a circular motion in
build up on the stem and guides. Replace the groove with your thumb to even-
the trim if total stem-to-bushing or seat out any bumps.
guide clearance exceeds 1/16.
6
RE-ASSEMBLY:
1) Insert the spring into the spring retainer in 6) Place the top body section onto the
the bottom body section. bottom body section.
2) Insert the disc/stem assembly into the 7) Hand tighten body bolts. With wrench,
disc guide of the bottom body section tighten bolts (as shown in Figure 1)
insuring that the seating surface faces gradually in three or four steps to the
upward. torque shown in Table 1.
3) Place a new gasket on the bottom body 8) Lift the disc to work the valve a couple of
section. times to check for free disc movement.
4) Place the seat ring (seating surface 9) Re-install the valve in the line with the flow
downward) on the gasket. arrow on the body pointing in the direction
of flow. (To insure correct operation of
5) Place a new gasket on top of the seat the gaskets, the body bolts should be re-
ring. torqued after start-up.)
TABLE 1: TORQUE VALUE RANGES

Bolt Size Initial Torque (Ft. lbs.) Bolt Size Initial Torque (Ft. lbs.)
3/8 15 1 260
7/16 20 1-1/8 390
1/2 35 1-1/4 500
9/16 50 1-3/8 770
5/8 60 1-1/2 950
3/4 110 1-5/6 1300
7/8 170
NOTE: Torque values are based on new fasteners.
FIGURE 1: BOLT TORQUING SEQUENCE
Small Valves Large Valves
7
GLC MAINTENANCE PROCEDURES
C) PUNCH-PRICKED SEAT :
Flow
1) From the outlet end, drive the stem
with a soft metal or plastic bar/rod.
This will push the disc/stem and seat
out the inlet end.
2) Remove the spring, bushing, (and
body seal o-ring on some units).
2) Inspection:
Inspect the seating surfaces, bushing and
seat guide for wear. The seat and disc
may be lapped with a suitable fine grade
lapping compound. Remove any scale
build up on the stem and guides.
Replace the trim if total stem-to-bushing
Caution: The upstream (seat) end of the or seat guide clearance exceeds 1/16.
valve should never be disconnected from
the line if there is any chance that line SOFT SEATING: For valves with an o-
pressure has not been completely relieved ring soft seat, inspect the o-ring and
from the downstream end of the valve. replace if cracked or excessively
deformed.
3) Refacing:
DIS-ASSEMBLY: A) METAL TO METAL SEATING:
1) Remove the seat from the GLC. A total of .03 metal per surface has
There are three (3) different seat designs been provided on the seat and disc to
for the GLC: permit refacing when necessary. It is
important that the facing remain
A) DROP-IN SEAT : perpendicular to the axis of the parts.
1) Remove the retaining screws. The finish should be 32 Ra or better.
2) Pull the seat from the body.
3) Remove the disc and spring. B) SOFT SEATING:
4) Press out guide bushing The disc may be refaced as outlined
above. The seat CAN NOT be
(interference fit).
refaced; if the o-ring groove is
damaged, replace the trim. It is
B) THREADED SEAT :
acceptable for the contact surface of
1) Unscrew the seat.
2) Removed the disc/stem and spring. and/or pits, provided the groove is un-
3) Press out the guide bushing damaged.
(interference fit).
8
4) Soft Seat Replacement:
A) To replace the ring, pry it out of the B) THREADED SEAT :
groove using a thin piece of metal (a 1) Press bushing into the body.
.005" thick feeler gage works well) 2) Place spring, (large end first for
taking care not to scratch the conical springs) into the body.
bottom of the o-ring groove. 3) Insert the disc/stem assembly.
B) Clean out the groove. 4) Coating the seat threads with anti-
C) Lubricate a new o-ring with water seize compound is recommended.
soluble lubricant such as Then screw in seat until locked.
dishwashing detergent or suitable
lubricant compatible with the C) PUNCH-PRICKED SEAT :
process fluid. 1) Press bushing into body.
D) To install the new o-ring, push one 2) Place spring, (large end first for
section of the o-ring into the groove conical springs) into the body.
with your thumb or a soft roller, 3) Insert the disc/stem assembly.
then push the section 180 opposite 4) Install the body o-ring (If required).
from the first into the groove. 5) Press in seat until bottomed. (If seat
Continue by pushing in the o-ring at is not tight, remove and re-stake
points 90 to the original sections. the O.D. of the seat with a sharp
Finally, push the rest of the ring into point punch at 3 or 4 places to
the groove. create interference points, then
E) Rub the o-ring in a circular motion press seat back into body.)
in the groove with your thumb to
even-out any bumps. 2) Lift the disc to work the valve a couple of
times to check for free disc movement.
RE-ASSEMBLY:
1) Seat Installation 3) Re-install the valve in the line with the flow
Install the seat into the valve body. arrow on the body pointing in the direction
NOTE: There are three (3) different of flow.
seat designs:
A) DROP-IN SEAT :
1) Press bushing into body.
2) Place spring, (large end first for
conical springs) into the body.
3) Insert the disc/stem assembly.
4) Install the body o-ring (if
required).
5) Lower the seat into the body and
install the retaining screws.
9
PDC MAINTENANCE PROCEDURES
2) Slide the Disc off the Disc Guide.
Flow 3) Remove guide ring and seal ring. Take care

not to scratch the groove surfaces. It may be
necessary to destroy the seal ring to remove.
4) Remove the spring retainer:
A) 2 through 8:
The retainer is threaded-in, then the
threads are staked to lock them in.
1) Grind away the damaged threads where
they are staked.
2) Stick two (2) 1/8 rods (or drill bits) in the
two (2) holes.
3) With a large screwdriver wedged
between the rods, unscrew the retainer.
B) 10 and larger
The retainer is dropped-in, then the edge of
the bore is staked to lock it in.
1) Grind away the upset metal.
2) Push the check disc and retainer out.
5) Clean the Disc, Disc Guide and check ball

(or the check disc on 10 and larger valves)
with a suitable solvent.
DIS-ASSEMBLY:
1) Remove the seat from the PDC. 6) Inspection:
There are two (2) different seat A) Inspect the bore of the disc; replace if
designs for the PDC: scored.
B) Inspect the Orifice in the Disc Guide;
A) DROP-IN SEAT :
clean out if dirty or clogged.
1) Remove the retaining screws. C) Inspect the Bushing in the Body for
2) Push out the disc, disc guide excessive wear; if I.D. of Bushing is visibly
and seat as an assembly. out-of-round due to wear on one side or if
3) Remove the o-ring (on some stem-to-bushing or seat guide clearance
models). exceeds 1/16" remove it by pressing it out.
D) Remove any scale build-up on stem and
B) PUNCH-PRICKED SEAT : disc bore.
1) From the outlet end, drive the
stem with a soft metal or plastic SOFT SEATING: For valves with an o-ring
bar/rod. This will push the disc, soft seat, inspect the o-ring and replace if
disc guide and seat as an cracked or excessively deformed.
assembly out the inlet end.
2) Remove the o-ring (on some
models).
10
7) Refacing: 1) Reinstall the check ball (or the check disc
A) METAL TO METAL SEATING: on 10 and larger valves), spring and the
A total of .03 metal per surface spring retainer into the disc guide.
has been provided on the seat and
disc to permit refacing when 2) Stake the outside of the spring retainer at
necessary. It is important that the four (4) places to lock it in place.
facing remain concentric to the
axis of the parts. The finish should 3) Install new guide ring. Coat new seal
be 32 Ra or better. ring with general purpose lithium grease
B) SOFT SEATING: and install on Disc Guide with the open
The disc may be refaced as side of the U facing up toward the
outlined above. The seat CAN compression chamber. The seal ring will
NOT be refaced; if the o-ring fit tightly over the Disc Guide, so be
groove is damaged, replace the careful not to distort it or damage its
trim. It is acceptable for the sealing edges.
contact surface of the seat to have
small scratches and/or pits, 4) Seat Installation
provided the groove is un- A) DROP-IN SEAT :
damaged. 1) Press bushing into body.
2) Place spring, (large end first for
8) Soft Seat Replacement: conical springs) into the body.
A) To replace the ring, pry it out of the 3) Install the body o-ring (if required).
groove using a thin piece of metal 4) Apply a coating of grease to the seal
(a .005" thick feeler gage works ring and guide ring.
well) taking care not to scratch the 5) Lower the disc/disc guide/seat
bottom of the o-ring groove. assembly into the body and
install the retaining screws.
B) Clean out the groove.
B) PUNCH-PRICKED SEAT :
C) Lubricate a new o-ring with water 1) Press bushing into body.
soluble lubricant such as 2) Place spring, (large end first for
dishwashing detergent or suitable conical springs) into the body.
lubricant compatible with the 3) Install the body o-ring (If required).
process fluid. 4) Apply a coating of grease to the seal
ring and guide ring.
D) To install the new o-ring, push one 5) Re-stake the O.D. of the seat with a
section of the o-ring into the groove sharp point punch at 3 or 4 places to
with your thumb or a soft roller, create interference points, then press
then push the section 180 the disc/disc guide/seat assembly
opposite from the first into the into the body.
groove. Continue by pushing in the
o-ring at points 90 to the original 5) Lift the disc to work the valve a couple of
sections. Finally, push the rest of times to check for free disc movement.
the ring into the groove. The valve should close in the horizontal
orientation.
E) Rub the o-ring in a circular motion
in the groove with your thumb to 6) Re-install the valve in the line with the flow
even-out any bumps. arrow on the body pointing in the direction
of flow.
RE-ASSEMBLY:
11
SCV MAINTENANCE PROCEDURES
3) Inspection:
Flow
Seating surfaces may be cleaned using a
soft cloth and an appropriate solvent.
Avoid scratching the seating surface.
Check for scratches on the seating
surfaces. If they can be felt with your
fingernail, recondition or replace the disc
and/or seat. Check the disc and guide
ribs for signs of wear. If the total disc/rib
clearance exceeds 1/16", replace the
valve. Inspect the body o-ring for signs of
cracking or ruptures. Replace it if
necessary.

deformed.
WARNING:If the system fluid is hazardous, 4) Soft Seat Replacement:

take appropriate precautions. Make sure to A) To replace the ring, pry it out of the
bleed off pressure from the line before groove using a thin piece of metal (a
removing the valve. Hold the valve by the .005" thick feeler gage works well)
Hex end nearest to the mating pipe and taking care not to scratch the bottom
loosen. Again, do not hold the valve by the of the o-ring groove.
opposite end, as this may loosen the valve B) Clean out the groove.
body joint. C) Lubricate a new o-ring with water
soluble lubricant such as dishwashing
detergent.
D) To install the new o-ring, push one
section of the o-ring into the groove
with thumb or a soft roller, then push
the section 1800 opposite from the first
DIS-ASSEMBLY: into the groove. Continue by pushing
1) Place the outlet Hex end of the valve in a in the o-ring at points 900 to the
vice or other suitable fixture. original sections. Finally push the rest
of the ring into the groove.
2) Unscrew the seat from the body and E) Rub the o-ring in a circular motion in
remove the disc and spring. the groove with your thumb to even-out
any bumps.
12
RE-ASSEMBLY: 5) Tighten to 200 ft-lbs. for 1" and larger
1) Place the spring into the body, large end units, 100 ft-lbs. for 3/4" and 1/2" units
first, then the disc, seat side up. and 50 ft-lbs. for 1/4".
2) Clean all the threads of the seat and coat 6) Lift the disc to work the valve a couple of
with an anti-seize compound. times to check for free disc movement.
3) Install the new body o-ring in the thread 7) Reinstall the valve in the line with the
undercut of the seat. flow arrow on the body pointing in the
direction of flow.
4) While holding the disc down in the body,
and compressing the spring, screw the Caution: Do not allow any pipe thread
seat into the body. sealants or tape to be forced into
the valve operating area or become
lodged on the valve sealing
surfaces.
WELDING PRECAUTION FOR SOCKET WELD SCV CHECK VALVES
KEEP BELOW LISTED TEMPERATURES
BODY SEAL O-RING
When welding the check valve into the line, avoid heating the marked body joint region above the
temperatures listed below. Damage to the body seal (or optional soft seat) o-ring may result.
O-Ring Max.
Material Temperature
Buna-N 275F
Chemraz 500F
EPDM 300 F
Kalrez 600F
Teflon Encapsulated Viton 400F
Viton 400F
Zelon (1) 470F (750 CWP SCV)
400F (3600 CWP SCV)
Notes: 1. Standard O-ring for the 750 CWP SCV and 3600 CWP SCV.
13
WLC MAINTENANCE PROCEDURES
GUARD
SEAT
A) 1-1/2" AND SMALLER:
1) Pull the seat from the body. The
seat is only held in by the friction of
the body o-ring seal. All internal
parts will come out with the seat.
SPRING RETAINING 2) With a pair of pliers, squeeze the
RING ends of the retaining ring together to
release the guard and lift it off the
BODY seat.
3) Remove the disc and spring.
B) 2" AND LARGER WITH RAISED FACE:

DISC
1) Unscrew the seat (or remove the
retaining set screws on cast iron
units and lift out the seat).
2) The disc/stem, spring, and bushing
O-RING O-RING
can be easily removed by hand.
1 and 1-1/2 WLC
C) 2" AND LARGER WITH RTJ ENDS:
1) From the outlet end, drive the stem
with a soft metal or plastic drift.
This will push the disc/stem and
seat out the inlet end.
2) Remove the spring, bushing and
body seal o-ring.
2) Inspection:
Inspect the seating surfaces, bushing and
seat guide (and guard on 1-1/2" and
smaller) for wear. The seat and disc may
be lapped with a suitable fine grade
lapping compound. Remove any scale
build up on the stem and guides.
Replace the trim if total stem-to-bushing
or seat guide clearance (or disc-to-guard
2 and larger WLC leg on 1-1/2" and smaller units) exceeds
1/16.

DIS-ASSEMBLY:
1) Remove the seat from the valve. There
deformed.
are three (3) different seat designs for the
WLC:
14
3) Refacing: 3) Position the disc over the spring
A) METAL TO METAL SEATING: A total and between the four guard legs.
of .03 metal per surface has been 4) While holding the disc and spring in
provided on the seat and disc to permit the guard with one hand, compress
refacing when necessary. It is the retaining ring with suitable pliers
important that the facing remain into the seat groove with the other,
perpendicular to the axis of the parts. then position the disc/spring/guard
The finish should be 32 Ra or better. over the seat with the notches in the
guard legs aligned with the retaining
B) SOFT SEATING: The disc may be ring and release the retaining ring,
refaced as outlined above. The seat locking the guard onto the seat.
CAN NOT be refaced; if the o-ring 5) Lift the disc to work the valve a
groove is damaged, replace the trim. It couple of times to check for free
is acceptable for the contact surface of disc movement.
and/or pits, provided the groove is un- B) 2" AND LARGER WITH RAISED FACE:
damaged. 1) Install the guide bushing.
2) Place the spring (small end for
4) Soft Seat Replacement: conical springs) on the guide
A) To replace the ring, pry it out of the bushing shoulder.
groove using a thin piece of metal (a 3) Insert the disc/stem assembly.
.005" thick feeler gage works well) 4) Coating the seat threads with anti-
taking care not to scratch the bottom seize compound is recommended.
of the o-ring groove. Then screw in seat until locked.
B) Clean out the groove. Lubricate a new (Drop in the seat and re-install the
o-ring with water soluble lubricant such retaining set screws for cast iron
as dishwashing detergent or suitable units.)
lubricant compatible with the process
fluid. C) 2" AND LARGER WITH RTJ ENDS:
C) To install the new o-ring, push one 1) Install the guide bushing.
section of the o-ring into the groove 2) Place the small end of the spring on
with your thumb or a soft roller, then the guide bushing shoulder.
push the section 1800 opposite from 3) Insert the disc/stem assembly.
the first into the groove. Continue by 4) Install the body o-ring.
pushing in the o-ring at points 900 to 5) Press in seat until bottomed. (If seat
the original sections. Finally, push the
is not tight, remove and re-stake the
rest of the ring into the groove.
O.D. of the seat with a sharp point
D) Rub the o-ring in a circular motion in
punch at 3 or 4 places to create
the groove with your thumb to even-out interference points, then press seat
any bumps. back into body.)
RE-ASSEMBLY: 2) Re-install the valve in the line with the flow
1) Seat Installation arrow on the body pointing in the direction
There are three (3) different seat designs of flow.
for the WLC:
A) 1-1/2" AND SMALLER:

1) Place retaining ring in groove of
seat.
2) Place spring, small end first, onto
guard spring hub.
15
END FLANGE GASKET ILLUSTRATION
GASKET
SPLIT IN SEALING
FACE
O - RING OR GASKET SEAL INCLUDED FOR FULL FACE DESIGN
FULL FACE SEAT SPLIT FACE SEAT

(3 ANSI 600 FLANGE SHOWN) (3 ANSI 150 FLANGE SHOWN)

Other DFT Publications
DFT In-Line Check Valve Catalog/Product Selection Guide
DFT Severe Service Control Valve Catalog/Product Selection Guide
DFT Application Guide
DFT Mining Trifold
DFT Oil & Gas Trifold
DFT Pulp & Paper Trifold
DFT SCV Trifold
DFT Steel Trifold
Kalrez, Teflon and Viton are registered trademarks of E.I. Dupont Company
Chemraz is a registered trademark of Greene,Tweed & Company.

Printed in the U.S.A. Copyright 2002, DFT , All Rights Reserved 05/28/2002 Rev #4
16
TYPE EU & ER
ELECTRICACTUATORS
EUand ERelectric actuators offerthe simplest,most I'
economical, and reliable automatic control of quarter
turn valves. The only requirement for installation is
simple wiring from a convenient switch or centralized
control center. The low-cost Type EU uni-directional
electric actuators offer distinct price advantages over
other available electric actuators. The reversible Type
ERactuators provide maximumversatilityas well as
economy.
These compact actuators offer high-torque output
and fast, reliable response. All components are con-
tained in a rugged housing that protects internal
components. The EUand ERunits are rated for NEMA
4and4X.
Allactuators have self-lubricating shaft bearings, and
the gear box is lubricated and sealed at the factory. No
subsequent lubrication is required.
FEATURES AND BENEFITS
Maximum Allowable Duty Cycle Thermally Protected Motors

0 Units with ACmotors have a maximumallowable 0 ACmotors have a thermal overload device built into
duty cycle of 25% at an ambient temperature of 80F the motor winding to prevent motor damage.
(27"C), allowing these actuators to fill practically Motor Brake
every service application. DCunits have a maximum
allowable duty cycle of 85% at ambient temperature. 0 All ERactuators are equipped with motor brakes as
standard. (Not available on EU actuators.)
Versatile Actuator Mounting Design
0 Actuator mounting provides for rigid vibration Weatherproof Enclosures Available for
Exposed or Hazardous Locations
proof attachment of the actuator to the valve.
0 The actuator female square drive is directly aligned 0 AllEUand ERactuators have watertight NEMA4 and
with the valve stem, avoiding side thrust.
4X enclosures and are CSA-approved (pending on
FM).CEMarking available.
0 Actuator can be mounted in any orientation for Declutchable Manual Override
maximum installation flexibility.
0 All ERactuators are equipped with a declutchable
Rugged Enclosures Protect Drive Train manual override. (Not available on EUactuators).
in Severe Services
0 Heavy-duty enclosures guard against drive-train Low Profile Design

misalignment or changes in settings. 0 Low profile design is perfect for applications with
0 Easy access to internal components is provided if limited space environments.
resetting switches or rewiring is ever required.
~ metso
Y automation
METSO AUTOMATION
SPECIFICATIONS
Temperature: -40F (-40C)to + 150F(+66C) Temperature C

with heater and thermostat -40 -25 0 25 50 66
Heater recommended below +40F (+4C) 25
Conduit Connection: 1/2" NPT
<II 20
Enclosure: NEMA4,4X U
(?;
Duty Cycle: ACunits: 25% 15
DCunits: 100% ::s
C
..
Approximate Weight: 6 Ib (3 kg) c 10
Lubrication: Permanently lubricated gear train &bearings ..
<II
CI. 5
Options: (Referto Bulletin A121-2for Option details)
. ExtraSingle LimitSwitch (EUonly) SPDT 0
.Two Extra LimitSwitches (ERonly) SPDT -50'
I
-25 0 25 50 75 100 125 150
. 30 watts*
Heater with Thermostat 115V,15 watts / 230V,
-40
Temperature of
. Other voltages available - consult factory * DC heater options require factory installation
* Inrush current is approximately 3 times max. amperes at rated torque.
WIRING DIAGRAMS
Series ER DC Series ER AC
CW CCW Terminal
Limit Switch Limit Switch
Strip
NC ,NO NC ~ _NO RED
BLK
AC Neutral 1
COM COM
AC Hot, Opt. Heater 2
AC Hot, CCW,Open 3
AC Hot,CW,Closed 4
CCW,Open, Indication 5
CW,Closed, Indication 6
NC 7 RED NC
Aux. Limit Switch Com 8 WHTCOM NO
NO 9 BLK
NC 10 RED
NC ...
Aux. Limit Switch Com 11 WHTCOM
NO
NO 12 BLK
-NEG
-2-
TYPE EU & ER ELECTRIC ACTUATORS
WIRING DIAGRAMS (Continued)
Series EU, AC, DC
Terminal
Strip
BLK
DC Negative, AC Neutral 1
DC Positive,AC Hot, Opt. Heater
DC Positive,
DC Positive,
AC Hot, 0 & 180 Control
AC Hot, 90 & 270 Control

NO
NO
BLK
8
0 & 180 Indication BLK
90 & 270 Indication
NC RED
Aux. Limit Switch Com COM

BLK
NO 9
BILL OF MATERIALS AND PARTIAL PARTS
3 a-Ring
5 Capacitor (ER only)
DIMENSIONS
0.38 0.31
ER Models Only
(10) (8)
t -1~
0.75 (19)
~r Mounting
Configuration
EU,ER
T fi
4.30
(109)
S
L
I I-, . Bolt Circle Thread
F03: 1.417(38) M5xO.8-6Hx9.5
2.20 *F05: 1.968(50) M6x1.0-6HxlO.5
(56)
1.73
S: 0.55 in.(14 mm)
(44) 4.40
(112)
1- Female 8-point drive
5.95 4.72 * All EUlERunits mount to
(51) (120) F05 linkages
-3-
METSO AUTOMATION
HOW TO ORDERTYPE EU AND ERELECTRICACTUATORS
To specify a complete actuator code, simply make a selection from each of the boxes below.
Example: Uni-directional12 FT'LBSactuator for 115 VACwould be coded as an EU12-01Q-, as shown below:
2
12
Uni-Directional Weatherproof Electric Actuator Female Square
12 FToLBS(16.3 Nom)Torque Output (All)
50 50 FToLBS(67.8 Nom)Torque Output (All)
1. These two options cannot be combined.

2. DC Heater is factory installed only.
08 24 VDC
* Other voltages available - consult factory.
HOW TO ORDERACCESSORYKITS FOR ELECTRICACTUATORS
To order an accessory for an ERor EU actuator that is to be

field-retrofitted, specify the kit numbers shown at right.
EXAMPLE: To order a separate heater with the actuator

specified at the top of the range, simply request an
EK5098-01.
Tropical Heater
EK5123 EK5123
(115 VAC)
* Tropical heater turns

on below 90F (3rC) and shuts off at 110F (43C).
Designed for excessively moist environments.
Installation Instructions, Maintenance and Operation

IMO's (Installation, Maintenance, and Operating instructions) or AMI's (Assembly, Mounting, and Installation instructions)
are shipped with the products. Additional copies of these instructions are available. Call your local Metso Automation
Distributor, or visit our web site.
Europe, Levytie 6,P.O.Box 310,00811Helsinki,Finland.Tel.int.+358 20483150. Faxint.+358 20483151
Europe (UK), 2 Lindenwood, Crockford Lane,Chineham Business Park,Basingstoke, RG2480Y UK.Tel.int. +44 (0) 8706 061478. Fax int.+44 (0) 1256707661
North America, 44 Bowditch Drive, P.O.Box8044, Shrewsbury, Massachusetts, 01545-8044 USA. Tel.int. +1 5088520200. Faxinto+1 5088528172
Latin America, Av. Central, 181- Characas Reunidas, 12238-430, SaoJose dos Campos. SP BRAZIL.Tel. into +55 1239353500. Fax into +55 12 39353535
Asia Pacific, 501 Orchard Road,#05-09 Wheelock Place, 238880 Singapore. Tel. into +657355200. Fax into +657354566
wwwojamesbury.com
~V metso
automation
A120-3-12/03 @ 2003 Metso Automation Printed in U.s.A.-R-j
~ metso
Y automation
IMO - 593 Issue Date: 11/01
INSTAllATION,MAINTENANCE, AND
OPERATING INSTRUCTIONS
ERV ELECTRIC
ACTUATORS
FOR 115 AND 230 VAC
Readentire instructions carefully before installation or servicing
1 GENERAL
1.2 CAUTION
This instruction manual contains important information WHENEVERAN ACTUATORISTO BE REMOVEDFROMTHE VALVEAND
regarding the installation, maintenance, and operation of THEN REMOUNTED,THE LIMIT SWITCHSETTINGSMUST BE CHECKED
the Jamesbury ERV Electric Actuator. Please read these TO MAKE SURETHE VALVE IS MAKING THE PROPERTRAVEL.REFER-
ENCETHIS IMO FOR CAM ADJUSTMENT INSTRUCTIONS.WHEN SER-
instructions carefullyand save them for further reference.
VICING A VALVE/ACTUATORASSEMBLY,THE BEST PRACTICEIS TO
The ERVSeries Actuators are designed to provide reliable REMOVETHE ENTIREASSEMBLYFROM SERVICE.REFERTO THE VALVE
INSTALLATIONAND MAINTENANCE INSTRUCTIONSBEFOREREMOV-
and efficient operation of 1/4 turn valves. The supported ING VALVEFROMTHE LINE.
torque range for actuation is between 12 and 250 ft-Ibs.The
ERVseries is available in ACmodels with a 75% Duty Cycle
and DCmodels with 100% Duty Cycle.These units are avail- 1.3 GeneralTechnicalInformation
able at either 115 or 230 VACThismanual only applies to the ERVSeries ACvoltage actuators use a reversing induction
115 and 230 VACmodels. There are a variety of options and motor. Allof the ERVseries have manual override capabili-
accessories to extend the versatilityof the ERV.lnstaliationis ties.
simple and reliabilityis high.
1.4 Operation
A 75% duty cycle means that for every operation cycle that
the actuator is ON (to open or close the valve),the actuator
must be off for a time equal to one-quarter of the operating
cycle.Forexample: Ifthe operating cycle time is 15 seconds,
1.1 WARNING for every operation cycle that the actuator is ON,it must be
BEFOREREMOVINGTHE COVER,SHUT OFF ALL ELECTRICALPOWER OFFfor 5 seconds. Exceeding the actuators rated duty cycle
AND DISCONNECT ALL CONNECTIONS.TO PREVENTIGNITION OF
may cause the thermal overload switch to temporarily shut
HAZARDOUS ATMOSPHERES,DISCONNECTSUPPLYCIRCUIT BEFORE
OPENING UNIT. KEEPASSEMBLYTIGHTLY CLOSEDWHEN IN OPERA- off power to the motor.Continual overload may burn out the
TION.TO MAINTAIN THE HAZARDOUS LOCATIONRATINGOF THE ERV motor.
ACTUATOR,IT IS ESSENTIALTHAT THE MATING OF THE SURFACESOF
THE FLANGES BE PROTECTEDFROM NICKSAND SCRATCHESWHILE
Operating temperature range is from -40F(-40C)to 150F
DISASSEMBLED.UPON REASSEMBLY, THERE MUST NOT BE ANY DIRT (65C),however,the heater option is recommended below
OR PARTICLESON THE MATING SURFACESOR FLANGES. +40F(5C).
2
2 INSTAllATION CAUTION: The Jamesbury ACVoltage Actuators are revers-

ing induction motors which cause high voltages. Devices
Mount these actuators by following actuator mounting connected to terminal 3 and 4 must be rated for minimum
instructions (AMI) contained in the linkage kit.
250 VAC(440 VACfor 230 VACapplications). Due to the
To obtain copies of these AMI's, contact your
induced feedback voltage, multiple actuators cannot be
nearest stocking distributor or write: Metso Automation, 44
wired in parallel. Separate (isolated contacts) must be pro-
Bowditch Drive,P.O.Box8044, Shrewsbury,MA01545. vided for each actuator.
3 MANUALOVERRIDE INSTRUCTIONS
5 OPTIONAL ACCESSORIES
Allof the ERVSeries ElectricActuators have a manual over-
1. Feedback Potentiometer -Instructions availablefrom fac-
ride feature.Toactivate the override, push the override shaft
tory.
down approximately 1/4 inch to disengage the motor from
2. Six Position Terminal Strip - Instructions available from
the gear train. Failure to disengage motor prior to turning
factory.
override will cause damage to the actuator. While holding
the shaft down, turn the shaft with a wrench or handle to the 3. Handwheel - Instructions available from factory.
4. Twelve-Position Terminal Strip - Instructions available
desired position. The override shaft on ERV12, 25, and 50
from factory.
actuators must be rotated in the opposite direction of the 5. TwoExtraLimitSwitches-Instructions availablefrom fac-
output shaft. In ERV83, 125, 167,208, and 250 actuators, the
tory.
override and the output shaft turn in the same direction.
6 FEATURES OF THE MOTOR BOARD AND
Do not drive the actuator beyond the limit switch full
TERMINAL BLOCK FUNCTIONS
open or full closed positions. Ifover travel is caused by the
override, options such as the potentiometer can be dam- The Motor board in the ERVseries actuator has a number of
aged. The manual override shaft must be returned to its features which are accessed through convenient plug in
fully upward position before the motor is re-engaged. connectors (See Figure 2).
Rotate the shaft slightly to align the spur gears until the Terminal 1:
shaft "springs" back to its re-engaged position.
Supply power to the optional heater and thermostat.
4 CAM ADJUSTMENT INSTRUCTIONS
Terminals 2,3.4:
To set the-AEtuatorsstaR: and stop-position, follo\Dctbe~st~s
listed below (See Figure 1): PowersUpp1iectforhasicoperation of actuator:for On/OFF
and jogging applications the actuator is controlled by AC
Forthe top cam (CCW):(valveopen stroke) power, supplied by the user either to terminal 2 and 3 for
1. Loosen the set screw in the top cam. This can be done CCW control, and to 2 and 4 for CW control.
using a 1/16 hex wrench. Terminals 5 and 6:
2. Move cam to desired stop position. Power to terminals 2
and 3 or use the manual override until the valve is in the These are line output position indicator voltages. TerminalS
fullopen position. is the CCWlimit voltage, terminal 6 is the CW limit voltage.
3. Remove the power from the terminals. Rotate the cam in 7 OPERATINGINSTRUCTIONS
the direction of travel to the exact point where the limit Normal operating voltage for electric actuator: 115 VAC,230
switch "clicks"open. Tighten the set screw. VAC, oras specified on the actuator. Seewiring diagram for
For bottom cam (CW):(valveclosed stroke) proper wiring.
1. Loosen the set screw in the bottom cam. This can be 8 MAINTENANCE
done using a 1/16 hex wrench. NO PREVENTATIVE OR PERIODICMAINTENANCEOF THE
2. Move cam to desired stop position. Power terminals 2 ACTUATORISREQUIREDDURINGITSOPERATIONALLIFE.
and 4 or use the manual override to position valve until All rotating power train components are permanently lubri-
the valve is in the fullclosed position. cated with multi-purpose lithium grease suitable for the
3. Remove the power from the terminal. Rotate the cam in operating temperature range of the actuator.
the direction of travel to the exact point where the limit
switch "clicks"closed.Tighten the set screw.
4. Check range of motion. If valve does not fully open or
close, repeat steps 1-3 for the corresponding cam.
A ball valve is fully open when the hole in the ball is in the
center of the valve body waterway.
A butterfly valve is fully open when the disc is perpendicular
to the valve body flange.
3
CAUTION: Usethe correct parts. Failureto do so could result

in improper operation or personal injury. Contact your
Metso Automation distributor for authentic replacement
parts.
ACactuator are equipped with thermal overload protection.
If the actuator does not run, allow to cool before operating.
9 TROUBLESHOOTING Counter-Clockwise
CCW Cam
9.1 PROBLEM:
Motorwill not run.
1.
POSSIBLE SOLUTIONS:
Check incoming voltage as it enters terminal 2,3, and \

~
4.
2. Check that all connections are tight.
3. Review the cam adjustment section to ensure that
the cams are set correctly.
4.
I
Visually inspect the motor board and capacitor for
discoloration (burnt circuits).
5. If motor is hot, allow it to cool.
6. If these steps fail to identify the problem, contact the
distributor in your area. Clockwise
9.2 PROBLEM: Motor runs, but output shaft does CW Cam
notturn.
Figure 1
POSSIBLESOLUTION:
1. Check that the manual override is not pushed down.
WIRING DIAGRAM
Motor & Gearbox
Motor Board
Heater
Clockwise Limit
Counterclockwise Limit
Clockwise Hot
Option
Connector
Motor
J3
~
r;-.,
Counterclockwise Hot Connector ~ Brake Solenoid
AC Common Brake r;-..
AC Hot Option
Connection ~
E10
E11
J4 E12
To Control Board
Figure 2
101856 jEEJE r I~~
unter-Clockwise (Upper)
mit Switch
10 REPAIRKITS/SPAREPARTS
Forfurther information or assistance on repair kitsand spare
parts call 1-800-626-5965 for the number of your nearest
distributor or the Metso Automation Service Center. You
may also visit our website at www.jamesbury.com.
-,",
4
T
ASSEMBLYDRAWING
Spare Parts List

Item No. Description
1 Cover with screws
2 Override shaft
3 Limit switch
4 Cam with set screw
5 Capacitor with wires
6 Motor board with screws
7 Brake
Option Kits
8 2 extra limit switches
10 9 Terminal block
7
E / 10 Heater Thermostat
6
TITI
~ ~~
Figure 3

Europe, Levytie 6, P.O.Box 310,00811 Helsinki, Finland.Tel.int +35820483.150. Fax int.+358 20 483151
Europe (UKI.8 Pipers Wood Industrial Park, Waterlooville, Hampshire PO7 7XU UK. Tel. int +44 (0)23 9223 8500. Fax int.+44 (0)23 9223-8510
North America, 44 Bowditch Drive, P.O.Box 8044, Shrewsbury, Massachusetts, 01545-8044 USA.Tel. int. + 1 5088520200. Fax int.+l 5088528172
North America, 3100 Medlock Bridge Road,Suite 250, Norcross,GA 30071, USA.Tel.int.+l 7704467818. Fax int.+l 7702428386
Latin America, Av. Central, 181- Characas Reunidas, 12238-430, Sao Jose dos Campos. Tel. into +55 123353500. Fax into +55 123353535
Asia Pacific, 501 Orchard Road, #05-09 Wheelock Place, 238880 Singapore. Tel into+657355200. Fax into+657352955
www.jamesbury.com . www.metsoautomation.com
~ metso
V automation
@ 2001 Metso Automation Printed in U.s.A.-M-L
IMO - 593ES
Fecha de publicacin: 2/04
INSTRUCCIONES DE INSTALACIN,
MANTENIMIENTO Y OPERACIN
ACTUADORES
ELCTRICOS ERV
PARA 115 Y 230 VCA
Lea todas las instrucciones detenidamente antes de la instalacin o el servicio
1 GENERAL 1.2 PRECAUCIN

Este instructivo contiene informacin importante acerca de la SIEMPRE QUE SE VAYA A RETIRAR UN ACTUADOR DE LA VLVULA PARA
instalacin, operacin y solucin de problemas de los actuadores MONTARLA POSTERIORMENTE, DEBEN VERIFICARSE LOS AJUSTES DEL
elctricos ERV Jamesbury para 115 y 230 VCA. Lea estas INTERRUPTOR DE LMITE DE CARRERA PARA ASEGURARSE QUE LA
instrucciones cuidadosamente y gurdelas para posterior VLVULA EST DESPLAZNDOSE LA LONGITUD ADECUADA. MENCIONE
referencia. ESTE IMO PARA INSTRUCCIONES DE AJUSTE DE LA LEVA AL DAR
MANTENIMIENTO A UN CONJUNTO VLVULA/ACTUADOR, LA MEJOR
PRCTICA ES RETIRAR DE SERVICIO TODO EL CONJUNTO. CONSULTE LAS
Los actuadores de la serie ERV de Jamesbury estn diseados
INSTRUCCIONES SOBRE LA INSTALACIN Y EL MANTENIMIENTO DE LA
para proporcionar una operacin confiable y eficiente de VLVULA ANTES DE RETIRARLA DE LA LNEA.
vlvulas de 1/4 de vuelta. El rango soportado de torque para su
accionamiento est entre 12 y 250 LBPIE (16.3 y 339 Nm). La
serie ERV est disponible en modelos de CA con un ciclo de
servicio de 75% y en modelos de CC con un ciclo de servicio de 1.3 Informacin tcnica general
100%. Estas unidades estn disponibles para 115 o 230 VCA. Este
manual slo se aplica a los modelos de 115 y 230 VCA. Hay varias Los actuadores de CA de la serie ERV usan un motor de induccin
opciones y accesorios para ampliar la versatilidad del ERV. Su reversible. Todos los actuadores de la serie ERV tienen
instalacin es sencilla y su confiabilidad es alta. capacidades de control manual.
1.4 Operacin
Un ciclo de servicio de 75% significa que por cada ciclo de
operacin en que el actuador est ENCENDIDO (para abrir o
1.1 ADVERTENCIA
cerrar la vlvula), debe estar apagado un tiempo igual a un
ANTES DE RETIRAR LA CUBIERTA, APAGUE TODA ALIMENTACIN cuarto del ciclo de operacin. Por ejemplo: Si el tiempo del ciclo
ELCTRICA Y DESCONECTE TODAS LAS CONEXIONES. PARA EVITAR LA de operacin es 15 segundos, por cada ciclo de operacin que el
IGNICIN EN ATMSFERAS PELIGROSAS, DESCONECTE EL CIRCUITO DE
actuador est ENCENDIDO, debe estar APAGADO 5 segundos.
ALIMENTACIN ANTES DE ABRIR LA UNIDAD. MANTENGA LA UNIDAD
HERMTICAMENTE CERRADA DURANTE LA OPERACIN. PARA MANTENER
Exceder el ciclo de servicio de los actuadores puede causar que
LA CALIFICACIN DE UBICACIN PELIGROSA DEL ACTUADOR ERV, ES el interruptor de proteccin trmica por sobrecarga corte
ESENCIAL PROTEGER LAS SUPERFICIES DE CONTACTO DE LAS BRIDAS temporalmente la energa al motor. Una sobrecarga continua
CONTRA HENDIDURAS Y RAYONES DURANTE SU DESENSAMBLAJE. AL puede quemar el motor.
REENSAMBLAR, NO DEBE HABER NINGUNA SUCIEDAD NI PARTCULAS EN
LAS SUPERFICIES DE CONTACTO NI EN LAS BRIDAS. El rango de temperatura de operacin es desde -40 a 150 F
(-40 C a 65.5 C), pero se recomienda usar un calentador
opcional por debajo de +40 F (4.5 C).
2
2 INSTALACIN Para la leva superior (Sentido antihorario):
Monte estos actuadores siguiendo las instrucciones de montaje 1. Afloje el tornillo de ajuste en la leva superior. Esto puede
del actuador (AMI) contenidas en el juego del mecanismo. Para hacerse con una llave hexagonal de 1/16 (1.6 mm).
obtener un copia de estos AMIs, contacte con su distribuidor de
Metso Automation ms cercano o visite nuestro sitio web en 2. Mueva la leva a la posicin de parada deseada. Aplique
www.jamesbury.com. energa a los terminales 2 y 3 o use el control manual hasta
que la vlvula est en la posicin completamente abierta.
3 INSTRUCCIONES DE CONTROL MANUAL
3. Corte la energa a los terminales. Gire la leva en la direccin
Todos los actuadores elctricos de la serie ERV tienen una de desplazamiento hasta el punto exacto en que el
interruptor de lmite de carrera abra haciendo clic. Apriete el
caracterstica de control manual. Para activar el control manual,
tornillo de ajuste.
empuje el eje de control manual hacia abajo aproximadamente
1/4 de pulgada para desenganchar el motor del tren de Para la leva inferior (sentido horario):
engranajes. Si no desengancha el motor antes de activar el
control manual, daar el actuador. Mientras sostiene el eje hacia 1. Afloje el tornillo de ajuste en la leva inferior. Esto puede
abajo, gire el eje con una llave o palanca hasta la posicin hacerse con una llave hexagonal de 1/16 (1.6 mm).
deseada. El eje de control manual en los actuadores ERV 12, 25 y
2. Mueva la leva a la posicin de parada deseada. Aplique
51 debe girarse en la direccin opuesta al eje de salida. En los
energa a los terminales 2 y 4 o use el control manual hasta
actuadores ERV 83, 125, 167, 208 y 250, los ejes de control manual
que la vlvula est en la posicin completamente abierta.
y de salida giran en la misma direccin.
3. Corte la energa a los terminales. Gire la leva en la direccin
No trabaje el actuador ms all de los ajustes del interruptor de de desplazamiento hasta el punto exacto en que el
lmite de carrera; es posible daar las opciones instaladas, como interruptor de lmite de carrera abra haciendo clic. Apriete el
el potencimetro de retroalimentacin. El eje de control manual tornillo de ajuste.
debe ser regresado a su posicin totalmente hacia arriba antes
que el motor sea enganchado nuevamente. Gire el eje 4. Verifique la amplitud del movimiento. Si la vlvula no se abre
ligeramente para alinear los engranajes de dientes rectos hasta o cierra completamente, repita los pasos 1-3 para la leva
que el eje salte de regreso a su posicin enganchada. correspondiente.
Una vlvula de bola est completamente abierta cuando el

4 INSTRUCCIONES DE AJUSTE DE LA LEVA agujero en la bola est en el centro del curso del flujo del cuerpo
de la vlvula.
Para fijar la posicin de arranque y parada de los actuadores, siga
los pasos indicados a continuacin (Vea la Figura 1): Una vlvula de mariposa est completamente abierta cuando el
disco est perpendicular a la brida del cuerpo de la vlvula.
PRECAUCIN: Los actuadores de CA de Jamesbury son motores

de induccin reversibles que producen altos voltajes. Los
dispositivos conectados a los terminales 3 y 4 deben tener
Leva de sentido capacidad para 250 VCA por lo menos (440 VCA para aplicaciones
antihorario de 230 VCA). Debido al voltaje inducido de retroalimentacin, no
pueden conectarse multiple actuadores en paralelo. Deben
proporcionarse terminales separados (contactos aislados) para
cada actuador.
5 ACCESORIOS OPCIONALES
1. Potencimetro de retroalimentacin - Instrucciones
disponibles de la fbrica.
2. Regleta de terminales de seis posiciones - Instrucciones

Leva de sentido 3. Volante - Instrucciones disponibles de la fbrica.

horario
4. Regleta de terminales de doce posiciones - Instrucciones
Figura 1
5. Dos interruptores de lmite de carrera adicionales -
Instrucciones disponibles de la fbrica.
3
DIAGRAMA DE CABLEADO
Condensador
del motor Motor y caja de engranajes
Sentido
antihorario: Rojo
Conector del motor Ret: Negro
Lmite de sentido horario Sentido horario: Blanco
Lmite de sentido antihorario Conector de
Sentido horario vivo calentador opcional Calentador
Sentido antihorario vivo Conexin de Solenoide de freno
Comn de CA freno opcional
CA vivo
Marrn
Rojo Com. Interruptor de lmite de carrera de
J4 Naranja N.O.
N.F. Sentido horario (inferior)
a tablero de control
Amarillo
Verde Com. Interruptor de lmite de carrera de
Azul N.O. Sentido antihorario (superior)
N.F.
Figura 2
6 CARACTERSTICAS DEL TABLERO DEL Los actuadores de CA cuentan con proteccin trmica por
sobrecarga. Si el actuador no funciona, espere que se enfre antes
MOTOR Y FUNCIONES DEL BLOQUE DE
de operarlo.
TERMINALES
El tablero del motor en los actuadores de la serie ERV tiene varias 9 SOLUCIN DE PROBLEMAS
funciones a las que puede accederse mediante prcticos
conectores (Vea la Figura 2). 9.1 PROBLEMA: El motor no funciona.
Terminal 1: SOLUCIONES POSIBLES:
Suministra energa al calentador opcional y al termostato.
1. Verifique el voltaje de entrada en los terminales 2, 3 y 4.
Terminales 2, 3 y 4:
Energa suministrada para la operacin bsica del actuador. Para
2. Verifique que todas las conexiones estn apretadas.
aplicaciones de encendido/apagado, y arranques y paradas
frecuentes, el actuador es controlado por energa de CA,
3. Revise la seccin sobre el ajuste de la leva para asegurarse
suministrada por el usuario ya sea a los terminales 2 y 3 para control
que las levas estn fijadas correctamente.
de sentido antihorario, y al 2 y 4 para control de sentido horario.
Terminales 5 y 6: 4. Inspeccione visualmente si hay seales de decoloracin en el

Estos son voltajes indicadores de la posicin de la salida de la tablero del motor y el condensador (circuitos quemados).
lnea. El terminal 5 es el voltaje lmite de sentido antihorario y el
terminal 6 es el voltaje lmite de sentido horario. 5. Si el motor est caliente, deje que se enfre.
6. Si despus de seguir estos pasos, no puede identificar el

7 INSTRUCCIONES DE OPERACIN problema, contacte con su distribuidor Jamesbury ms
cercano.
Voltaje de operacin normal para un actuador elctrico: 115 VCA,
230 VCA, o segn se indique en el actuador. Realice el cableado de
acuerdo con el diagrama de cableado. 9.2 PROBLEMA: El motor funciona, pero el
eje de salida no gira.
8 MANTENIMIENTO
SOLUCIN POSIBLE:
NO SE REQUIERE DAR MANTENIMIENTO PREVENTIVO NI
PERIDICO AL ACTUADOR DURANTE SU VIDA TIL. 1. Verifique que el control manual no est presionado hacia
abajo.
Todos los componentes giratorios del sistema de transmisin estn
lubricados en forma permanente con grasa de litio multiuso, 10 JUEGOS PARA REPARACIN/PARTES DE
adecuada para el rango de temperatura de operacin del actuador. REPUESTO
PRECAUCIN: Use los componentes correctos. No hacerlo Para mayor informacin o ayuda tcnica sobre los juegos de
podra causar una operacin inadecuada o lesiones personales. reparacin y las partes de repuesto, visite nuestro sitio web en
Contacte con su distribuidor de Metso Automation para obtener www.jamesbury.com.
partes de repuesto originales.
4
DIBUJO DE CONJUNTO
Lista de partes de repuesto

1 tem No. Descripcin
1 Cubierta con tornillos
2 Eje de control manual
3 Interruptor de lmite de carrera
4 Leva con tornillo de ajuste
5 Condensador con alambres
6 Tablero de motor con tornillos
7 Freno
Juegos opcionales
8 2 interruptores de lmite de
carrera adicionales
10 9 Bloque de terminales
10 Termostato del calentador
8
2
6
3 4
Figura 3

Europe (UK), 2 Lindenwood, Crockford Lane, Chineham Business Park, Basingstoke, RG24 8QY UK.Tel. int. +44 (0) 8706 061478. Fax int. +44 (0) 1256 707661
Latin America, Av. Central, 181- Chracas Reunidas, 12238-430, So Jose dos Campos. SP BRAZIL. Tel. int. +55 12 3935 3500. Fax int. +55 12 3935 3535
www.jamesbury.com
IMO-593ES-2/04 2004 Metso Automation Printed in U.S.A.-J-J

How to order
~eroquip
0
Coupling
Tube sizes over 4.50" 114.3mm
(Pipe sizes over 4.00" 101.6mm )
Coupling
(Tube sizes thru 4.50. 114.3mm
~I
~
/ Pipe sizes thru 4.00.)
t)'
~c
II
Gasket
Retainer II
Standard (Un-Restrained) Style
Coupling
(Tube sizes thru 4.50" 114.3mm ,
Pipe sizes thru 4.00")
/ ~I
Sleeve
I Self-Restrained
Gasket Gasket
Retainer
Self-Restrained Style
NH16XX ( ) 000 ( ) 0000 ~

Basic Part Number (from pages 10 - 17) ~ T T T ~int Length (in thousands of inch).
Example: NH1600 L J~~amPle: 2.5" = 0250
Style is available in lengths shown. Other lengths
Gasket Material: are available in multiples of 1-inch on special
C = Buna-N(Standard) requests. Contact Aeroquip for availability.
D = EPDM
. N = BUNA-N(High Temperature) Sleeve Material:
.. VS == Silicone
Fluorocarbon
B = Plated Steel (Standard)
S = Stainless Steel (Sleeve only-
. G = Mineral Fiber consult Aeroquip for availability)
(EXHAUST APPLICATIONS
NOT SUBJECT TO FLEXING) Size of Pipe or Tube to be connected:
. Available in Standard (Un-Restrained) Model Only. (in hundredths of inch) Example: .75" = 075
<Y
Example Part Number: NH1600CO75BO250
Complete assemblies may be ordered by the proce-

dure shown above. Standard components may be
ordered as shown on page 7.
6
=-\eroquip Joints for rigid pipe
Basic part number NH1600

NH1650
Dimensions: inches in bold j,
mm in light Allowable misalignment: :t4' per end
I I
Pipe Pipe Straight

Size 0.0. B C Part Number' A
.38 .675 1.48 2.34 **NH1600X038X0200 2.00
17.1 37.6 59.4 - 50.8
.50 I .840 1.65 2.53 NH1600X050X0225 2.25
21.3 41.9 64.3 NH1650X050X0225 57.2
.75 I 1.050 1.86 2.75 NH1600X075X0250 2.50
26.7 47.2 69.9 NH1650X075X0250 63.5
1.00 I 1.315 2.37 3.48 NH1600X100X0288 2.88
33.4 60.2 88.4 NH1650X100X0288 73.2
1.25 I 1.660 2.71 3.85 NH1600X125X0325 3.25
42.2 68.8 97.8 NH1650X125X0325 82.6 I
1.50 I 1.900
48.3
2.96
75.2
4.11
104.4
NH1600X150X0350
NH1650X150X0350
3.50
88.9 I
01
2.00 I 2.375 3.43 4.60 NH1600X200X0400 4.00
60.3 87.1 116.8 NH1650X200X0400 101.6
2.50 I 2.875 4.73 6.23 NH1600X250X0650 6.50
73.0 120.1 158.2 NH1650X250X0650 165.1
3.00 I 3.500 5.36 6.87 NH1600X300X0650 6.50
88.9 136.1 174.5 NH1650X300X0650 165.1
3.50 I 4.000 5.86 7.38 NH1600X350X0650 6.50
101.6 148.8 187.5 NH1650X350X0650 165.1
4.00 I 4.500 6.36 7.89 NH1600X400X0650 6.50
114.3 161.5 200.5 NH1650X400X0650 165.1
5.00 I 5.563 8.22 10.62 **NH 1600X500X0650 6.50
141.4 208.8 269.7 NH1650X500X0650 165.1 I
6.00 I 6.625
168.3
8.86
225.0
11.24
285.5
**NH1600X600X0650
NH1650X600X0650
6.50
165.1 I
0'
NOTE: Letter X in part numbers shown indicates a code letter to . self-restrained
Red part numbers are standard type. Black part numbers are
type.
be filled in. See page 6 for explanation of part numbers and how
to order. ..Sleeve in this size is cylindrical (no-bulge).Allowable
misalignment is ::1::2'per end for this size.
(t
10
{)
Basic part number: NH1600 (Long) Basic part number: NH1601

Dimensions: inches in bold NH1650 (Long) NH1651
ro mm in light
I
Allowablemisalignment::t4 per end
Straight
Allowable misalignment: :t2 per end
Pipe Pipe Double-Bulged 45 Long Elbow

Size O.D. Part Number. Et Part Number. L R
.38 .675 HNH 1600X038X0200 2.00 NH1601X038X 4.16 .88
17.1 - 50.8 - 105.7 22.3
.50 I .840 NH1600X050X0350 3.50 NH1601X050X 4.37 1.06
21.3 NH1650X050X0350 88.9 NH1651X050X 111.0 26.9
.75 I 1.050 NH1600X075X0400 4.00 NH1601X075X 5.33 1.31
26.7 NH1650X075X0400 101.6 NH1651X075X 135.4 34.3
1.00 I 1.315 NH1600X100X0450 4.50 NH1601X100X 5.77 1.62
33.4 NH1650X100X0450 114.3 NH1651X100X 146.6 41.1
1.25 1.660 NH1600X125X0550 5.50 NH1601X125X 5.97 1.88
I 42.2 NH1650X125X0550 139.7 NH1651X125X 151.6 47.8
1'0 I
1.50 1.900
48.3
NH1600X150X0575
NH1650X150X0575
5.75
146.1
NH1601X150X
NH1651X150X
6.18
157.0
2.12
53.8
2.00 2.375 NH1600X200X0675 6.75 NH1601X200X 6.40 2.62
60.3 NH1650X200X0675 171.5 NH1651X200X 162.6 66.5
2.50 I 2.875 NH1600X250X01125 11.25 NH1601X250X 7.26 3.25
73.0 NH1650X250X01125 285.8 NH1651X250X 184.3 82.6
3.00 I 3.500 NH1600X300X01125 11.25 NH1601X300X 8.54 5.00
88.9 NH1650X300X01125 285.8 NH1651X300X 216.9 127.0
3.50 I 4.000 NH1600X350X01125 11.25 NH1601X350X 9.18 6.00
101.6 NH1650X350X01125 285.8 NH1651X350X 233.1 152.4
4.00 I 4.500
114.3
NH1600X400X01125
NH1650X400X01125
11.25
285.8
NH1601X400X
NH1651X400X
9.82
249.4
7.00
177.8
5.00 5.563 HNH 1600X500X0650 6.50
141.4 NH1650X500X0650 165.1
6.00 6.625 HNH 1600X600X0650 6.50
fQ I 168.3 NH1650X600X0650 165.1
NOTE: Letter X in part numbers shown indicates a code letter to be filled
in. See page 6 for explanation of part numbers and how to order.
. Red part numbers are standard type.
restrained type.
Black part numbers are self-
.. Sleeve In this size Is cylindrical {no-bulge}. Allowable misalignment Is
:1:2per end for this size.
t Straight. Double-Bulged joints are available In longer lengths than "E"
shown in increments of 1 inch. Consult Aeroqulp. "E" dimension is
minimum length for longer joints.
~
~eroquip
BULLETIN NO. 120/02
(Supersedes 120/01)
Mid-West
Instrument

Model 120 Series Filter Minder

Piston-Type Differential Pressure Gauge
MEDIUM RANGE: 0-5 P.S.I.D. to 0-110 P.S.I.D. (0.35 to 7.0 bar)
A low cost differential pressure gauge for use
in measuring the pressure drop across filters,
strainers, separators, valves, pumps, chillers,
etc., and for local flow indication and control.
Simple, rugged, compact design.
Working pressure 6000 P.S.I.G. (400 bar)
models 120-A and 120-S.
Working pressure 5000 P.S.I.G. (340 bar)
models 120-M and 120-N.
Over-range protection to max. pressure.
Aluminum or 316 stainless steel housing
with 316 stainless steel internals.
Monel or Aluminum Bronze housing with
monel internals.
Weather-resistant construction standard.
Accuracy +3-2-3% full scale (ascending).
Shatter resistant lens.
More cost effective and more accurate than 2-1/2" Plastic Dial Assy.
using two pressure gauges in monitoring
differential pressure.
3-1/2" and 4-1/2" annodized aluminum dial assemblies.
2-1/2" and 4-1/2" plastic dial assemblies. Uni-directional or bi-directional.
Five Year Limited Warranty
Differential pressure is sensed by the movement of a floating piston

magnet against a calibrated spring. The gauge pointer, outside the
pressure housing, follows the movement of the piston magnet and
indicates differential pressure.
Available with magnetically actuated hermetically sealed CSA listed
reed switches to provide high and low limit alarm or control.
4-1/2" Plastic Dial Assy
An optional maximum indication follower pointer provides automatic

indication of maximum differential occuring during a time period or
system cycle.
Reversed pressure ports are optionally available to facilitate
installation and readability depending on which side of a filter, etc.,
the instrument must be installed. 2-1/2" Plastic Dial Assy. w/Max.
Follower Pointer
Why use a dp gauge like this, instead of one or two
pressure gauges to monitor a filter? Let's take a
typical filter application 1000 P.S.I.G. system
pressure and 25 P.S.I.G. maximum dp. Two 1%
accuracy pressure gauges (0-2000 P.S.I.G.) could
have a combined error of +40 P.S.I.G. (more than the
maximum allowable dp!) A 0-50 P.S.I.D. Model 120
would have an error of +1 P.S.I. at a reading of 25
P.S.I.D., 40 times the accuracy of more costly
pressure gauges!
NOTE: Due to precision sizing of piston and body
bore, leakage across the piston will not
exceed 15 SCFH air at 100 P.S.I.D. at
ambient conditions.
Cutaway View w/1/4" FNPT Back Connections

Model 120 Filter Minder
Differential Pressure Gauge with Control Switching
The Model 120 Filter Minder gauge is available with one or two hermetically sealed
reed switches.The switches are adjustable (see table for adjustment range) within a
defined percentage of the full scale range of the gauge and are available in SPDT and
SPST, normally open or normally closed configurations for various load power ratings.
The switches can be set to activate or deactivate on rising or falling pressure.
All hazardous location switches are CSA & UL Listed.The CSA & UL listings are for
the entire design and not just the enclosure. All standard and weatherproof units are
CE marked for conformance with the Low Voltage Directive to harmonized standard
EN 61010-1.
The standard reed switch is enclosed in a weather-resistant plastic housing.
Adjustment of the switch setting is made with an external screw adjustment.
The switch functionality will be different for gauges with bi-directional operation for
Standard Enclosures for two (2) Switches positive and negative delta pressure. For example a SPDT switch with positive P
w/1/4" FNPT Conduit Connection. applied to the gauge, the red wire will be N.O. and the black will be N.C.. For negative
Nema 4X /IP65 P the functionality will be reversed.
Location for a single SPDT (grommet or conduit) switch will be on the bottom of the gauge body for a
normal port and on the top for a reverse port. Locations for a single SPST (grommet or conduit) N.O.
or SPST N.C. switch will be on the bottom and top respectively for a normal port gauge.The locations
will be reversed for a reverse port gauge. For more details request IM 120/latest.
A non-indicating (no dial) differential pressure switch is also available.
Special Switch Enclosures

1 Hazardous Locations Division 1:
CSA & UL listed design with SPST 1 2
or SPDT switches in NEMA 7/9
enclosure approved for use in Class UL
1 Division 1, Groups C & D; Class 2, LISTED
Division 1, Groups E, F, & G atomospheres.

2 Hazardous Locations Division 2:
CSA & UL listed design with SPST
or SPDT switches in a general
purpose enclosure approved for use UL

in Class 1, Division 2, Groups LISTED

A, B, C, & D; Class 2, Division 2,
Groups F & G atmospheres.
3
3 Weatherproof:
Switch(es) and gauge are
enclosed in a non-corrosive, molded, plastic
enclosure that are oil-tight, dust-tight, and
water-tight per NEMA 4X. Design is CE
marked for conformance to the Low Voltage
Directive.
Reed Switch Ratings
(Resistive Load)
Type SPST SPST SPDT SPDT
Option: B,C,D*** E,F,G H A Red (Normally Open)
*Power 50 W 60 W 60 W 3W
Max. Current 0.5 Amps 3.0 Amps 1.0 Amps 0.25 Amps
Switch
Max. Voltage Shown at White (Common)
240 240 240 125
VAC/VDC Zero
**Setting (%F.S.) 10 to 100 25 to 95 25 to 100 10 to 90 Pressure Black (Normally Closed)
Hysterisis 10% / 2% 15% / 8% 20% / 13% 10% / 5%
(Max/Nom) (F.S.) (F.S.) (F.S.) (F.S.)
Repeatability 1% F.S. 1% F.S. 1% F.S. 1% F.S.
Leads 22 Awg. (2), 24" (2), 24" (3), 24" (3), 24"
*Product of the Switching Voltage & Current shall not exceed power rating of the device.
**Except where otherwise noted.
***B, C, & D options are available, however they are not identified in Electrical
Specifications. (Recommend using E, F, or G)
STANDARD MODEL SPECIFICATIONS

120-AA-00-OO
6000 P.S.I.G. Working Pressure Aluminum Body, Stainless Steel Piston, Ceramic
Magnets, Buna N Seals, 2-1/2" Engineering Plastic Case with Shatter-Resistant Lens.
1/4" FNPT Back Connections. Accuracy +3-2-3% Full Scale (Ascending).
PART NUMBERING SYSTEM

1 2 0
OPTIONS (Up to four options)

O. None (Standard)
BASIC MODEL NUMBER A.
B.
Reversed High/Low Process Connections
DIN2353 12-S (12mm) Steel Tube Fittings (2)
C. Mounting Holes in Gauge Body for Field Mounting of Electrical Configurations Options A & B
MATERIAL
A. Aluminum Body, S.S. Piston (Standard)
D.
F.
Mounting Holes in Gauge Body for Field Mounting of Electrical Configurations Options L & M
Pipe Mounting Kit (Carbon Steel) (Not available w/C or D Electrical Switch Options)
L. Liquid Fill (Not available w/follower pointer) (Not available with 3-1/2" dial)
M. Monel Body (See 120 ABM) (5000 P.S.I.G. working pressure)
M. Maximum Indicator Follower Pointer
N. Aluminum Bronze Body (See 120 ABM) (5000 P.S.I.G. working pressure)
T. Oxygen Cleaning
S. 316 S.S. Body & S.S. Piston (Standard)
U. S.S. Tag Mounted w/S.S. Wire
Z. SPECIAL (Uncoded Options)
V. S.S. Tag Mounted w/S.S. Screws
DIAL TYPE
A. 2-1/2 Round Uni-Directional Engrd. Plastic Housing Assy. (Standard)
W.
X.
Wall Mounting Kit
Individual Gauge Packaging
Z. Special (Uncoded Options)
B. 2-1/2 Round Bi-Directional Engrd. Plastic Housing Assy.
C. 4-1/2 Round Uni-Directional Engrd. Plastic Housing Assy.
D. 4-1/2 Round Bi-Directional Engrd. Plastic Housing Assy.
E. 3-1/2 Round Uni-Directional Anod. Aluminum Housing Assy.
F. 3-1/2 Round Bi-Directional Anod. Aluminum Housing Assy.
G. 4-1/2 Round Uni-Directional Anod. Aluminum Housing Assy.
(Up to three options)

H.
T.
4-1/2 Round Bi-Directional Anod. Aluminum Housing Assy.
Non-Indicating Differential Pressure Switch Only (Select Appropriate Electrical Option) ELECTRICAL CONFIGURATIONS
(NOTE: All options marked, except E, F, J & K)
O. None
A. One (1) Switch in STD. Enclosure with Grommet Wire Seal
B. Two (2) Switches in STD. Enclosures with Grommet Wire Seal
C. One (1) Switch in STD. Enclosure with 1/4 FNPT Electrical Connection NEMA 4X
SEALS
0. Buna N (Standard)
D.
E.
Two (2) Switches in STD. Enclosures with 1/4 FNPT Electrical Connection NEMA 4X
One (1) Switch in General Purpose Enclosure, C.S.A. & U.L. Listed, Division II Locations (1) (3)
1. Viton F. Two (2) Switches in General Purpose Enclosure, C.S.A. & U.L. Listed, Division II Locations (1) (3)
2. Neoprene G. One (1) Switch & Gauge in NEMA 4X Plastic Enclosure (Not Available With End Connections)
4. Teflon H. Two (2) Switches & Gauge in NEMA 4X Plastic Enclosure (Not Available With End Connections)
J. One (1) Switch in Explosion Proof Enclosure with Glass Window Cover and C.S.A. & U.L. Listing (2)

5. Ethylene Propylene
6. Perfluoroelastomer K. Two (2) Switches in Explosion Proof Enclosure with Glass Window Cover and C.S.A. & U.L. Listing (2)
9. Special (Uncoded Options) L. One (1) Switch in STD. Enclosure with Plug-In Connector (DIN 43650/IP65-PG11)
*Viton is a Registered Trademark of DuPont Dow Elastomers. M. Two (2) Switches in STD. Enclosure with Plug-In Connector (DIN 43650/IP65-PG11)
**Teflon is a Registered Trademark of DuPont. Z. Special (Uncoded Options)
(1)
Complete Assembly Rated Class I, Div. II, Groups A, B, C, & D; Class II, Div. II, Groups F and G.
(2)
Complete Assembly Rated Class I, Div. I, Groups C & D; Class II, Div. I, Groups E, F, & G.
(3)
5000 PSIG Working Pressure.
CONNECTIONS
(NOTE: Models 120M and 120N available only with end connections)
0.
2.
1/4" FNPT Back Connections (Standard)
1/4" FNPT End Connections
ELECTRICAL SPECIFICATIONS (For Resistive Loads)
A. S.P.D.T., 3W, 0.25 Amp., 125 VAC/VDC (Standard) (Switch adjustable range of 10-90%)
6. 7/16" - 20 Str. Thd. O-Ring Port (Back Connections) E. S.P.S.T., 60W, 3.0 Amp., 240 VAC/VDC (Normally Open) (Switch adjustable range of 25-95%)
7. 1/2" FNPT Stainless Steel Adaptors F. S.P.S.T., 60W, 3.0 Amp., 240 VAC/VDC (Normally Closed)
8. 1/2" FNPT Monel Adaptors (Switch adjustable range of 25-95%)
9. Special (Uncoded Options) G. S.P.S.T., 60W, 3.0 Amp., 240 VAC/VDC One (1) Normally Open, One (1) Normally Closed (4)
H. S.P.D.T., 60W, 1.0 Amp., 240 VAC/VDC (Switch adjustable range of 25-100%)
(4)
Available with Electrical Configurations B, D, F, H, K and M only.
NOTE: NOT ALL OPTIONS AVAILABLE IN COMBINATION WITH OTHER OPTIONS.
NOTE: FACTORY PRESET SWITCHES AT NO CHARGE (SPECIFY SETTING)
NOTE: THE USE OF DIAPHRAGM SEALS IS NOT RECOMMENDED FOR MODEL 120 SERIES GAUGE.
ATTEMPTS TO INSTALL SUCH SEALS ON THIS GAUGE WILL VOID THE WARRANTY.
MOUNTING INFORMATION & DIMENSIONAL DATA
MODEL 120: 2-1/2" INCH PLASTIC DIAL ASSY.
MODEL 120: 4-1/2" INCH PLASTIC DIAL ASSY.
NOTES: 1. Drawings show standard gauge nominal dimensions. (not to scale)

2. Dimensions shown in parentheses are in millimeters.
3. Mounting dimensions for 3-1/2" & 4-1/2" alum. Dial assys. Contact Factory
Manufacturer reserves the right to change specifications without prior notice.
PROOF PRESSURE: 12,000 PSI for models 120-A and 120-S.

10,000 PSI for models 120-M and 120-N.
TEMPERATURE LIMITS: -40F(-40C) to +200F(+93C) - These limits are based on the entire instrument
being saturated to these temperatures. System (process) temperatures may exceed these limitations with
proper installation. Contact our customer service representative for details.
STANDARDS: All Model 120 Series differential pressure gauges either conform to and/or are designed to
the requirements of the following standards:
ASME B1.20.1 NACE MR0175
ASME B40.1 NEMA Std. No. 250
CSA-C22.2 No. 14.25 and 30 SAE J514
EN-61010-1 UL Std. No. 50,508 and 1203
Mid-West
Instrument

R E P R E S E N T E D B Y:
6500 Dobry Dr. Sterling Heights, MI 48314 U.S.A.

(586) 254-6500 FAX (586) 254-6509
E-mail: sales@midwestinstrument.com
Website: www.midwestinstrument.com
Printed in U.S.A.
BULLETIN NO.ELEC IM120/02A

Mid-West
SUPERSEDES ELEC IM120/02
Instrument
Model 120 Electrical: Installation and Operating Instructions
ELECTRICAL Red (Normally Open)
Switch
Gauges with switches have one or two hermetically sealed Shown at White (Common)
adjustable set point reed switch assemblies. Load ratings and Zero
capabilities for each switch type are defined as follows: Pressure Black (Normally Closed)
Figure 1
REED SWITCH RATINGS (Resistive Load)
Type SPST SPST SPDT SPDT
Use the Mid-West Power Relay 1000TR or equivalent relay
for loads above the switch rating,.
Option: B,C,D *** E ,F,G H A
*Power 50 W 60 W 60 W 3W The following warnings apply to all gauge options with
Max. Current 0.5 Amps 3.0 Amps 1.0 Amps 0.25 Amps electrical interface:
Max. Voltage 240 240 240 125
VAC/VDC
WARNING: ELECTRICAL CONNECTIONS SHOULD
**Setting 10 to 100 25 to 95 25 to 100 10 to 90
BE PERFORMED BY QUALIFIED
( %F.S.)
PERSONNEL AND MEET THE
Hysterisis 10% / 2% 15% / 8% 20% / 13% 10% / 5%
REPRESENTATIVE COUNTRY'S
(Max/Nom) (F.S.) (F.S.) (F.S.) (F.S.)
NATIONAL ELECTRICAL CODE.
Repeatability 1% F.S. 1% F.S. 1% F.S. 1% F.S.
WARNING: FAILURE TO CONNECT TO THE
PROTECTIVE CONDUCTOR TERMINAL
Leads 22 Awg. (2), 24 (2), 24 (3), 24 (3), 24
MAY RESULT IN A SHOCK HAZARD.
* Product of the switching voltage and current shall not Grommet Wire / FNPT Wiring Interface
exceed the power rating of the device.
** Except where otherwise noted The standard switch enclosure is weather resistant with 24"
*** B,C,& D options are available, however they are not flying lead wire interface. A rubber grommet provides the
identified in Electrical Specifications. (Recommend seal around the wires (See Figure 2). (Options A & B)
using E, F, or G)
The conduit version provides a NEMA 4X rated
The SPDT switch ('A' or H Electrical Option) lead colors and environmental seal with a 1/4" FNPT wiring interface in the
associated functionality at '0' PSID is shown in Figure 1. rear center of the gauge body (See Figure 4).(Options C & D)
SPST switches (' E', 'F', or 'G' Electrical Options) may be
normally closed or normally open at '0' PSID dependent upon A provision to connect a protective conductor terminal is
the option specified on the purchase order. provided on the High port end of the gauge body. A 6-32
screw, 18 Awg, 24 " long, green/yellow wire, and a #6
All switch types are field adjustable. The defined range of the terminal is provided.
adjustment is specified in the table above. All switches
come with a decal to identify adjustment direction to increase Standard location of a SPDT switch will be on the bottom of
the set point. Do not use excessive force when rotating the gauge for a standard port gauge. For a reverse port
the adjustment screw as the adjustment mechanism gauge the switch will be on top. (See Figure 2). SPDT
may be damaged. Also note the location of the screw Switch leads are color coded and labeled as follows:
adjust (See Figure 4.) Do not mistake it for the
calibration adjust for the gauge. White- 1 or 2 Com
Black- 1 or 2 NC
Red - 1 or 2 NO
Note: Switches can be set below the defined minimum set
point however, the switch may not remain activated at Location for the SPST switch will vary depending on the
maximum PSID. If the unit is set below the defined minimum switch type required. A standard port gauge has the normally
set point, the customer should verify that the switch remains open switch located on the bottom of the gauge body and
activated from the set point to over range of the gauge. the normally closed switch located on the top. This applies
to both a single switch unit or a double switch unit with one of
Provide standard protection techniques for the switch each type ("G" option Electrical Specifications).
contacts for capacitive and inductive loads. Use current
limiting techniques near the switch to protect the contacts A reverse port gauge has the normally open switch located
due to high inrush (i.e.; in line resistor or inductor) for long on the top and the normally closed switch located on the
cable interfaces. Provide clamping devices at or near bottom. Leads are labeled as follows:
inductive loads (i.e.; relay). Maximum wire length between
the 3W switch and its load, should not exceed 70 100 Single Switch Unit: 1NC or 1NO
Feet. for 120 VAC applications. Contact the factory for Double Switch Units: 1NC or 1 NO and 2NC or 2NC
assistance regarding this condition.
Deviations from the above configurations may exist.
Therefore check the description block of your order to verify
your configuration.
DIN Plug- in Connector (Options L & M) Adjustment of the set point can be accomplished by removing
the switch adjustment access plug(s). Insert the screw driver
The DIN interface conforms to DIN 43 650A / ISO 4400 and through the hole into the switch adjustment slot and rotate
when mated provides an IP65 rated protection class. The until the desired set point is reached. Do not use excessive
right angle mating connector is supplied with the gauge upon force. Reinstall the access plugs with at least 5 threads
order. Clocking (orientation) can be changed by prying out of engagement after completion.
the insert and rotating the insert to the desired clocking (90
increments). (See Figure 5) Enclosures with SPDT or SPST switches comply with NEC
Class 1, Groups C & D; Class 2 Groups E,F, & G, NEMA 7
Wiring for the SPDT bottom and top switch for the defined and 9. All switches are CSA / NRTL listed.
port configuration is as follows:
Division II Hazardous Ratings (Options E & F):
Standard Port. - 1.- Common, 2. - N.C., 3. - N.O.
Reverse Port - 1. - Common, 2. - N.O., 3. - N.C. The E & F Electrical Configuration are CSA and U.L. certified
for Class I, Division II, Groups A, B, C, & D, Class II,
Wiring for the SPST switch is between terminals 1 & 2. Groups F & G hazardous environments All switches are
presently CSA /US listed (See Figure 8).
A protective conductor terminal is provided on the DIN
connector. Interface is 24, 18 Awg. flying leads with FNPT Conduit.
NEMA 4X (Weatherproof Enclosure) (Options G & H) MISCELLANEOUS
The gauge and switch(es) are mounted inside the enclosure Bi-directional Dial:
with the switch(es) wired to a seven (7) position terminal SPDT Switch units, with the bi-directional dial, require the
strip. The terminal strip connection uses 6-32 screws and is following setting instructions:
rated for use with wire up to 14 Awg.. An opening is provided
on the bottom of the enclosure for a 1/2" flexible cable or 1. If the switch is to operate for positive P, rotate the
conduit connection. adjusting screw Counter Clockwise (Red - NO,
Black- NC, White- Common).
Access the terminal strip by removing the cover from the 2. If the switch is to operate for negative P, rotate the
enclosure and loosening the (4) screws. Insert wires adjusting screw Clockwise (Red- NC, Black- NO,
through an appropriate weatherproof connector (not White -Common)
supplied) into the enclosure and connect to the terminal strip.
See the terminal strip diagram shown below or on the The functionality of SPST switches will be reversed for
outside of the switch enclosure. Reinstall the cover and (4) negative P and positive P. i.e.; a normally open switch (B
screws (See Figures 6 & 7). option), will switch from open to closed for set points above 0
PSID, but will switch from closed to open for set points below
0 PSID.
TROUBLE SHOOTING
NO NC CM CM NC NO
SINGLE DOUBLE A. Switch doesn't function
Wiring to the terminal strip for SPST switches is defined by
the functionality required. i.e.; a normally closed switch is i. Make sure that the switch load does not exceed the
wired between the CM and NC connections with the NO specified wattage rating of the switch. (steady-
connection unused and a normally open switch is wired state and transient). Contact factory for assistance
between the CM and NO connections with the NC connection for excessive loads, otherwise proceed to the next
unused. step.
ii. Perform a continuity check of the switch contacts
Access holes and plugs are provided for external adjustment by trying to actuate the switch using an external
of the switches if required (Except Model 120 4 1/2" Dial). magnet. An operational switch usually indicates a
The cover for the Model 120 with 4 1/2" Dial must be problem with the gauge. If not operational proceed
removed to adjust the switch settings. to the next step.
iii. Verify the reed switch wires are connected to the
NEMA 7 (Explosion-proof ) Enclosure terminal strip (NEMA 4X enclosure only). Contact
(Options (J & K) the factory for assistance if the switch is connected
and/or request an "RGA" number.
WARNING: THE COVER AND/OR SWITCH ADJUST C. Gauge accuracy and set point problems:
ACCESS PLUGS MUST NEVER BE i. Verify gauge is not in an electromagnetic /
REMOVED WHEN THERE IS POWER TO magnetic environment. i.e.; close proximity to high
THE UNIT. MAKE ALL ADJUSTMENTS IN current power lines.
A NONHAZARDOUS AREA. ii. All others, contact the factory for assistance.
The gauge and switches are mounted inside the enclosure
(See Fig. 4). A 1/2"-14 FNPT conduit connection is provided
in the bottom side of the enclosure. A proper explosion
proof, dust tight, sealing fitting with appropriate sealing
cement must be used when making connections to the 24",
18 Awg. wire leads. The leads are labeled and/or color
coded as described in the grommet / conduit section.
MOUNTING INFORMATION &
DIMENSIONAL DATA
FIGURE 3
FIGURE 2 Model 120 Reverse Port
Model 120 Reverse Port
SPDT Flat Pack Switch Options R & S)
Grommet Interface Switch Options A & B)
FIGURE 4 FIGURE 5
Model 120 Reverse Port
Model 120 Standard Port
Din Connector Interface
FNPT Interface Switch (Options C & D)
Switch (Options L & M)
FIGURE 7
FIGURE 6 Model 120 4 Dial
Model 120 2 Dial NEMA 4 X (Options G & H)
NEMA 4 X (Options G & H)
FIGURE 8
Model 120 2 Dial Options (E & F)
Hazardous Locations,
Division II, Class I,
Groups A, B, C, D
Class II Groups F & G
(CSA & U.L. Listed for all switch
specifications)
Explosion-Proof Enclosures Class I, Groups C & D,
FIGURE 9
Class II, Groups E, F, & G (Options J & K)
2 Inch
Dial
4 Inch
Dial
Typical 2
Pipe
Mounting

Mid-West
Instrument
6500 Dobry Dr. Sterling Heights, MI 48314
(586)254-6500 FAX (586)254-6509
E-Mail: sales@midwestinstrument.com
Web Page: www.midwestinstrument.com
BULLETIN NO. IM120/03
Mid-West
(Supersedes IM120/01)

Instrument

Model 120 Series Filter Minder
Installation and Operating Instructions
INSPECTION The precise piston/bore fit allows minimal leakage

from high to low sides. This leakage is only 5 to 15
Before installation check the nameplate on each SCFH air at ambient conditions and a pressure
instrument against the receiving paperwork and the differential of 100 PSID.
intended application for correct part number,
materials of construction, working pressure, dial INSTALLATION
range, etc. If equipped with switches, check electrical
Model 120 Series "Filter Minder" is calibrated and
rating, type of enclosure, etc. Inspect for shipping tested prior to shipment and is ready for immediate
damage and, if damaged, report it immediately. installation. Use of the following installation
NOTE - Before attempting repairs contact your procedures should eliminate potential damage and
local Mid-West Representative or our factory. provide optimum trouble-free operation.
Failure to do so will void any warranty.
1. CONNECTIONS
PRODUCT DESCRIPTION 1/4 FNPT are provided as standard but check

paperwork for connections ordered. There are two
The Model 120 Series "Filter Minder" is a rugged, connections on the housing identified as hi and lo
medium-range differential pressure instrument for high pressure and low pressure (Fig. 2). Be sure
available as a switch, a gauge, or both. See "Part these get plumbed to the proper connections on your
Numbering System". (Fig. 4) for available options. system. Improper connection will not damage the
Differential pressure is sensed by the movement of a instrument, but it will not function properly. Flexible
floating piston magnet against a calibrated spring. The tubing is recommended to minimize the effect of any
magnetically coupled gauge pointer outside the vibration that may exist.
pressure housing follows the movement of the piston 2. INSTRUMENT LOCATION
magnet and indicates differential pressure on the dial On liquid service the instrument should be mounted
scale. below the process connections to facilitate self-
When equipped with switches, a contact is made or bleeding. On gas service it should be located above
broken by the magnetic field of the piston magnet. the process connections to promote self-draining. If
See Bulletin ELECIM120/latest for gauges with the process contains particulates, a pigtail loop or
switches. drop leg (manometer U-tube configuration) in the
tubing will minimize the possibility of it migrating into
The unit provides full over-range protection to the the instrument.
rated working pressure of the housing in either
direction.
3. PANEL MOUNTING TROUBLE SHOOTING
Gauges with 2-1/2 dials can only be mounted 1. Gauge does not indicate differential.
through the rear of the panel. Make the proper panel A. Check for proper hook up, high to hi and low
cutout as indicated in (Fig.1). Remove the (4) bezel to lo.
screws. Insert the gauge front through the rear of the
B. Make certain block valves are open and, if using
panel and reinstall the bezel screws through the front
a 3-valve manifold, that the equalizer (balance)
of the panel and into the gauge bezel. Tighten the
valve is closed.
screws securely, alternating in a diagonal pattern.
C. If A & B check out correctly, loosen or
Gauges with 3-1/2" dial should be mounted from the disconnect the high pressure line to determine
front of the panel. Contact factory for mounting if there is pressure to the instrument.
information and dimensional data. D. If there is pressure to the instrument, check to
determine that there is differential across the
Gauges with 4-1/2" dial should be mounted from the unit being monitored. If so, contact the factory
front of the panel. Make the cutout as indicated in (Fig. for assistance and/or an RGA (return goods
1). Insert the (4) panel mounting studs, finger tight, into authorization) number to return the instrument
the metal inserts located in the rear of the bezel. Insert for repair or replacement.
the gauge through the panel, aligning the panel
mounting studs with the holes in the panel. Install the (4)
#8-32 nuts onto the studs and tighten securely.
4. PIPE MOUNTING
An optional pipe mounting kit is available for mounting
the gauge to a 2 vertical or horizontal pipe (Fig. 3).
Model 120 2-1/2 Inch Dial (Std.)
Model 120 4-1/2 Inch Dial (Opt'l)
(Fig. 1)
Supplementary 120 Dimensional/Mounting Data
(Fig. 2)
(Fig. 3)
NOTES: 1. Drawings show standard gauge nominal dimensions. (not to scale)

2. Dimensions shown in parentheses are in millimeters.
3. Manufacturer reserves the right to change specifications without prior notice.
STANDARD MODEL SPECIFICATIONS
120-AA-00-OO
6000 P.S.I.G. Working Pressure Aluminum Body, Stainless Steel Piston, Ceramic Magnets, Buna N Seals,
2-1/2" Engineering Plastic Case with Shatter-Resistant Lens. 1/4" FNPT Back Connections.
Accuracy +3-2-3% Full Scale (Ascending).
PART NUMBERING SYSTEM 1 2 0
OPTIONS (Up to four options)

O. None (Standard)
BASIC MODEL NUMBER A.
B.
Reversed High/Low Process Connections
DIN2353 12-S (12mm) Steel Tube Fittings (2)
C. Mounting Holes in Gauge Body for Field Mounting of Electrical Configurations Options A & B
MATERIAL
A. Aluminum Body, S.S. Piston (Standard)
D.
F.
Mounting Holes in Gauge Body for Field Mounting of Electrical Configurations Options L & M
Pipe Mounting Kit (Carbon Steel) (Not available w/C or D Electrical Switch Options)
L. Liquid Fill (Not available w/follower pointer) (Not available with 3-1/2" dial)
M. Monel Body (See 120 ABM) (5000 P.S.I.G. working pressure)
M. Maximum Indicator Follower Pointer
N. Aluminum Bronze Body (See 120 ABM) (5000 P.S.I.G. working pressure)
T. Oxygen Cleaning
S. 316 S.S. Body & S.S. Piston (Standard)
U. S.S. Tag Mounted w/S.S. Wire
Z. SPECIAL (Uncoded Options)
V. S.S. Tag Mounted w/S.S. Screws
DIAL TYPE
A. 2-1/2 Round Uni-Directional Engrd. Plastic Housing Assy. (Standard)
W.
X.
Wall Mounting Kit
Individual Gauge Packaging
B. 2-1/2 Round Bi-Directional Engrd. Plastic Housing Assy.
C. 4-1/2 Round Uni-Directional Engrd. Plastic Housing Assy.
D. 4-1/2 Round Bi-Directional Engrd. Plastic Housing Assy.
E. 3-1/2 Round Uni-Directional Anod. Aluminum Housing Assy.
F. 3-1/2 Round Bi-Directional Anod. Aluminum Housing Assy.
G. 4-1/2 Round Uni-Directional Anod. Aluminum Housing Assy.
(Up to three options)

H.
T.
4-1/2 Round Bi-Directional Anod. Aluminum Housing Assy.
Non-Indicating Differential Pressure Switch Only (Select Appropriate Electrical Option) ELECTRICAL CONFIGURATIONS
(NOTE: All options marked, except E, F, J & K)
O. None
A. One (1) Switch in STD. Enclosure with Grommet Wire Seal
B. Two (2) Switches in STD. Enclosures with Grommet Wire Seal
C. One (1) Switch in STD. Enclosure with 1/4 FNPT Electrical Connection NEMA 4X
SEALS
0. Buna N (Standard)
D.
E.
Two (2) Switches in STD. Enclosures with 1/4 FNPT Electrical Connection NEMA 4X
One (1) Switch in General Purpose Enclosure, C.S.A. & U.L. Listed, Division II Locations (1) (3)
1. Viton F. Two (2) Switches in General Purpose Enclosure, C.S.A. & U.L. Listed, Division II Locations (1) (3)
2. Neoprene G. One (1) Switch & Gauge in NEMA 4X Plastic Enclosure (Not Available With End Connections)
4. Teflon H. Two (2) Switches & Gauge in NEMA 4X Plastic Enclosure (Not Available With End Connections)
J. One (1) Switch in Explosion Proof Enclosure with Glass Window Cover and C.S.A. & U.L. Listing (2)

5. Ethylene Propylene
6. Perfluoroelastomer K. Two (2) Switches in Explosion Proof Enclosure with Glass Window Cover and C.S.A. & U.L. Listing (2)
9. Special (Uncoded Options) L. One (1) Switch in STD. Enclosure with Plug-In Connector (DIN 43650/IP65-PG11)
*Viton is a Registered Trademark of DuPont Dow Elastomers. M. Two (2) Switches in STD. Enclosure with Plug-In Connector (DIN 43650/IP65-PG11)
**Teflon is a Registered Trademark of DuPont. Z. Special (Uncoded Options)
(1)
Complete Assembly Rated Class I, Div. II, Groups A, B, C, & D; Class II, Div. II, Groups F and G.
(2)
Complete Assembly Rated Class I, Div. I, Groups C & D; Class II, Div. I, Groups E, F, & G.
(3)
5000 PSIG Working Pressure.
CONNECTIONS
(NOTE: Models 120M and 120N available only with end connections)
0.
2.
1/4" FNPT Back Connections (Standard)
1/4" FNPT End Connections
ELECTRICAL SPECIFICATIONS (For Resistive Loads)
A. S.P.D.T., 3W, 0.25 Amp., 125 VAC/VDC (Standard) (Switch adjustable range of 10-90%)
6. 7/16" - 20 Str. Thd. O-Ring Port (Back Connections) E. S.P.S.T., 60W, 3.0 Amp., 240 VAC/VDC (Normally Open) (Switch adjustable range of 25-95%)
7. 1/2" FNPT Stainless Steel Adaptors F. S.P.S.T., 60W, 3.0 Amp., 240 VAC/VDC (Normally Closed)
8. 1/2" FNPT Monel Adaptors (Switch adjustable range of 25-95%)
9. Special (Uncoded Options) G. S.P.S.T., 60W, 3.0 Amp., 240 VAC/VDC One (1) Normally Open, One (1) Normally Closed (4)
H. S.P.D.T., 60W, 1.0 Amp., 240 VAC/VDC (Switch adjustable range of 25-100%)
(4)
Available with Electrical Configurations B, D, F, H, K and M only.
NOTE: NOT ALL OPTIONS AVAILABLE IN COMBINATION WITH OTHER OPTIONS.
NOTE: FACTORY PRESET SWITCHES AT NO CHARGE (SPECIFY SETTING)
NOTE: THE USE OF DIAPHRAGM SEALS IS NOT RECOMMENDED FOR MODEL 120 SERIES GAUGE.
ATTEMPTS TO INSTALL SUCH SEALS ON THIS GAUGE WILL VOID THE WARRANTY. (Fig. 4)
Manufacturer reserves the right to change specifications without prior notice.

PROOF PRESSURE: 12,000 PSI for models 120-A and 120-S.
10,000 PSI for models 120-M and 120-N.
TEMPERATURE LIMITS: -40F(-40C) to +200F (+93C) - These limits are based on the entire instrument being saturated to
these temperatures. System (process) temperatures may exceed these limitations with proper installation. Contact our customer
service representative for details.
STANDARDS: All Model 120 Series differential pressure gauges either conform to and/or are designed to the requirements of the
following standards:
ASME B1.20.1 NACE MR0175
ASME B40.1 NEMA Std. No. 250
CSA-C22.2 No. 14.25 and 30 SAE J514
EN-61010-1 UL Std. No. 50,508 and 1203
R E P R E S E N T E D B Y:
Mid-West
Instrument

6500 Dobry Dr. Sterling Heights, MI 48314 U.S.A.

(586) 254-6500 FAX (586) 254-6509
E-mail: sales@midwestinstrument.com
Website: www.midwestinstrument.com
Printed in U.S.A.
Cat
alog HY09-
1000/
US Al
uminum Bushing Series
GeneralInform ation Pum p & M otor Catal

og
General Information
for P 1 6 S eries
Available in various configurations
P 1 6 S ingle S ection
T P 1 6 T and em , 2 & 3 P lace
P V P 1 6 P riority V alve
C P 1 6 C lutch P um p V B elt and S erp entine
C ast iron p um p ing sections

for d urability
Alum inum flanges and covers for op tim um

p ow er to w eigh t ratio.
J ournal bearings for long life

and good over-h ung load cap ability
B una-N S eals are stand ard for

p etroleum and gly col based
fluid s. V itonE seals are op tional.
P ressure balanced p lates for

greater efficiency .
3 Parker Hannifin Corporation
Gear Pump Division
Youngst
own,Ohio USA
Catalog HY09-1000/US Aluminum Bushing Series
Ordering Information Pump & Motor Catalog
How to Order P16 Series:
Select the desired symbol (

in the correct position)to construct a model code.
Assembly Example:
16
Series Section Rotation Flange PVP Pumps Only

Repeat for each
Size tandem section Options
OPTIONS ROTATION PRIORITY PRESSURE
PVP ONLY SETTING

Code Description Code Direction
Code Flow Code Setting

V Viton A C
CW ise
C CW ise 1 1-2 5 500 PSI
MODEL 2 2-3 10 1000 PSI

SHAFT
3 3-4 12 1200 PSI
Code Description
Code Description
4 4-5
P Pump (
single) Use 2 digit
1 5/89-Tooth Spline
5 5-6 maximum to
TP Tandem Pump
2 7/813-Tooth Spline
6 6-7 indicate pressure
PVP Priority Valve Pump 3 7/8Straight Keyed setting
7 7-8
CP Clutch Pump 5 7/8Straight Keyed Long
8 8-9
6 3/4Straight Keyed
9 9-10
8 7/8Straight Keyed
w/ 5/8Thread Consult Factory

SECTION SIZE 9 7/8Tapered For Flows
Cu.I
n./ CC
s/ Greater than
OR
10 GPM
Code Rev. Rev.
CLUTCH
45 .
878 14.
388
Code Drive Type
65 1.
270 20.
812
0 None
85 1.
663 27.
252
1 V-Belt - Light Duty
100 1.
964 32.
184
2 V-Belt - Heavy Duty
115 2.
241 36.
723
3 Direct Drive
150 2.
934 48.
080
4 6-Rib Flat Belt
180 3.
511 57.
535
200 3.
902 63.
942
OR
COVER PLATE (
FOR MODEL CP) FLANGE
Code Port I
nlet Outlet Code M ounting
1 Side #20 SAE #16 SAE D SAE

A2-Bolt
(
1-5/8
-12UN-2B) (
1-5/16
-12UN-2B) SW ITCH KIT
E 6-Bolt Round
2 Rear 1NPT 3/4NPT
Code Switch Kit
F Pad
3 Side 1-1/44-Bolt 3/44-Bolt
(
Foot)M ount S W ith Switch Kit
4 Side 1NPT 3/4NPT
G SAE
C4-Bolt O W ithout Switch Kit
5 Side #20 SAE #12 SAE
(
1-5/8
-12UN-2B) (
1-1/16
-12UN-2B) J SAE
B4-Bolt
6 Rear #16 SAE #12 SAE N SAE

B2-Bolt
(
1-5/16
-12UN-2B) (
1-1/16
-12UN-2B) OR
S PTO Direct
7 Rear 1BSPT 3/4BSPT
T PTO Direct
8 Side 1BSPT 3/4BSPT
(
Chelsea SPL.
)
NONE Omit For COVER PLATE (
FOR MODEL P,TP,& PVP)
(
1-5/8
-12UN-2B) (
1-1/16
-12UN-2B)
Clutch Pumps
10 Side/Rear 1-1/44-Bolt #12 SAE Code Port I
nlet Outlet
(
1-1/16
-12UN-2B)
11 Side 1-1/44-Bolt #12 SAE (
1-5/8
-12UN-2B) (
1-5/16
-12UN-2B)
(
1-1/16
-12UN-2B)
2 Rear 1NPT 3/4NPT
3 Side 1-1/44-Bolt 3/44-Bolt
4 Side 1NPT 3/4NPT

(
1-5/8
-12UN-2B) (
1-1/16
-12UN-2B)
6 Rear #16 SAE #12 SAE
*Consult f
actoryf
or priorityf
lows over 10 GPM . (
1-5/16
-12UN-2B) (
1-1/16
-12UN-2B)
Note:Add pref
ix
Vto pump model number (
VP16) 7 Rear 1BSPT 3/4BSPT
when ordering pumps with Viton Seals. 8 Side 1BSPT 3/4BSPT

(
1-5/8
-12UN-2B) (
1-1/16
-12UN-2B)
10 Side/Rear 1-1/44-Bolt #12 SAE

(
1-1/16
-12UN-2B)
11 Side 1-1/44-Bolt #12 SAE

(
1-1/16
-12UN-2B)
Gear Pump Division
Youngstown, Ohio USA

P16 Specifications Pump & Motor Catalog
Specifications
for P16 Series
Description ........................................................... G ear Pumps
F low R ange ....................................... TO 38 G PM ( 14 3.8 L TR )
Displacements ................. TO 3.9 0 2 C.I.R . ( 63.9 4 CCs/R EV.)
M ax imum Pressure to ............................ 30 0 0 PSI ( 20 7 BAR )
M ax imum Speed to .................................................. 360 0 R PM
R otation ............................................................................ A or C
Bearings ......................................................................... Journal
Construction .................................. Cast Iron G ear Plate with
Aluminum F lange and Cover Plate
Performance D ata
Displacement/
Revolution Maximum Maximum
(Theoretical) Pressure Speed
Pump Section US Cubic Cubic Imperial
Model Size Gallons Inches Liters Centimeters Gallons PSI BAR RPM
P16 45 .0038 .878 .0144 14.388 .0031 3000 207 3600
P16 65 .0055 1.270 .0208 20.812 .0045 3000 207 3600
P16 85 .0072 1.663 .0273 27.252 .0059 3000 207 3400
P16 100 .0085 1.964 .0321 32.184 .0070 3000 207 3300
P16 115 .0097 2.241 .0367 36.723 .0080 3000 207 3100
P16 150 .0127 2.934 .0481 48.080 .0105 3000 207 2800
P16 180 .0152 3.511 .0575 57.535 .0126 2200 152 2500
P16 200 .0169 3.902 .0639 63.942 .0140 2000 138 2200
All data based on SAE 10W oil at 150F.
Available with Viton Seals.
CAUTION:
Inlet vacuum should not exceed 5 Hg at normal operating speed and temperature.
Operation of pumps in excess of 5 Hg requires factory approval.
Gear Pump Division

P16 Dimensional Data Pump & Motor Catalog
Dimensional Data
Flange Type Shipping
W eights
Pum p D E F (A ppro x .)
M o d els A B A B A B lb s . k gs .
P16 - 45 89 .9 (3.54) 115.6 (4.55) 118.4 (4.66) 144.1 (5.67 ) 9 2.9 (3.66) 118.6 (4.67 ) 12 5.5
P16 - 65 9 5.3 (3.7 5) 121.2 (4.7 7 ) 123.6 (4.88) 149 .6 (5.89 ) 9 8.6 (3.88) 124.2 (4.89 ) 13 5.9
P16 - 85 100.9 (3.9 7 ) 126.5 (4.9 8) 129 .3 (5.09 ) 154.9 (6.10) 103.6 (4.09 ) 129 .5 (5.10) 14 6.4
P16 - 100 104.9 (4.13) 130.6 (5.14) 133.3 (5.25) 159 .0 (6.26) 107 .9 (4.25) 133.6 (5.26) 15 6.8
P16 - 115 108.9 (4.29 ) 134.6 (5.30) 137 .4 (5.41) 163.1 (6.42) 112.0 (4.41) 137 .7 (5.42) 16 7 .3
P16 - 150 118.4 (4.66) 144.1 (5.67 ) 146.8 (5.7 8) 17 2.5 (6.7 9 ) 121.4 (4.7 8) 147 .1 (5.7 9 ) 17 7 .7
P16 - 180 126.5 (4.9 8) 152.2 (5.9 9 ) 154.9 (6.10) 180.6 (7 .11) 129 .5 (5.10) 155.2 (6.11) 19 8.6
P16 - 200 131.8 (5.19 ) 157 .5 (6.20) 160.3 (6.31) 185.9 (7 .32) 134.9 (5.31) 160.5 (6.32) 20 9 .1
Flange Type Shipping

W eights
Pum p G& J N S& T (A ppro x .)
M o d els A B A B A B lb s . k gs .
P16 - 45 118.4 (4.66) 144.1 (5.67 ) 88.1 (3.47 ) 113.8 (4.48) 132.6 (5.22) 158.2 (6.23) 12 5.5
P16 - 65 123.6 (4.88) 149 .6 (5.89 ) 9 3.7 (3.69 ) 119 .4 (4.7 0) 138.2 (5.44) 163.8 (6.45) 13 5.9
P16 - 85 129 .3 (5.09 ) 154.9 (6.10) 9 9 .1 (3.9 0) 124.7 (4.9 1) 143.5 (5.65) 169 .2 (6.66) 14 6.4
P16 - 100 133.3 (5.25) 159 .0 (6.26) 103.1 (4.06) 128.8 (5.07 ) 147 .6 (5.81) 17 3.2 (6.82) 15 6.8
P16 - 115 137 .4 (5.41) 163.1 (6.42) 107 .2 (4.22) 132.8 (5.23) 151.6 (5.9 7 ) 17 7 .3 (6.9 8) 16 7 .3
P16 - 150 146.8 (5.7 8) 17 2.5 (6.7 9 ) 116.6 (4.59 ) 142.2 (5.60) 161.0 (6.34) 186.7 (7 .35) 17 7 .7
P16 - 180 154.9 (6.10) 180.6 (7 .11) 124.7 (4.9 1) 150.4 (5.9 2) 169 .2 (6.66) 19 4.8 (7 .67 ) 19 8.6
P16 - 200 160.3 (6.31) 185.9 (7 .32) 130.1 (5.12) 155.7 (6.13) 17 4.5 (6.87 ) 200.1 (7 .88) 20 9 .1
Shaft Location
For 'A' Rotation
C D im ens io ns
FL A N G E
135.8
(5.35) TY P E M M IN
20.8
(.82)
104.6 D 6.35 (.250)
20.8 (4.12)
(.82) E 4.7 4 (.187 )
F
G 6.35 (.250)
J 6.35 (.250)
11.4 N 9 .52 (.37 5)
(.45)
C A S 5.08 (.200)
B .060 T 5.08 (.200)
Mtg. Surface
Inch equivalents for millimeter dimensions are shown in (**).
Gear Pump Division

P16 Series Shafts Pump & Motor Catalog
Shafts Available for P16 Series Inch equivalents for millimeter dimensions are shown in (**).
5/8"Dia. 9 Tooth Spline 7/8"Dia. 13 Tooth Spline 7/8" Straight Shaft
1 Flat Root Side Fit

Torque Limit 52 Lbs. Ft. (70.5 Nm)
2 Flat Root Side Fit
Torque Limit 184 Lbs. Ft. (249.4 Nm)
3 Torque Limit 184 Lbs. Ft. (249.4 Nm)
Available in all sizes and D, F and N
Flanges Only
Available with D F & N Flanges and in Available in all sizes and flanges.
sizes P16-45 thru P16-100 only

Full Spline 29.4 MIN. 24.9 1/4" x 1/4" x 1-1/2" Lg. Key
(1.16) Flange Mtg. (.98) 6.3 6.3 38.1
Full Spine 18.3 Surface
(.72) Flange Mtg.
MIN. Surface
(.874) 22.2
(.875) 22.2
39.6 'D' Flange
31.7 'D' Flange (1.56) Major Dia. 1.5 (.06)
(1.25)
36.5 'F' Flange 30.2 (1.19)
28.4 (1.44) Flg Mtg
'F' Flange Surface
(1.12) 42.9 6.3
'J. E. G' Flanges (.25)
33.7 (1.69) 52.3
'N' Flange 'D' Flange
(1.33) 41.6 'N' Flange (2.06)
(1.64) 74.6
Spline Data Spline Data
'F' Flange
(2.94)
Diametral Pitch ..... 16/32 Diametral Pitch ..... 16/32 54.3 'N' Flange
Pressure Angle ..... 30 Pressure Angle ..... 30 (2.14)
No. Of Teeth .......... 9 No. Of Teeth .......... 13
7/8" Straight Shaft 3/4" Straight Shaft 7/8" Straight Shaft
Available in all sizes and flanges.

Available in sizes P16-45 thru P16-115

Available with N flange and sizes P16-65,
only only and all flanges P16-85 and P16-100 only.
24.9 (.982) 1/4" x 1/4" x 1-3/4" Lg. Key

6.3 6.3 44.4 3/16" x 3/16" x 1-1/4" Lg. Key 5/8" - 18UNF - 2A
4.5 x 4.5 x 31.7 Flange Mtg. 0.156 1/4" x 1" Woodruff Key
Surface Dia. Thru
22.2 (.875) Dia. Flg Mtg Surface
22.2 (.874) 21.1
(.832)
1.5 (.06) Flange Mounting 25.7
(.999)
6.3 (.25) 38.1 (1.50) Surface 41.1 (1.62)
19.0 (.749) 49.2 'D' Flange
60.4 'D' Flange (1.94) 27.94
(2.38) 18.9 (.748) 45.9 'F' Flange (1.10)
57.1 'F' Flange .Dia. (1.81)
(2.25) 52.5 'J' 'E' & 'G' Flanges 44.45(1.75)
63.5 (2.07) 22.2 (.874)
'J' 'E' & 'G' Flanges 51.0 'N' Flange 22.23 (.875) 58.67(2.31)
(2.50) (2.01)
62.2 'N' Flange DIA.
(2.45) 51.99(2.047)
61.98(2.44)
7/8"Tapered Shaft
Available in all sizes and D, F and N
flanges only
4.0 15.7 Flange Mtg.

5/32" x 5/8" Woodruff Key Sur face
21.4 (.846) 16.07 (.633)

Dia. Dia.
21.2 (.836) 16.00 (.630)
78'
67.9 D Flange
(2.28)
5/16-24 NF
DEPTH 25.4 (1.00) 54.8 F Flange
(2.16)
59.9 N Flange
(2.36)
Clutch No.4
Flat Ribbed Belt Drive Suction for Clockwise Rotation C
Discharge for Counter clockwise Rotation A
135.8
(5.35)
E
Dia.
20.8 104.6
(.82*) (4.12)
C A*
11.4
D Max B.060 (.45)
Gear Pump Division

P16 Series Mounting Flanges Pump & Motor Catalog
Mounting Flanges Available Inch equivalents for millimeter dimensions are shown in (**).
SAE
A2-
Bolt 6-
Bolt Round Pad Mount
D E Available with No. 2, 5 or 6 Shafts Only

F
47.7 10.7 DIA. Mounting
(1.88R) Surface
82.55 (3.250)
11.1 82.49 (3.248) 66.7 (2.625)
(.44) 71.4
PILOT DIA. (2.81) 66.3 (2.623)
Mounting 35.7 Pilot Dia.
Slots (1.40)
53.0 6.3 (.25) 20.6
(2.09) 11.1
6.0 (.24) (.81) (.44) 4.9 (.19)
4.6 (.18)
50.8
106.0 Dia. (2.00)
(4.18) 41.2
(1.62) 61.9 6 Holes
130.2 Mounting Surface (2.44) Mounting Surface
(5.12) 15.7
82.5 1/2 - 13 NC 22.2
(3.25) (.87) (.62)
DEPTH 28.7
25.4 (1.00) 44.4 (1.13)
2 PLACES (1.75)
SAE
C4-
Bolt SAE
B4-
Bolt SAE
B2-
Bolt
G Available for
No. 2 or 5 Shaft Only

J Available for
No. 2, 5 or 6 Shaft Only

N
146.0 14.2 (.56) 14.2 (.56) (.56)14.2
(5.75) Dia. 4 Holes Dia. 2 Holes
Dia. 4 Holes
101.60 (4.000)
89.8
114.4 127.00 (5.000) (3.54) 101.55 (3.998) 101.60 (4.000)
(4.50) 126.94 (4.998) PILOT DIA. 120.6 101.55 (3.998)
Pilot Dia. 44.9 (4.75) Pilot Dia.
117.3 (1.77) 60.3
57.2 (4.62) (2.38)
146.0 (2.25)
(5.75)
44.9 73.0 9.6 (.38)
(1.77) 6.3 (.25)
(2.88) 9.4 (.37)
57.2 6.3 (.25) 6.0 (.24) 146.0
(2.25) 6.0 (.24) 89.8 (5.75) Mounting Surface
(3.54) Mounting Surface 174.7
114.4 Mounting Surface 117.3 (6.88)
(4.50) (4.62)
P.T.O. Direct Mount P.T.O. Direct Mount
S Available with
No. 2 Shaft Only

T T19C Trans
Available with No. 2 Shaft Only
66.7 (2.626) TYP.

66.7 (2.626) TYP. 66.5 (2.622)
66.5 (2.622) BODY MILLED FLAT
ON SUCTION SIDE
3.1
3.1 (.125)
(.125)
3.3 69.85 (2.750)

8.3 69.85 (2.750) (.328)
(.328) 69.80 (2.748)
69.80 (2.748) Dia. PILOT DIA.
Dia. PILOT DIA.
33.3 33.3 4.3 (.17) Mounting

(1.312) 4.8 (1.312) 4.8 Surface
Mounting (.191) 3.8 (.15)
(.191) 4.3 (.17)
Surface CL PTO Pilot CL Shaft
CL PTO Pilot CL Shaft 3.8 (.15)
52.3
(2.06)
Gear Pump Division

P16 Series Cover Plates Pump & Motor Catalog
Cover Plates Available for P16 / CP16 Inch equivalents for millimeter dimensions are shown in (**).
Rear Ported Straight Thread Rear Ported NPT Side Ported SAE 4-Bolt
1 2 3 Metric Threads are available Consult
factory. SAE 4-Bolt NPT Connectors Are
Available. See Accessory Section.

Rear Ported BSPT
69.8 66.5
7
(2.75) (2.62) 69.8 66.5 21.8 (.87) 30.1 (1.18)
(2.75) (2.62)
10.9 7/16-14NC* 15.0 (.59)
(.43) Depth
22.3 (.88)
3/8-16NC
Depth
22.3 (.88) 58.6
47.6 3/4" SAE (2.31)
4-Bolt
23.8 Conn.
(.94) 29.3
(1.16)
SAE 20 1-1/4" SAE
1-5/8-12N-2B SAE 16 4-Bolt
Suction 35.0 35.0 1-5/16-12UN-2B 3/4" Conn.
(1.38) (1.38) Discharge 1" Suction Discharge
35.0 35.0 Discharge Side Suction Side
(1.38) (1.38)
Side Ported NPT Side Ported Straight Thread Rear Ported Straight Thread
4 5 SAE 12 Discharge 6
Side Ported BSPT Side Ported Straight Thread
8 9 SAE 16 Discharge
69.8 66.5
3/4" Pipe 1" Pipe SAE 12 SAE 16 SAE 20* (2.75) (2.62)
(1-1/16-12UN-2B) (1-5/16-12UN-2B) (1-5/8-12UN-2B)
Thread Thread
SAE 16 SAE 12
Discharge Suction Discharge Discharge Suction 1-5/16-12U N-2B 1-1/16-12UN-2B
Suction 35.0 35.0
(1.38) (1.38) Discharge
Side Ported SAE 4-Bolt Side Ported SAE 4-Bolt
10 Rear Ported Straight Thread 11 Straight Thread

Must use 1-1/4 Length
Max. Capscrews
30.18
(1.188) 69.85 66.55 1-1/16"
14.99 (2.75) (2.62)
(.59*) 12UN-2B 7/16"-14NC Depth .75
1.25 30.18
DIA (1.188) 14.99
(.59*)
58.75 1.25
(2.313) DIA
29.21
(1.15)
58.75
(2.313)
29.21
(1.15)
1-1/4" SAE 35.05
4-Bolt Conn. (1.38)
Suction Side
1-1/16" 12UN-2B 1-1/4" SAE
Discharge 4-Bolt Conn.
Gear Pump Division

P16 Series Cover Plates/Discharge Ports Pump & Motor Catalog
Cover Plates Available for PVP16 Inch equivalents for millimeter dimensions are shown in (**).
Side Ported SAE 4-Bolt Side Ported Straight Thread
3 SAE 8 3/4-16UNF-2B
5
Priority Discharge 53.8
SAE 8 (2.12)
3/8-16NC Depth 3/4-16UNF-2B
22.3 (.88) Priority Discharge
3/4" SAE
4-Bolt Conn. SAE 10
Secondary 7/8-14UNF-2B
47.6 (1.86) Discharge Secondary
58.7 Discharge
29.2 (2.31)
1 1/4" SAE (1.15*)
23.6 4-Bolt Conn.
(.93)
Suction
10.9 14.9
(.43) SAE 20
7/16-14NC (.59) 1 5/8-12UN-2B
21.8 Depth Suction
(.86) 22.3 (.88) 30.1 32.2
(1.19) (1.31)
87.3
SAE 4-Bolt NPT Connectors Are Available. See Accessory Section
(3.44)
Rear Ported Straight Thread
6 14.2 (.56)
CL of Drive Shaft for 35.0 SAE 8
(1.38) 3/4-16UNF-2B
Counterclockwise
Rotation Priority Discharge
20.8
(.82) 51.5 51.5
(2.03) (2.03)
41.9
(1.65) 6.8
(.27)
CL of Drive Shaft
for Clockwise SAE 10
Rotation 7/8-14UNF-2B
70.8 70.8 Secondary Discharge
SAE 20 (2.79) (2.79)
1-5/8-12UN-2B
Suction CL of Drive Shaft
Discharge Ports for Connector Plate and Cover Plate for T P16
SAE 4-Bolt NPT-Pipe Thread SAE 12 SAE 16
3 Metric threads are available -
Consult Factory. SAE 4-Bolt

4 5 Straight Thread 9 Straight Thread
NPT Connectors Are Available.

BSPT-Pipe Thread
See Accessory Section
8
22.0
(.875)
10.9
*3/8-16UNC (.43)
Depth .88 22.3
46.7
(1.87)
23.3
(.93)
3/4" SAE 4-Bolt Conn. 3/4-14 PT 1-1/16-12UN-2B 1-5/16-12UN-2B
Gear Pump Division

25Series
0 F CHARLOTTE
Qt:.
Verticalor HorizontalMounts
for NemaMotorFrames
182TC- 256TC
~ ,
DIM ENS ION A L DATA U

PUMP MAX. M R
MODEL FLANGE COUPLING TAPPED TAPPED
NUMBER STYLE A DIA. L HOLES HOLES AJ AK WEIGHT
SAE AA 2 @ 3/8-16 4 @ 17/32

2 BOLT 2.001" 4.875" 4.875" ON N/A ON 8.502" 8#
3.25" B.C. 7.25" B.C.
USA 4@ 5/16-18 4@ 17/32
4F17 1.782" 4.875" 4.875" N/A ON ON 8.502" 8#
4 BOLT 2.84" B.C. 7.25" B.C.
SAEA 2@ 3/8-16 4 @ 3/8-16 4 @ 17/32

2 & 4 BOLT 3.251" 4.875" 4.875" ON ON ON 8.502" 7#
4.18" B.C. 4.125" B.C. 7.25" B.C.
SAE B 2@ 1/2-13 4@ 3/8-16 4 @ 17/32

2 & 4 BOLT
4.001" 4.875" 4.875" ON ON ON 8.502" 7#
5.75" B.C. 5.00" B.C. 7.25" B.C.
SAE C 2 @ 5/8-11 4 @ 1/2-13 4 @ 17/32

2 & 4 BOLT 5.001" 4.875" 4.875" ON ON ON 8.502" 13#
7.125" B.C. 6.375" B.C. 7.25" B.C.
Q)
SAE AA 2@ 3/8-16 4@ 17/32
2 BOLT 2.001" 4.875" 5.875" ON N/A ON 8.502" 9#
3.25" B.C. 7.25" B.C.
Comprehensive dimensional data available upon request - ask for HESCO-CAD.

4
25Series
~ 0 F CHARLOTTE
~ 'J/
L
I
F
I
F
"'
I
I-r~
AK. )1
I
I
I
:
I
I
I
I
F A
"'
I
~ If
"' AJ
------
DIMENSIONAL DATA continued U

PUMP MAX. M R
MODEL FLANGE COUPLING TAPPED TAPPED
NUMBER STYLE A DIA. L HOLES HOLES AJ AK WEIGHT
USA 4@ 5/16-18 4@ 17/32
4F17 1.782" 4.875" 5.875" N/A ON ON 8.502" 9#
4 BOLT 2.84" B.C. 7.25" B.C.
SAEA 2 @ 3/8-16 4@ 3/8-16 4@ 17/32

2 &4 BOLT 3.251" 4.875" 5.875" ON ON ON 8.502" 9#
4.188" B.C.. 4.125" B.C. 7.25" B.C.
SAE B 2@1/2-13 4 @ 3/8-16 4@ 17/32

2 &4 BOLT 4.001" 4.875" 5.875" ON ON ON 8.502" 8#
5.75" B.C.. 5.00" B.C. 7.25" B.C.
SAE C 2 @5/8-11 4 @ 1/2-13 4@ 17/32

2 & 4 BOLT 5.001" 4.875" 5.875" ON ON ON 8.502" 7#
7.125" B.C.. 6.375" B.C. 7.25" B.C.
SAEA 2 @3/8-16 4@ 3/8-16 4@ 17/32

2 &4 BOLT 3.251" 4.875" 6.875" ON ON ON 8.502" 9#
4.188" B.C.. 4.125" B.C. 7.25" B.C.
SAE B 2 @1/2-13 4 @ 3/8-16 4@ 17/32

2 & 4 BOLT 4.001" 4.875" 6.875" ON ON ON 8.502" 9#
5.75" B.C.. 5.00" B.C. 7.25" B.C.
SAE C 2 @5/8-11 4@ 1/2-13 4@ 17/32

2 & 4 BOLT
5.001" 4.875" 6.875" ON ON ON 8.502" 9#
7.125" B.C.. 6.375" B.C. 7.25" B.C.
Comprehensive dimensional data available upon request - ask for HESCO-CAD.
5
Capacity:
Pilot operated, balanced piston relief valve 25 gpm (95 L/min.)
Functional Group: Model:
Products : Cartridges : Relief : 2 Port : Pilot Operated, Balanced Piston RPEC
Product Description
Pilot-operated, balanced-piston relief cartridges are normally closed pressure regulating valves. When the
pressure at the inlet (port 1) reaches the valve setting, the valve starts to open to tank (port 2), throttling flow to
regulate the pressure. These valves are accurate, have low pressure rise vs. flow, they are smooth and quiet,
and are moderately fast.
Technical Features
Will accept maximum pressure at port 2; suitable Main stage orifice is protected by a 150 micron
for use in cross port relief circuits. If used in stainless steel screen.
cross port relief circuits, consider spool leakage.
Not suitable for use in load holding applications Back pressure on the tank port (port 2) is directly
due to spool leakage. additive to the valve setting at a 1:1 ratio.
All 2-port relief cartridges (except pilot reliefs) Stainless steel cartridge options P or W are
are physically and functionally interchangeable intended for use within corrosive environments
(same flow path, same cavity for a given frame with all external components manufactured in
size). stainless steel or titanium. Internal working
components remain the same as the standard
valves.
Incorporates the Sun floating style construction
to eliminate the effects of internal parts binding
due to excessive installation torque and/or
cavity/cartridge machining variations.
Technical Data
U.S. Units Metric Units
Cavity T-10A
Capacity 25 gpm 95 L/min.
Adjustment - Number of Clockwise Turns to
5 5
Increase Setting
Factory Pressure Settings Established at 4 gpm 15 L/min.
Maximum Operating Pressure 5000 psi 350 bar
Maximum Valve Leakage at 110 SUS (24 cSt) 2 in/min.@1000 psi 30 cc/min.@70 bar
Response Time - Typical 10 ms 10 ms
Valve Hex Size 7/8 in. 22,2 mm
Valve Installation Torque 30 - 35 lbf ft 45 - 50 Nm
Adjustment Screw Hex Socket Size 5/32 in. 4 mm
Adjustment Nut Hex Size 9/16 in. 15 mm
Adjustment Nut Torque 108 lbf in. 12 Nm
Model Weight .30 lb 0,15 kg
Seal Kits Buna: 990-010-007
Seal Kits Viton: 990-010-006
Related Information
Option Selection
RPEC-L A N
Preferred Options
External
Control Adjustment Range Material/Seal
Material
L Standard Screw A 100 - 3000 psi (7 - 210 N Buna-N
Adjustment bar), 1000 psi (70 bar)
Standard Setting
W 150 - 4500 psi (10,5 -
315 bar), 1000 psi (70
bar) Standard Setting
Standard Options
C* Tamper Resistant - B 50 - 1500 psi (3,5 - 105 P Stainless/Buna-
Factory Set bar), 1000 psi (70 bar) N
F Hex Head Screw Standard Setting V Viton
with Locknut C 150 - 6000 psi (10,5 - W Stainless/Viton
K Handknob 420 bar), 1000 psi (70
bar) Standard Setting
O Handknob with
Panel Mount N 60 - 800 psi (4 - 55
bar), 400 psi (30 bar)
Standard Setting
Q 60 - 400 psi (4 - 25
Standard Setting
Additional Options
The following options are not widely used and may be application specific. Please contact
your Sun distributor for application information.
J Capped Screw D 25 - 800 psi (1,7 - 55
Adjustment bar), 400 psi (30 bar)
M Capped Screw Standard Setting
Adjustment with E 25 - 400 psi (1,7 - 28
Lockwire Holes bar), 200 psi (14 bar)
Q* Capped and Standard Setting
Lockwired G 60 - 3000 psi (4 - 210
R* Lockwired Screw bar), 1000 psi (70 bar)
Adjustment Standard Setting
W* Max. Setting H 30 - 3000 psi (2 - 210

Limiter bar), 1000 psi (70 bar)
Standard Setting
Y* Max. Setting
Limiter with K 75 - 1500 psi (5 - 105
Handknob bar), 1000 psi (70 bar)
Standard Setting
P 40 - 400 psi (2,8 - 28
Standard Setting
V 150 - 800 psi (10,5 - 55
Standard Setting
Customer specified setting stamped on hex +$1.10

*Special Setting required, specify at time of order
Related Information :
Explanation of Sun cartridge control options - US units.
Explanation of Sun cartridge control options - metric units.
Two-piece, floating cartridge construction.
Copyright 2003 Sun Hydraulics Corporation.

All rights reserved.
Terms and Conditions - Statement of Privacy
RA 23 316/06.98
4/3-, 4/2- and 3/2- way Directional Valves
Model WE 10.../.C (Series 3X) RA
with Wet Pin AC or DC Solenoids 23 316/06.98
... 4600 PSI ... 32 GPM
Size 10 (D 05) Replaces: 02.96
(315 bar) (120 L/min)
Direct solenoid operated spool type directional control valve

Mounts on standard ISO 4401-5, NFPA T3.5.1M R1 and
ANSI B93-7 D 05 interface
For subplates, see data sheet RA 45 054
High flow body and spool design
Removable coils for quick replacement, or conversion,
in AC or DC voltages
Wet pin DC solenoids & wet pin AC solenoids (dual frequency)
Individual solenoid plug-in connectors, or central wiring box
to NEMA 4 specifications (see data sheet RA 08 002)
Optional manual overrides
Inductive limit switch on spool position, upon request
(see data sheet RA 24 830) Model 4 WE 10..3X/C G24N9Z45
53 standard spool configurations available
Important!
The length of the mounting bolt in series 3X/.. is 1-1/2"
(40 mm) [formerly 2" (50 mm)]
Functional description
A B
a b
TA A P B TB
5 2 4 1 3 4 2 5
Model 4 WE 10 E 3X/C G24N9Z45
Directional control valves model WE 10 are direct solenoid The spool is shifted by energizing wet pin solenoid(s) (2).
operated spool valves. They control the start, stop and direction of The force of solenoid (2) pushes against spool (3). The spool is
fluid flow. shifted from a neutral position to a desired end position. Move-
These directional valves consist of the housing (1), one or two ment selects a flow pattern of P to A and B to T, or P to B and A
removable solenoids (2), control spool (3) and one or two return to T. When solenoid (2) is de-energized, control spool (3) returns
springs (4). to the original position by spring(s) (4).
In the de-energized condition, spool (3) is held centered, or an An override (5) is available for operation of the valve (without
offset position by return spring(s), (4) (except detented spools). electrical power).
1/12
RA 23 316/06.98
Functional description (continued)
Model .WE 10.3X/OC

(only possible with spools A,C and D)
This model is a 2-position directional valve with two solenoids, no
detents, and no return springs. The spool position is determined
by which solenoid is energized. The spool position can only be A
maintained by continuously energizing one of the two solenoids.
Model .WE 10.3X/OFC (detented valve - for pulse operation)

(only possible with spools A,C and D) Detent
This model directional valve has a detent assembly and 2 sole-

noids. The spool is held in position by the detent, so continuous a
energization of the solenoid is not necessary. Pulsing the sole-
noid (approximately 100 ms) is all that is required to shift the valve,
and maintain a shifted position.
Model .WE 10.3X/OFC (with detent)

Orifice Inserts (Model 4WE 10.. 3X/B..) TA
To limit maximum flow, orifice inserts are optionally available.
Primarily, the orifice insert is intended to prevent flow rates in
excess of the maximum performance data (page 5 & 6) of the
valve. For this purpose the insert is installed in the P port,
however, will fit any of the ports, allowing for design flexibility.
Note: P O-ring 12 x 2
For soft shift applications, see data sheet RA 23 184 or 23 351.
Symbols
1
Note:
When ordering a spool with only two
positions o & a or o & b, specify the
desired position a or b after the spool
code.
A B A B A B A B Example: Spool E with spool position a
b b b b Ordering code: 4 WE10EA3X/
b b
P T P T P T P T
CW110N9A
A B A B A B A B
b b b .../O.. = A.1)
P T P T P T P T =M
A B A B A B A B
b b b
=.B
b b .../OF.. b =P
P T P T P T P T
=A = E 1)
=Q
= E1-2)
=C =F =R
=D =G =T
A B A B
b b b =H =U
P T P T
=B =J =V
=Y =L =W
2/12
RA 23 316/06.98
Ordering code
2 3 4 5 6 7 9 10 11 12 15 16 19 22 23
WE 10 3X C
3 Service ports =3 *
4 Service ports =4
Directional control valve, electrically operated
ISO size 5, NFPA/ANSI D 05 interface
Spool type example: C, E
For possible spool configurations, see page 2
Three position spools with: solenoid A only =A
solenoid B only =B
Example: 4 WE 10 EA 3X/CW110N9DA
Series 30 to 39 = 3X
(30 to 39; externally interchangeable)
Spring return = no code
Without spring return =O
Without spring return with detent = OF
High performance dual frequency 2-piece wet pin solenoid,
with removable coil =C
AC Voltage DC Voltage
Dual frequency DC Voltage* = G + Voltage
120 V or 110 V - (50 or 60 Hz)1) = W 110 (Example: 24 V DC = G 24)
Other AC voltages 2) = W + Voltage 1) see page 4 for voltage-frequency
(Example: 220 V (50 or 60 Hz) = W 220) relationships

DC solenoid with rectifier for AC operation 2) see page 4 for available voltages
(Not frequency related)* = W 110 R

(Only available with D cover or Z55
plug-in connector)
Without manual override = no code
With protected manual override (standard) = N9
Covered manual override, with rubber boot =N
Electrical connections to data sheet RA 08 002, meets or exceeds NEMA 4
Central solenoid connections
1/2" NPT conduit connector in valve body (standard) =A
1/2" NPT conduit connector in conduit box = DA
1/2" NPT conduit connector in valve body with light(s) = AL
1/2" NPT conduit connector in conduit box with light(s) = DAL
Angled plug in valve body = ZA
Angled plug in conduit box = DZA
Angled plug in valve body with light(s) = ZAL
Angled plug in conduit with light(s) = DZAL
ANSI B 93.55 M plug-in type connections (without female end)
Terminal box with 3-pin connector (single solenoid) = DK23
Terminal box with 5-pin connector (double solenoid) = DK25
Terminal box with 3-pin connector and lights (single solenoid) = DK23L
Terminal box with 5-pin connector and lights (double solenoid) = DK25L
Individual solenoid plug connections for cable or conduit (1/2" NPT)
Without plug in connector(s) = K4
Angled plug = Z45
Large angled plug = Z55
Large angled plug with light = Z55L
Additional inductive limit switch to data sheet RA 24 830 (only possible on valves with one solenoid)
Without limit switch = no code Position b monitored = QBG24
Position a monitored = QAG24 Position o monitored = Q0G24
Orifice inserts, used when flow volume exceeds the power limit of the valve
Without orifice insert = no code Orifice 0.039" (1.0 mm) dia. = *10
Orifice 0.031" (0.8 mm) dia. = *08 Orifice 0.047" (1.2 mm) dia. = *12
NBR seals, for petroleum oils (HM, HL, HLP) = no code
FPM seals, for phosphate ester fluids(HFD-R) =V
Further details to be written in clear text
* Port in which orifice(s) is installed:
B.. = in port P R.. = in port B Example: 4 WE 10 E 3X/CG12N9A/B 12 = 1.2 mm orifice in P
H.. = in port A N.. = in ports A and B
3/12
RA 23 316/06.98
Technical data (For operation outside these parameters, please consult us!)
General
Installation position Optional
Maximum ambient temperature F (C) 122 (50)
Weight (approx.) Valve with 1 solenoid lbs (kg) DC 9.9 (4.5); AC 8.2 (3.7)
Valve with 2 solenoids lbs (kg) DC 13.4 (6.1); AC 9.9 (4.5)
Hydraulic
Nominal pressure, ports A, B, P PSI (bar) 4600 (315)
Maximum pressure port T PSI (bar) DC up to 3050 (210); AC up to 2320 (160)
With spools A and B, port T must be used as a drain line,
if the operating pressure exceeds the permissible pressure
at port T
Maximum flow GPM (L/min) 32 (120)
Flow area for spool V in2 (mm2) 0.017 (11) (A/B T); 0.016 (10.3) (P A/B)
for spool W [3%] in2 (mm2) 0.004 (2.5) (A/B T)
(in center position 0): for spool Q [6%] in2 (mm2) 0.009 (5.5) (A/B T)
Hydraulic fluids Petroleum oils (HM, HL, HLP)
Phosphate ester fluids (HFD-R)
Fluid temperature range F (C) NBR seals; 22 ... 176 F ( 30 ... 80 C)
FPM seals; 5 ... 176 F ( 20 ... 80 C)
Viscosity range SUS (mm2/s) 35 ... 2320 (2.8 ... 500)
Maximum degree of fluid contamination Class 18/15 according to ISO 4406.
Therefore, we recommend a filter with a retention rate of
10 75.
Electrical
Type of supply DC AC
Available voltages V 12, 24, 42, 60, 96, 110, 125, 24, 42, 110, 120, 127, 220, 240
(See below for ordering codes for AC solenoids) 180, 196, 220 (50/60 Hz)
Power requirements W 35
Holding power VA 90
In-rush power VA 550
Duty cycle Continuous Continuous
Shifting time ON ms 45 ... 60 15 ... 25
(to ISO/DIS 6403) OFF ms 20 ... 30 20 ... 30
Shifting frequency Cycles/hour 15,000 7,200
Insulation - exceeds NEMA class B IP 65 IP 65
Coil temperature F (C) ... 302 (150) ... 356 (180)
Note: AC solenoids
These solenoids are dual frequency for 2 or 3 different voltage/ 42 V, 50 Hz 127 V, 50 Hz
W42 W127
42 V, 60 Hz 127 V, 60 Hz
Ordering
Ordering
frequency ranges:
Code
Code
E.g. solenoid model W110 is for: 110 V, 50 Hz 110 V, 50 Hz 220 V, 50 Hz

110 V, 60 Hz W110 110 V, 60 Hz W220 220 V, 60 Hz
120 V, 60 Hz 120 V, 60 Hz 240 V, 60 Hz
When making the electrical connection, the ground

screw ( PE) must be connected to earth ground
4/12
RA 23 316/06.98
Flow vs. pressure drop curves, measured at = 190 SUS (41 mm2/s) and t = 122 F (50 C)
(14) 11
200 Spool Flow direction
10
(13) type PA PB AT BT
175
Pressure differential in PSI (bar)
(12) A, B 4 4
9
(11) C 4 4 5 6
150 8 D, Y 6 6 7 7
(10)
(9) 7 E 2 2 5 5
125 6 F 1 2 6 5
(8) 5 G 4 4 7 8
(7) 100 4 H 2 2 7 8
(6) 3 J 2 2 4 4
2
(5) 75 L 3 3 4 6
1
(4) M 2 2 5 6
50 P 1 3 6 7
(3) Q 2 3 2 4
(2) 25 R 4 7 5
(1) T 4 4 7 8
U, V 3 3 4 4
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 W 3 3 5 6
0 Cross-over pos. P A B A A T P T
(20) (40) (60) (80) (100) (120)
R 10
Flow in GPM (L/min)
Center position P A P B B T A T P T
F 5 10 10
P 6 9 11
G, T 10
H 4
Performance limits, measured at = 190 SUS (41 mm2/s) and t = 122 F (50 C)
Because of silting, the shifting function of the valves is depen- If only one direction of flow is required, for example, when a 4-
dent upon filtration. To obtain the maximum flow values shown, way valve has one port plugged, or unbalanced flows from large
full filtration of 25 m is recommended. The flow forces acting rod cylinders, the permissible flow in critical cases can be
within the valve also influence performance. In 4-way valves, the considerably lower. The A or B spool (3-way) can be used as an
data provided is for applications with 2 directions of flow (flow approximation of the limited flow performance.
from P to A and an equal, simultaneous return from B to T, see
table).
Performance limits measured with solenoids at operating temperature, 10 % undervoltage and without tank port pressure.
Valves with DC solenoids

(315) 4500
(300) 1 Curve Spool type
10
4000 1 C, C/O, C/OF
4
Operating pressure in PSI (bar)
(250) D, D/O, D/OF

3500 Y, M
5 2 2 E
(200) 3000 3 A/O, A/OF
6 3 L, U, J, Q, W
2500
4 H
(150) 51) R
2000
8 6 G
7
(100) 1500 7 T
9 8 F, P
1000 9 A, B
(50) 10 V
500
1) Return flow
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 (independent of area ratio)
0
(20) (40) (60) (80) (100) (120)
Flow in GPM (L/min)
5/12
RA 23 316/06.98
Performance limits, measured at = 190 SUS (41 mm2/s) and t = 122 F (50 C)
Valves with AC solenoids, e.g. W110: 120 V, 60 Hz

240 V, 60 Hz
(315)
(300) 4500
7
9 11 1
4000
(250) 2
3500
10
(200) 3000
5
2500
(150)
2000
7 see graphs at left
(100) 1500
42 V, 50 Hz; 110 V, 50 Hz; 120 V, 60 Hz;
1000 127 V, 50 Hz; 220 V, 50 Hz; 240 V, 60 Hz
(50) 9
Curve Spool type
500
7 1 C, C/O, C/OF
0 D, D/O, D/OF
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 Y
0
2 E, L
(20) (40) (60) (80) (100) (120)
U, Q, W
Flow in GPM (L/min) 3 M
(315) 4 A, B
(300) 4500 5 A/O, A/OF, J
6 6 G
4000
4 3 7 F, P
(250)
3500 8 V
8 9 T
(200) 3000 10 H
2500 11 R
(150)
2000
(100) 1500
6
1000
(50)
500
4
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
0
(20) (40) (60) (80) (100) (120)
Flow in GPM (L/min)
Valves with AC solenoids, e.g. W110: 120 V, 60 Hz see graph at left

(315)
(300) 4500 42 V, 60 Hz; 110 V, 60 Hz;
127 V, 60 Hz; 220 V, 60 Hz
4000
3 Curve Spool type
(250)
3500
2 1 C, C/O, C/OF
5 6 1
(200) 3000 D, D/O, D/OF
4 Y
2500 2 A/O, A/OF
(150)
2000
3 E
(100) 1500 4 M
5 V
1000 6 H
(50)
500
Performance limits of special spools, on
request
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
0
(20) (40) (60) (80) (100) (120)
Flow in GPM (L/min)
6/12
RA
RA23
23316/06.98
316/2.96
Unit dimensions, valve with DC solenoids: dimensions in inches (millimeters)
7
2.126
(54)
0.728 (18.5)
0.69
(17.5)
A B
2.76 TA TB 1.81
(70) (46)
11; 14 12 13
7.1 5.2 7.2 8

0.6 0.6
(15) (15)
1/2" NPT
A 0.433 B B
(11)
1.575 1/2" NPT
4.69 (40)
4.84
(119) (123)
1.181
(30)
0.260
(6.6) 4 10
0.83 3.583 0.83
(21)
8.41 (91)
0.22 (21) 0.22
(5.5) (213.5) (5.5)
8.41
(213.5)
2.95 11.57 2.95
(75) (294) (75)
2 1 3 6
16
1/2" NPT
15 *
4.84
3.93 (123)
(100)
2.66
(67.5)
3.68
1.55 (93.5)
(39.5)
*Note: See next page for terminal box connections
Tightening torque (typical) 53 in-lbs + 17 in-lbs (6 Nm + 2 Nm)
7/12
316/2.96
RA 23 316/06.98
Unit dimensions, valve with DC solenoids: dimensions in inches (millimeters)
1 3 position valve 10 Space required for N option 0.0004/4.0 in

without manual override 11 Nameplate 0.01/100 mm
with manual override N9 12 5) O-Rings 12 mm x 2 mm (for 32
2 2 position valve with 1 solenoid valve with cartridge throttle) (Rmax 4)
(A, C, D, EA...) R-Rings 13 mm x 1.6 mm x 2 mm
without manual override 13 Additional T port (TB) may be used
with manual override N9 in conjunction with pressure Required surface finish of
3 2 position valve with 1 solenoid reducing valve Model ZDR 10 D.. interface when mounting the
(B, Y, EB...) (RA 26 585) when mounted on a valve without our subplate
without manual override suitably drilled interface
with manual override N9 14 Porting pattern to ISO 4401-5, NFPA
4 Cover for valve with 1 solenoid T3.5.1M R1 and
5.1 Solenoid a ANSI B 93.7 D 05
5.2 Solenoid b 15 Conduit box version, DA
6 Space required to remove solenoid 16 Conduit box with lights, DAL
7 Standard 1/2" NPT electrical
conduit connector (suffix A) Subplates Terminal connections for conduit
7.1 Angled electrical connector plug G 66/05 (3/8" NPT); version
Z45 for cable or 1/2" NPT flexible G 66/12 (SAE-6; 9/16-18); For 1 solenoid:
conduit (may be rotated in 90 G 67/05 (1/2" NPT); Solenoid always to terminals 1
increments). G 646/12 (SAE-10; 7/8 - 14); and 2
7.2 Large angled electrical connector G 534/05 (3/4" NPT); Earth to terminal
plug Z55 or Z55L (with light) for G 534/12 (SAE-12; 1-1/16 - 12) For 2 solenoids:
cable or 1/2" NPT flexible conduit Solenoid a to terminals 1 and 2
(may be rotated in 90 increments). Valve Mounting Bolts Solenoid b to terminals 3 and 4
8 Space required to remove plug 4) 1/4 - 20 UNC x 1-1/2" (M6 x 40 mm)
Earth to terminal
9 Manual override N9 (standard) socket head cap screws
permissible manual operation only (SAE grade 8 or better)
to 725 PSI (50 bar) tightening Tightening torque 11.4 lb-ft (15.5 Nm)
torque = 5.9 lb-ft (8 2 Nm) Subplate and valve mounting bolts must
do not damage the manual over- be ordered separately, see RA 45 054
ride bore. Handknob part
# RR00 024943 may be used.
8/12
RA
RA23
23316/06.98
316/2.96
Unit dimensions, valve with AC solenoids: dimensions in inches (millimeters)
7 2.126
(54)
0.728 (18.5)
0.69
(17.5)
A B
2.76 TB 1.81(46)
(70)
TA
9 11;14 12 13 9
0.6
0.6 (15)
(15)
8 1/2" NPT
7.1 A B
0.433 B
(11)
4
1/2" NPT
4.69
(119) 1.575 4.84
(40) (123)
5.1 0.260
1.181 (30) (6.6) 4
0.6 0.83 3.583 0.83
(15) (21) (91) (21)
7.44 0.6
(189) (15)
10 7.44
(189)
1.81 9.57 1.81
6 (46) (243) (46)
2 1 3
16
1/2" NPT
*
15
4.84
3.93 (123)
(100)
2.66
(67.5)
3.68
1.55 (93.5)
(39.5)
*Note: See next page for terminal box connections
9/12
RA 23 316/2.96
316/06.98
Unit dimensions, valve with AC solenoids: dimensions in inches (millimeters)
1 3 position valve 10 Space required for N option 0.0004/4.0 in

without manual override 11 Nameplate 0.01/100 mm
with manual override N9 12 5) O-Rings 12 mm x 2 mm (for 32
2 2 position valve with 1 solenoid valve with cartridge throttle) (Rmax 4)
(A, C, D, EA...) R-Rings 13 mm x 1.6 mm x 2 mm
without manual override 13 Additional T port (TB) may be used
with manual override N9 in conjunction with pressure reducing Required surface finish of
3 2 position valve with 1 solenoid valve Model ZDR 10 D.. (RA 26 585) interface when mounting the
(B, Y, EB...) when mounted on a suitably drilled valve without our subplate
without manual override interface
with manual override N9 14 Porting pattern to ISO 4401-5, NFPA
4 Cover for valve with 1 solenoid T3.5.1M R1 and
5.1 Solenoid a ANSI B 93.7 D 05
5.2 Solenoid b 15 Conduit box version, DA
6 Space required to remove solenoid 16 Conduit box with lights, DAL
7 Standard 1/2" NPT electrical
conduit connector (suffix A) Subplates Terminal connections for conduit
7.1 Angled electrical connector plug G 66/05 (3/8" NPT); version
Z45 for cable or 1/2" NPT flexible G 66/12 (SAE-6; 9/16-18); For 1 solenoid:
conduit (may be rotated in 90 G 67/05 (1/2" NPT); Solenoid always to terminals 1
increments). G 646/12 (SAE-10; 7/8 - 14); and 2
7.2 Large angled electrical connector G 534/05 (3/4" NPT); Earth to terminal
plug Z55 or Z55L (with light) for G 534/12 (SAE-12; 1-1/16 - 12)
For 2 solenoids:
cable or 1/2" NPT flexible conduit Solenoid a to terminals 1 and 2
(may be rotated in 90 increments). Valve Mounting Bolts
Solenoid b to terminals 3 and 4
8 Space required to remove plug 4) 1/4 - 20 UNC x 1-1/2" (M6 x 40 mm)
Earth to terminal
9 Manual override N9 (standard) socket head cap screws
permissible manual operation only (SAE grade 8 or better)
to 725 PSI (50 bar) tightening Tightening torque 11.4 lb-ft (15.5 Nm)
torque = 5.9 lb-ft (8 2 Nm) Subplate and valve mounting bolts must
do not damage the manual over- be ordered separately, see RA 45 054
ride bore. Handknob part
# RR00 024943 may be used.
10/12
RA
RA23
23316/06.98
316/2.96
Ordering code, available spare parts and seals
Individual connection
113
113
113
160
160
113
113 157a
Central connection
113
113
113
160
160
113
113 157b
157b
Spare parts Solenoid

DC Voltage AC Voltage
Item Description Voltage Order No. Voltage Order No.
157a Coil for individual connection 12 V RR00 019792 110 V RR00 019816
24V RR00 019793 230 V RR00 071037
157b Coil for conduit version 12 V RR00 019782 110 V RR00 019801
24V RR00 019783 230 V RR00 071039
160 Seal kit Hand nut for pole tube w/o manual override RR00 835976 RR00 835967
and pole tube with protected manual override
Seal kit Hand nut for pole tube with manual override RR00 835964 RR00 835978
Seal kit Valve: Plug or conduit connection

Item Seal Material Order number
113 NBR seals RR00 312582
FPM seals RR00 312583
11/12
RA 23 316/06.98
Notes
Mannesmann Rexroth Corporation

Rexroth Hydraulics Div., Industrial, 2315 City Line Road, Bethlehem, PA 18017-2131 Tel. (610) 694-8300 Fax: (610) 694-8467
Rexroth Hydraulics Div., Mobile, 1700 Old Mansfield Road, Wooster, OH 44691-0394 Tel. (330) 263-3400 Fax: (330) 263-3333
12/12 All rights reserved Subject to revision

Printed in U.S.A.
IMO - 212 Issue Date: 12/01
INSTALLATION, MAINTENANCE, AND

SERIES 100
BALL VALVES
Read entire instructions carefully before installation or servicing
1 GENERAL 2 INSTALLATION
This instruction manual contains important information 2.1 Screwed End Valves
regarding the installation, operation and troubleshooting
of the Jamesbury Series 100 Ball Valves. Please read these Screwed end valves have NPT threads (not Dryseal type).
instructions carefully and save them for future reference. To insure a leaktight joint, liberal use of a compatible
pipe joint compound is necessary. It is recommended that
a screwed valve be installed with the body cap facing
upstream. Use standard piping practices when installing
1.1 WARNING valves with threaded parts. When tightening the valve to
the pipe, apply the wrench to the end nearest the pipe
FOR YOUR SAFETY, IT IS IMPORTANT THAT THE FOLLOWING PRECAU-
TIONS BE TAKEN PRIOR TO REMOVAL OF THE VALVE FROM THE LINE
being worked.
OR BEFORE ANY DISASSEMBLY:
3 MAINTENANCE
1. WEAR ANY PROTECTIVE CLOTHING OR EQUIPMENT NORMALLY
REQUIRED WHEN WORKING WITH THE FLUID INVOLVED. Periodically observe the valve to be sure of proper
performance. More frequent observation is recommended
2. DEPRESSURIZE THE LINE AND CYCLE THE VALVE AS FOLLOWS: under extreme operating conditions.
A. PLACE THE VALVE IN THE OPEN POSITION AND DRAIN THE Routine maintenance consists of tightening the stem nut
LINE. 1/8 turn periodically to compensate for the wear caused
B. CYCLE THE VALVE TO RELIEVE RESIDUAL PRESSURE IN THE BODY
by the stem turning against the resilient PTFE seal.
CAVITY BEFORE REMOVAL FROM THE LINE.
3.1 DISASSEMBLY
C. AFTER REMOVAL AND BEFORE DISASSEMBLY, CYCLE THE
VALVE AGAIN SEVERAL TIMES. NOTE: Replacement of all seats and seals is advised
whenever the valve is completely disassembled. When
3. WHEN INSTALLING OR REMOVING PIPING FROM THE VALVE, prying out soft parts, be sure not to scratch or damage any
PLACE A WRENCH ON THE BODY OR THE BODY CAP NEAREST
metal parts.
THE END BEING WORKED. MAKE CERTAIN BODY CAP END OF THE
VALVE DOES NOT TURN OUT OF THE VALVE BODY. (BODY/BODY
CAP JOINT IS A RIGHT HAND THREAD.) 1. Close the valve. Remove the stem nut (16), shakeproof
washer (9), handle (15), and gland nut (18). (See
Figure 1).
2
2. Unscrew and remove the body cap (2) and seal (6). 11. Grease and insert the gland nut (18). Tighten until
Loctite is applied to the cap (2) at assembly so heat snug, plus and additional 1/4 - 1/2 turn.
may be required.
12. Place the handle (15), shakeproof washer (9), and stem
3. If the ball (3) and seats (5) do not fall from the body nut (16) over the stem (4). Tighten the stem nut (16)
with the ball in the fully closed position, then gently until snug.
tap the ball (3) out from the end opposite the body
13. Cycle the valve slowly twice to ensure proper assembly.
cap (2). Be sure to use a soft material that will not
damage the ball.
TABLE 1 RECOMMENDED GREASE
4. Push the stem (4) from the top of the valve into the
Stem, Ball, Seat *Chevron Duralith EP2
body (3) and remove it through the body cap (2) end
of the body (1). *FEL-PRO 51168 Food
Gland Nut
Grade Anti-Seize Lubricant
5. Remove the stem bearing (8) and stem seals (7). The
* Or equivalent
stem seals may have to be pried out. Be careful not to
damage the gland nut (18) threads in the body (1).
3.2 Assembly TABLE 2 BODY CAP TIGHTENING TORQUE

REQUIREMENT ft-lbs (Nm)
NOTE: Recommended greases are shown in (Table 1).
Valve Size 152M (WCB) 156M (CF8M)
1. Press stem seals (7) into valve body (1). 1/4 (DN 6) 21.7 (29.4) 26.0 (35.2)
3/8 (DN 10) 21.7 (29.4) 26.0 (35.2)
2. Clamp the valve body (1) securely in a vise with the 1/2 (DN 15) 26.0 (35.2) 30.4 (41.2)
body cap side facing up. 3/4 (DN 20) 34.7 (47.0) 39.0 (52.9)
1 (DN 25) 43.4 (58.8) 47.7 (64.7)
3. Apply grease to one seat (5) and drop the seat (5) into
1-1/4 (DN 30) 56.4 (76.5) 60.7 (82.3)
the valve body (1) with the flat surface on the bottom.
1-1/2 (DN 40) 78.1 (105.9) 95.4 (129.3)
4. Apply grease to the stem (4) and insert the stem 2 (DN 50) 95.4 (129.3) 104.1 (141.1)
bearing (8) over the stem (4).
5. Insert the stem (4) through the open end of the body 4 REPAIR KITS/SPARE PARTS
(1) up into the stem hole.
TABLE 3 REPAIR KITS
6. Align the stem (4) blade inside the body (1) with the
Valve Repair Valve Repair
slot in the ball (3). Grease and insert the ball (3). Size Kit Size Kit
7. Grease and insert the second seat (5) into the body (1) 1/4 & 3/8 1-1/4
15M RKN-250 15M RKN-254
so that the sealing surface of the seat is towards the (DN 6 & 10) (DN 30)
ball (3).
1/2 1-1/2
15M RKN-251 15M RKN-255
(DN 15) (DN 40)
8. Insert the body seal (6) into the body (1).
3/4 2
9. Apply LOCTITE 680 or equivalent, one bead 360 15M RKN-252 15M RKN-256
(DN 20) (DN 50)
around the body cap (2) covering a minimum of two
threads. NOTE: Body (1) and body cap (2) threads must 1
be prepared according to LOCTITE instructions before 15M RKN-253
(DN 25)
assembly.
10. Insert the body cap (2), screw it down and tighten to For further information on spare parts and service or
the torque specified in (Table 2). assistance visit our web-site at www.Jamesbury.com.
3
15
4
16
9
7
6
8
18 5
1 3
Figure 1
TABLE 4 BILL OF MATERIALS AND PARTS LIST

Part Body Material
Part Name
Number Carbon Steel 152M 316 Stainless Steel 156M
1 Body Carbon Steel 316 Stainless Steel
2 Body Cap Carbon Steel 316 Stainless Steel
3 Ball 316 Stainless steel
4 Stem 316 Stainless steel
5 Seat Reinforced PTFE

6 Body Seal Reinforced PTFE
7 Stem Seal Reinforced PTFE
8 Stem Bearing Reinforced PTFE
9 Shakeproof Washer Carbon Steel 316 Stainless Steel
15 Handle Carbon Steel 316 Stainless Steel
16 Stem Nut Carbon Steel 316 Stainless Steel
18 Gland Nut Carbon Steel 316 Stainless Steel

4
5 ACCESSORIES 4. Place the weather seal (3) over the extension shaft (1)
and slide it down half way.
5.1 Stem Extension
5. Next, place the handle, lock washer, and upper stem
This section contains important information regarding the nut onto the top of the extension shaft. Tighten the
installation, operation and troubleshooting of the upper stem nut.
Jamesbury Series 100 Ball Valve Stem Extensions. Please
read these instructions carefully.
Upper Stem Nut

5.2 WARNING
Lockwasher
TO PREVENT INJURY, DO NOT ATTEMPT TO MOUNT A STEM
EXTENSION TO A PRESSURIZED VALVE. Handle
3
5.3 Description
Jamesbury Stem Extensions are designed to manually
actuate valves when valve handle accessibility is difficult.
These stem extensions are available in 4" (102 mm)
lengths as standard, to accommodate varying service 1
conditions.
4
5.4 Installation
Disassembly
2
1. Close the valve by rotating the handle clockwise.
2. Remove the upper stem nut, lock washer, and handle.

Save these parts for assembly onto the stem extension.
Assembly
1. Place the indicator stop plate (2) onto the stem, making
sure the bent tab is in the same orientation that the
handle was.
PARTS LIST
2. Screw the extension shaft (1) onto the stem until it ITEM PART NAME QTY
bottoms on the stem. If the drilled and tapped holes 1 Body 1
for the set screws do not line up with the flats of the 2 End Cap 2
stem, rotate stem and back off until these holes are 3 Ball 1
aligned with the flats. 4 Stem 1
3. Apply LOCTITE 272 or equivalent on the socket set

screw threads (4). Then screw them into the threaded Figure 1
holes at the bottom of the extension until they are tight.

Europe (UK), 8 Pipers Wood Industrial Park, Waterlooville, Hampshire PO7 7XU UK. Tel. int. +44 (0)23 9223 8500. Fax int. +44 (0)23 9223 8510
North America, 3100 Medlock Bridge Road, Suite 250, Norcross, GA 30071, USA. Tel. int. +1 770 446 7818. Fax int. +1 770 242 8386
Latin America, Av. Central, 181- Chracas Reunidas, 12238-430, So Jose dos Campos. Tel. int. +55 12 335 3500. Fax int. +55 12 335 3535
www.jamesbury.com
IMO-212-12/01 2001 Metso Automation Printed in U.S.A.-M-J

CHECK VALVES
Specifications:
5000 psi Operating Pressure

9 Sizes, 1/8 - 2
NPT or SAE O-Ring Connections and Manifold Mounting
Flows to 150 gpm
Carbon Steel Housing
RV - Inline Mounting FPM (Viton) O-Rings (standard or RVP series)
Metal to Metal Seal Design
Hardened and Ground Steel Poppet
3 Cracking Pressures: 7 psi (standard),
25 psi and 65 psi (optional)
Temperature Range:
-4 to 212F
B A
RVP - Manifold Mounting
Hydraulic Symbol
Model Code
RV - 06 - 01 .X / 5 - 25
Check Valve
RV = Inline Mounting
RVP = Manifold Mounting
Nominal Sizes
Nom Size SAE (RV Only) NPTF (RV Only)
(RV + RVP) Tube Size Thread Size Pipe Size Pipe OD
06 -2 5/16-24 UNF 1/8 .405
08 -4 7/16-20 UNF 1/4 .540
10 -6 9/16-18 UNF 3/8 .675
12 -8 3/4-16 UNF 1/2 .840
16 -12 1-1/16-12 UN 3/4 1.050
20 -16 1-5/16-12 UN 1 1.315
25 -20 1-5/8-12 UN 1-1/4 1.660
30 -24 1-7/8-12 UN 1-1/2 1.900
40 -32 2-1/2-12 UN 2 2.375
Housing Material
01 = Carbon Steel
Modification Number
Port Configuration
5 = NPTF - ANSI/ASME 1.20 Taper Pipe Thread
12 = SAE - SAEJ1926 Ports with ISO 725 Threads and O-Ring Sealing
0 = BSP to DIN 3852, Part 2-X (Special Order)
Omit = RVP Only
Supplementary Details
25 = 25 psi
65 = 65 psi Cracking Pressure
Note: RVP not available in size 40

Note: Not recommended for high-cycle applications!
14
PRESSURE DROP CURVES
RV 6-16 RV 20-40
160 160
10 140 10
140
RV 06
RV 08
RV 10
21
8 120 8 120
RV
P in bar
P in bar
P in psi
P in psi
100 100
20
6 80
6
80
25
RV
16
4 60 RV 4 60 RV 30
RV V 40
40 40 R
2 2
20 20
0 0 0 0
0 5 10 15 20 25 30 35 40 45 50 55 0 20 40 60 80 100 120 140 160
Flow gpm Flow gpm
0 20 40 60 80 100 120 140 160 180 200 0 50 100 150 200 250 300 350 400 450 500 550 600
Flow L/min Flow L/min
Pressure Drop curves were established by using mineral oil with kinematic viscosity 350 SUS at 86F / 30C
DIMENSIONS: RV
B A
Hex L
Port Size L WT
Model Hex in lbs.
Code NPT UNF (mm) (kg)
11/16 1.77 22
RV-06 1/8 5/16-24 UNF
(17) (45) (0.1)
3/4 2.17 .44
RV-08 1/4 7/16-20 UNF
(19) (55) (0.2)
1 2.60 .44
RV-10 3/8 9/16-18 UNF
(24) (65) (0.2)
1-1/4 2.87 .66
RV-12 1/2 3/4-16 UNF
(30) (73) (0.3)
1-7/16 3.46 1.1
RV-16 3/4 1-1/16-12 UN
(36) (88) (0.5)
1-13/16 5.00 2.4
RV-20 1 1-5/16-12 UN
(46) (127) (1.1)
2-3/8 5.63 4.0
RV-25 1-1/4 1-5/8-12 UN
(60) (143) (1.8)
2-9/16 5.63 5.7
RV-30 1-1/2 1-7/8-12 UN
(65) (143) (2.6 )
3-3/16 6.50 9.7
RV-40 2 2-1/2-12 UN
(80) (165) (4.4)
Note: Contact HYDAC for RVP Dimensions.
15
PRESSURE FILTER Sheet No.
Series HP 171 - 451 6000 PSI 1468 C
1. Type index:
1.1. Complete filter: (ordering example)
HP . 361. 10VG. HR. E. P. -. UG. 5. -. -. AE
1 2 3 4 5 6 7 8 9 10 11 12
1 series:
HP = pressure filter
2 nominal size: 171, 241, 361, 451
3 filter-material and filter-fineness:
25 VG = 20 m(c), 16 VG = 15 m(c), 10 VG = 10 m(c), 6 VG = 7 m(c),
3 VG = 5 m Interpor fleece (glass fiber)
4 resistance of pressure difference for filter element:
30 = p 435 PSI
HR = p 2320 PSI (rupture strength p 3625 PSI)
5 filter element design:
E = single-end open
6 sealing material:
P = Nitrile (NBR) V = Viton (FPM)
7 filter element specification: (see catalog)
- = standard
VA = stainless steel
IS06 = see sheet-no. 31601
8 connection:
UG = thread connection
9 connection size:
5 = -16 SAE 6 = -20 SAE 7 = -24 SAE
10 filter housing specification: (see catalog)
- = standard
IS06 = see sheet-no. 31605
11 internal valve:
- = without
S1 = with by-pass valve p 51 PSI
S2 = with by-pass valve p 102 PSI
R = reversing valve, Q 55.75 GPM
12 clogging indicator or clogging sensor:
- = without
AOR = visual, see sheet-no. 1606
AOC = visual, see sheet-no. 1606
AE = visual-electrical, see sheet-no. 1615
VS1 = electronical, see sheet-no. 1617
VS2 = electronical, see sheet-no. 1618
1.2. Filter element: (ordering example)
01E. 360. 10VG. HR. E. P. -
1 2 3 4 5 6 7
1 series:
01E. = filter element according to INTERNORMEN factory specification
2 nominal size: 170, 240, 360, 450
3 - 7 see type index-complete filter
2. Dimensions: inch
type HP 171 HP 241 HP 361 HP 451
connection -16SAE -20SAE -24SAE -16SAE -20SAE -24SAE -16SAE -20SAE -24SAE -16SAE -20SAE -24SAE
A 11.33 11.61 11.81 13.30 13.58 13.77 16.45 16.73 16.92 20.59 20.86 21.06
B 10.23 10.35 10.43 12.20 12.32 12.40 15.35 15.47 15.55 19.48 19.60 19.68
C 13.77 13.77 13.77 15.74 15.74 15.74 18.89 18.89 18.89 23.03 23.03 23.03
D 1.10 1.25 1.37 1.10 1.25 1.37 1.10 1.25 1.37 1.10 1.25 1.37
E 2.75 2.87 2.95 2.75 2.87 2.95 2.75 2.87 2.95 2.75 2.87 2.95
F 4.40 4.56 4.56 4.40 4.56 4.56 4.40 4.56 4.56 4.40 4.56 4.56
weight lbs. 24 25 26 27 28 29 31 32 33 36 38 39
volume tank .18 Gal. .23 Gal. .31 Gal. .42 Gal.
Connection assignments as shown in the table are standard. To exchange connections see item 9 in type index.
EDV 07/03 Changes of measures and design are subject to alteration!
900 Air Park Drive, Zanesville, Ohio 43701

phone 740 - 452 - 7775 e-mail sales@atico-internormen.com
fax 740 - 454 - 0075 url www.internormen.com
3. Spare parts:
item qty. designation dimension article-no.
HP 171 HP 241 HP 361 HP 451
1 1 filter element 01E. 170 01E. 240 01E. 360 01E. 450
2 1 O-ring 34 x 3,5 304338 (NBR) 304730 (FPM)
3 1 O-ring 75 x 3 302215 (NBR) 304729 (FPM)
4 1 support ring 81 x 2,6 x 1 304581
5 1 clogging indicator visual AOR or AOC see sheet-no. 1606
6 1 clogging indicator visual-electrical AE see sheet-no. 1615
7 1 clogging sensor electronical VS1 see sheet-no. 1617
8 1 clogging sensor electronical VS2 see sheet-no. 1618
9 1 O-ring 15 x 1,5 315357 (NBR) 315427 (FPM)
10 1 O-ring 22 x 2 304708 (NBR) 304721 (FPM)
11 1 O-ring 14 x 2 304342 (NBR) 304722 (FPM)
12 1 screw plug 20913-4 309817
item 12 execution only without clogging indicator or clogging sensor
4. Description:
The pressure filters of the series HP 171-451 are suitable for a working pressure up to 6000 PSI.
The pressure peaks are absorbed by a sufficient margin of safety. The HP-filter is in-line mounted.
The filter element consists of star-shaped, pleated filter material which is supported on the inside by a perforated core tube and is
bonded to the end caps with a high-quality adhesive. The flow direction is from outside to inside. Filter elements are available down
to a filter fineness of 4 m (c).
INTERNORMEN-Filter elements are known as elements with a high intrinsic stability and an excellent filtration capability, a
high dirt-retaining capacity and a long service life.
INTERNORMEN-Filter are suitable for all petroleum based fluids, HW-emulsions, most synthetic hydraulic fluids and lubrication oils.
INTERNORMEN-Filter elements are available up to a pressure difference resistance of p 2320 PSI and a rupture strength of p 3625 PSI.
The internal valves are integrated into the centering pivot for the filter element.
After reaching the opening pressure the by-pass valve causes that an unfiltered partial flow passes the filter. With the reverse valve
a protection of the filter element is given when having a reverse flow inside the filter. The reverse flow will not be filtered.
5. Technical data:
temperature range: +14F to + 176F (for a short time + 212F)
operating medium: mineral oil, other media on request
max. operating pressure: 6000 PSI
test pressure: 7917 PSI
connection system: thread connection
housing material: C-steel
sealing material: Nitrile (NBR) or Viton (FPM), other materials on request
installation position: vertical
Classified under the Pressure Vessel Directive 97/23/EC for mineral oil (fluid group 2), Article 3, Para. 3.
Classified under ATEX Directive 94/9/EC according to specific application (see questionnaire sheet-no. 34279-4).
6. Symbols:
without indicator with electrical with visual-electrical with visual- with visual with electronical with electronical
indicator indicator electrical indicator clogging sensor clogging sensor
AE 30 and AE 40 AE 50 and AE 60 indicator AOR/AOC VS1 VS2
AE 70 and AE 80
filter without
internal valve
filter with
by-pass valve
filter with
reversing valve
7. Pressure drop flow curves: Precise flow rates see INF-Expert-System Filter, respectively p-curves; depending
on filter fineness and viscosity.
8. Test methods: Filter elements are tested according to the following ISO standards:
ISO 2941 Verification of collapse/burst resistance
ISO 2942 Verification of fabrication integrity
ISO 2943 Verification of material compatibility with fluids
ISO 3723 Method for end load test
ISO 3724 Verification of flow fatigue characteristics
ISO 3968 Evaluation of pressure drop versus flow characteristics
ISO 16889 Multi-pass method for evaluating filtration performance
US 1468 C
NEEDLE VALVES
Specifications: 0
. 5000 PSI Operating Pressure
. 8 Sizes, 1/8" - 1-1/2"
. NPT or SAE O-Ring Connections, Manifold Mounting
DV - Inline Mounting and Cartridge Type
. Flows to 80 GPM
. Carbon Steel Housing
. FPM (Viton) O-Rings (Standard)
. Graduated knob and color coded spindle for
accurate flow control
. Provision for panel mounting
DVP - Manifold Mounting

. Exclusive safety spindle design
Temperature Range:
. -40 to 212F
'--'-'--'1
:~:
I
I
.
I
.
I
I
'
Hydraulic Symbol
.
1
0'
DVE - Cartridge Valve
Model Code
DV - 06 - 01 .x / 5 - S-M
Needle Valve :r -
DV = Inline Mounting
DVP = Manifold Mounting
DVE = Cartridge Valve
Nominal Sizes
Nom. Size SAE (DVonly) NPTF (DV Only)
(DV+ DVP) Tube Size Thread Size Pipe Size Pipe OD
06 -2 5/16-24 UNF 1/8" .405
08 -4 7/16-20 UNF 1/4" .540"
10 -6 9/16-18 UNF 3/8" .675"
12 -8 3/4-16 UNF 1/2" .840"
16 -12 1-1/16-12 UN 3/4" 1.050"
20 -16 1-5/16-12 UN 1" 1.315"
25 -20 1-5/8-12 UN 1-1/4" 1.660"
30 -24 1-7/8-12 UN 1-1/2" 1.900
DVE
Nom Size Thread Size
08 3/4-16UNF
10 7/8-14UNF
12 1-1/16-12 UN
16 1-5/16-12 UN
Housing Material -
01 = Carbon Steel
Modification Number
Port Configuration - f
5 = NPTF - ANSI B1.20.3
12 = SAE - SAEJ1926 Ports with ISO 725 Threads and O-Ring Sealing
0 = BSP to DIN 3852, Part 2-X (SpecialOrder) a
Omit = DVP Only
Supplementary Details
S = Panel Mounting Kit
M = Steel Knob (usewhenambienttemperatureexceeds140F)
10 I I:.'..~'~"
0 100
80
a; 60
.Q
40
2E
0
300
0
0
L
0 4
2
Flow gprn
8
I I I
12
Flow Urnin
3 4
PRESSURE DROP CURVES
I
16
I
5
4
5
20
a; 60
.Q
~ 40
100
80
20
0
0
I
2
10
4
20
6
Flowgprn
I I I I I I I
30
Flow Urnin
40
8 10 12
I
50
14
.Q
0.
100
80
a; 60
<1 40
20
0
1500
"OJ
0.
1~0
a. 900
<1 600
300
0
Flow Setting in Turns
~
.~
0
I I
0
2
10
1
I I
20
6
2 3
I I I
30
Flow Urnin
-
9
Flow gprn
40
4
12
I I
50
15
60
5
6
7
DV / DVP - 06 DV / DVP - 08 DV / DVP - 10
100 100
80 80 80
a; 60 a; 60 a; 60
.Q .Q .Q
0. 0.
<1 40 ~ 40 <140
20 20 300 20 300
0 o' 0
10 15 20 25 0 10 20 30 40 50 0 15 30 45 60 75
Flow gprn Flow gprn Flow gprn
I I I I I I I I I I I I I I I I I I I I I I I I I
10 40 60 80 100 0 40 80 120 160 200 0 50 100 150 200 250 300
Flow L/rnin Flow L/rnin Flow Urnin
DV / DVP - 12 DV / DVP - 16 DV / DVP - 20/25/30

1Q
~
50 50 0.511.52 34 5
700
'"
~
.Q
~ 20
40
30
'"
~
.Q
40
30
~ 20 ~ 300
l400
600
500 ~ 7
6
8
200 9
10 10 10
100
0 0 0
6 9 12 15 024 6 8 10 12 14 16 18 20
Flow gprn Flow gprn
I I I I I
0 10 20 30 40 50 60 0 10 20 30 40 50 60 70 80
Flow L/rnin Flow L/rnin
DVE - 08 DVE - 10
~
50 1 23 4 5 6
700
~
'"
.Q
0. 20
1<1
40
30 ~
'"
.Q
~
40
30
20
600
500
"~ 400
~ 300
~ 7
200
10 10
100
0 0
15 20 25 30 35 40 00 5 10 15 20 25 30 35 40
~o Flow gprn
L-l
Flow gprn
~
0 20 40 60 80 100 120 140 160 0 20 40 60 80 100 120 140 160
Flow Urn in Flow Urnin
DVE - 12 DVE - 16
Pressure Drop curves were established by using mineral oil with kinematic viscosity 165 SUS at 112F / 5aoe .a'4.r.~.. 11
DIMENSIONS: DV
Hex extension
0
Knob for
Sizes 20-40
has Hex extension
for wrench
F
,+
I I
I
I
Knob for
sizes 6-16 B
Thickness closed
of panel
1/4" max. A
open
I J
~~~
Note: Dimensions shown in inches (millimeters)

0
Model
Port Size A B C D E F aG aH J11 WT
in in in in in in in in Hex Ibs.
Code NPTF SAE (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (kg)
2.16 1.97 .31 .63 .75 1.50 .94 .51 26
DV-06 1/8" 5/16-24UNF Pg 7 -
(55) (50) (8) (16) (19) (38) (24) (13) (.12)
2.83 2.56 .49 .98 .94 1.89 1.14 .75 .55
DV-08 1/4" 7/16-20UNF Pg 11 -
(72) (65) (12.5) (25) (24) (48) (29) (19) (.25)
2.91 2.64 .59 1.18 1.14 2.28 1.14 .75 .88
DV-10 3/8" 9/16-18UNF Pg 11 -
(74) (67) (15) (30) (29) (58) (29) (19) (.40)
DV-12 3.62 3.23 .69 1.38 1.34 2.68 1.50 .91 1.5
1/2" 3/4-16UNF Pg 16 -
(92) (82) (17.5) (35) (34) (68) (38) (23) (.70)
4.17 3.78 .89 1.77 1.53 3.07 1.50 .91 2.6
DV-16 3/4" 1-1/16-12UN Pg 16 -
(55) (50) 18) 116) (19) (38) (24) (13) (1.2)
5.71 5.04 .98 1.97 2.13 4.25 1.93 1.50 3/4 4.6
DV-20 1" 1-5/16-12UN Pg 29
(145) (128) 125) (50) (54) 1108) 149) (38) (19) (2.1)
5.91 5.24 1.18 2.36 2.13 4.25 1.93 1.50 3/4 6.2
DV-25 1-1/4" 1-5/8-12UN Pg 29
(150) (133) 130) 160) (54) (108) (49) (38) (19) (2.8)
6.10 5.43 1.38 2.76 2.13 4.25 1.93 1.50 3/4 7.7
DV-30 1-1/2" 1-7/8-12UN Pg 29 I
(155) (138) (35) (70) (54) (108) (49) (38) (19) (3.5)
I
II
1lNote: pg. style thread per DIN 40430
0'
12 I I:.'~.~.~..
www.hammfg.com
Eclipse Series - NEMA 4, 12

Single Door Enclosures
Industrial Enclosures
Wallmount Enclosures
Single Door with quarter turns Single Door with 3 point latching
handle
Application Construction Finish

Designed to enclose electrical and/ Formed 14 or 16 gauge steel. Cover and enclosure are finished in
or electronic equipment and protect Smooth, continuously welded seams recoatable smooth ANSI/ASA 61
against harsh, industrial ground smooth. gray powder coating.
environments for wallmount Door stiffeners are provided where
applications. required for increased strength and
Impressive styling features like
Accessories
rigidity - designed to also permit
hidden hinges, attractive latching additional mounting options. Air conditioners...see page 348-357
systems make the Eclipse a suitable Formed lip on enclosure to exclude Blowers...see page 359
addition to any high-tech equipment flowing liquids and contaminants. Breather kits...see page 374
installation. Door latches feature the added DIN rails...see page 35
A wide range of sizes and practical safety of quarter turn slot requiring DIN rail mounting kit...see page 35
accessories make this product line a use of tool for opening. Door stop kit...see page 393
complete package. Doors may be easily removed for Filter fans...see page 360-367
For high temperature applications, a modifications and are Heaters...see page 369-371
gasket retainer may be required, interchangeable. Handles...see page 36
please refer to factory. Oil resistant gaskets are Inner panel...see page 34
permanently secured. Quarter turn inserts and keys
Standards Collar studs provided for mounting ...see page 36
inner panel. Literature pocket...see page 397
UL 508 Type 3R, 4, 12 and 13
Includes hardware kit with panel Mounting foot kit...see page 36
CSA Type 3R, 4, 12 and 13
mounting nuts and sealing washers Swing panel...see page 35
Complies with
for wall mounting holes. Swing frame...see page 34
NEMA Type 3R, 4, 12 and 13
Bonding stud provided on door and Replacement hinge pins...see page 34
IEC 529, IP65 grounding stud installed in Replacement quarter turn
enclosure. assemblies...see page 36
Hinges are constructed from 304 Thermostats...see page 374
stainless steel. Touch up paint...see page 396
Hinge pins are stainless steel. UL/CSA approved hardware kit
Quarter turn latches formed from ...see page 382
mild steel diecast key lockable Padlock Adapter (EPA)...see page 382
handle with black epoxy finish on 3
point latch.
Technical references and DXF downloads available at www.hammfg.com All dimensions in inches unless specified otherwise
22 Quality Enclosures. Service Excellence.

Hammond Manufacturing Canada: 519.822.2960 or 905.456.3770 USA: 716.651.0086 Data Subject to change without notice
www.hammfg.com
www.hammfg.com

Front View Side View
Hinge Side
End View
Cross Section of 14 Cross Section of 16

Gauge Body & Door Gauge Body & Door
Front Section
(Door and Body Flange removed)
Quarter Turn Lock

Section Y-Y L Handle
Lock Section X-X
Mounting Detail Cross Section Through

Door & Body Flange Removed Detail A End View
Door Cam Typ 2 pls when
L handle is used
Refer to part number and dimension chart on previous page
Quality Enclosures. Service Excellence. 23

www.hammfg.com

Overall Dimensions Door/Body Latches Opt. Panel Panel Size # Ship Wt.
Part No. A B C Gauge Qty Type Part No. D E Hinges F lbs.
EN4SD12126GY 12 12 6 16 1 Qtr Turn EP1212 10.2 10.2 2 6 12

EN4SD161210GY 16 12 10 16 1 Qtr. Turn EP1612 14.2 10.2 2 10 18
EN4SD423610GY 42 36 10 14 1 3-point EP4236 40.2 34.2 4 12 117
EN4SD482410GY 48 24 10 14 1 3-point EP4824 46.2 22.2 4 14 95
EN4SD483610GY 48 36 10 14 1 3-point EP4836 46.2 34.2 4 14 125
EN4SD603610GY 60 36 12 14 1 3-point EP6036 58.2 34.2 4 18 150
24 Quality Enclosures. Service Excellence.

www.hammfg.com
www.hammfg.com

Continued from previous page.
Overall Dimensions Door/Body Latches Opt. Panel Panel Size # Ship Wt.
Part No. A B C Gauge Qty Type Part No. D E Hinges F lbs.
EN4SD423612GY 42 36 12 14 1 3-point EP4236 40.2 34.2 4 12 121
EN4SD482412GY 48 24 12 14 1 3-point EP4824 46.2 22.2 4 14 98
EN4SD483612GY 48 36 12 14 1 3-point EP4836 46.2 34.2 4 14 148
EN4SD603612GY 60 36 12 14 1 3-point EP6036 58.2 34.2 4 18 165
EN4SD483616GY 48 36 16 14 1 3-point EP4836 46.2 34.2 4 14 148
Refer to drawing on following page
Optional Accessories
Inner panel...see page 34 Swing frame...see page 34 Swing panel...see page 35
DIN rail mounting kit...see page 35 DIN rails...see page 35 Handles...see page 36
Quarter turn inserts and Mounting foot kit...see page 36 Replacement hinge
keys...see page 36 pins...see page 34
Quality Enclosures. Service Excellence. 25

200 Smith Lane, Jackson, TN 38301 Phone: 731-424-5045 Fax: 731-265-2302
RECEIVING INSTRUCTIONS FOR OCS OIL COOLERS
INSPECTION
Inspect unit for shipping damage (especially core) before uncrating. Rotate fan, which should move freely.
Note that one blade is wired to guard on some models for shipping. Remove wire before rotating fan.
HANDLING
Exercise care to avoid damage to core. All units are shipped with wood skid facilitating forklift handling.
Lifting holes are provided.
STORAGE
Units normally have one coat of medium gray, semi-gloss enamel paint. A finish coat of paint should be
applied to all exterior ferrous surfaces unless storage is indoors. Do not paint core as this may impair airflow
and heat transfer. All openings are sealed with appropriate pipe plugs, pipe caps, thread protectors, and flange
covers at the factory. Be sure these are in place.
Form 2952-1 June, 1997/Revised 12/01 This form is shipped with product.
OCS Receiving & Installation Instructions.Doc page 1 of 3

INSTALLATION INSTRUCTIONS FOR OCS OIL COOLERS
LOCATION
Insure that no obstructions impede either discharge or inlet air flow. If unit is mounted in wall, provide ample
room ventilation. Cooler should be oriented to take advantage of prevailing winds to avoid recirculation and the
resultant loss of cooling effect. Expected wind direction on hot, summer days should especially be anticipated.
Ductwork on housing of unit adds airflow static resistance, which must be overcome with extra fan capacity.
Ducting should be larger in area than heat exchanger core face and contain only straight runs and long radius
turns.
Units should not be located in corrosive atmospheres as rapid deterioration of casing, cooling element, fan and
motor may take place resulting in shortened life and unnecessary replacement expense.
FOUNDATION AND MOUNTING
Flexible connections or non-rigid plumbing (hangers and right-angle bends) should be used to allow thermal
expansion of core, insulation from vibration and freedom from static loading. Piping should be sized based on
design flow and pressure drop requirements and not on the oil cooler supply and return tapping sizes.
A strainer or filter located ahead of the cooler or the heat source, depending on the type of service, should be
installed to trap scale; dirt or sludge that may be present in piping and equipment, or that may accumulate. A
thermostatic or spring loaded by-pass relief valve installed ahead of the cooler will be found helpful to hasten
warm-up and relieve the system of excessive pressures, as well as to control the oil temperature in certain
installations. These accessories should be considered in the original heat rejection and piping computations.
Young Touchstone OCS Oil Coolers are designed for operation with oil pressures of 200 psi maximum and
temperatures of 400 F maximum.
TYPE D DIRECT DRIVE COOLERS
Connect motor only to a power supply of the same characteristics as stamped on the motor nameplate. For
single speed motors, follow wiring diagram attached to motor. For multispeed motors, follow diagram included
with control furnished. Before starting motors, turn over fan by hand to eliminate possible motor burnout
should the fan have become damaged in shipment. Observe operation carefully after motor is started for the
first time.

INSTALLATION INSTRUCTIONS FOR OCS OIL COOLERS
TYPE E EXTERNAL DRIVE COOLERS
If drive requires vee belts, sheave alignment and correct belt tension must be maintained to transmit sufficient
power to fan and prevent excessive belt and bearing wear. Locate the idler sheave on the slack side of the belt
drive. Belt guards are provided by Young Touchstone on smaller coolers. Larger units must have guarding by
the owner of the cooler or OEM.
The assembly of sheaves and/or fans utilizing taper lock bushings requires clean surfaces and proper alignment
of bushing to sheave/fan. Initially snug the pull-up bolts, assuring correct fit of tapered mated surfaces. With
torque wrench, torque bolts in an alternating pattern to recommend torque. With a light hammer, tap between
the pull-up bolts, check torque, if necessary, re-torque to specifications.
Bolt dia. (lb.ft) Bolt dia. (lb.ft) Bolt dia. (lb.ft) Bolt dia. (lb.ft)
#10 5 3/8 30 5/8 135 1 450
1/4 9 1/2 60 3/4 225 1-1/8 600
5/16 15 9/16 75 7/8 300 1-1/4 750

MAINTENANCE INSTRUCTIONS FOR OCS OIL COOLERS
LUBRICATION
Lubricate motor according to instructions furnished with motor.
GENERAL INSPECTION
Inspect the unit regularly for loose bolts and connections, rust and corrosion and dirty or clogged cooling element (core).
EXTERNAL CLEANING
Dirt on fins reduces airflow and cooling capacity. Dirt on fan blades could reduce air output, unbalance fan or overload
motor. Dirt on motor reduces motor ventilation and cooling, causing overheating and possible burnout.
At least once each year, remove dust and greasy deposits from cooling element fins, motor, fan blades and fan shroud.
Use a stiff brush or air nozzle for loose dirt or a mild organic alkaline cleaning solution with brush for solid or greasy
deposits. Do not bend or damage cooling element fins. Care must be taken not to damage fan blades as resulting out-of-
balance condition may cause vibration, damage to motor bearings, and possible motor burnout due to overheating.
To clean heavy deposits on outside of core, remove core and tank assembly, plug all openings, and immerse in a mild
organic alkaline solution such as Fine Organics 2223 or Keychem 06000. A 10% concentration with water is typical and
solution should be heated to 160 to 180F to increase effectiveness. Agitation of the core increases effectiveness and
ultrasonic equipment can be effective for breaking up deposit particles. The length of time required to accomplish
cleaning is dependent upon the degree of fouling. Do not use a caustic solution boil out tank for cleaning, as damage to
the core fins will result.
INTERNAL CLEANING
Once a year, piping should be disconnected and a degreasing agent or flushing oil circulated through the unit to remove
sludge from turbulators and internal tube surfaces to return the unit to full capacity. For degreasing, Fine Organics 2223
or Keychem 06000 as indicated above may be used. A pump and filtration system can be used to circulate the degreasing
agent or flushing oil and capture deposit particles. Ideally the solution should be circulated in reverse direction to the
normal flow. If degreasing solution as recommended above is used, an oil flush of the core should follow soon after to
avoid rust formation on steel surfaces. A thorough cleaning of the entire system is preferable to avoid carry over from
unlearned piping, pump and accessories. If this is done, filter or strainer should be removed and necessary adjustment or
removal of by-pass valve effected. Regular cleaning or replacement of filter or strainer will help maintain a clean and
efficiently operating system.
Form 2952 June, 1997/Revised 6/00 This form is shipped with product.
OCS Maintenance & Warranty Instructions.Doc PAGE 1 OF 2

Standard Product One Year Limited Product Warranty Effective: May 1, 2003
(All products except DS1 radiators)
Contact the factory Service Department immediately through your local Young Touchstone Representative. In all
communications include complete nameplate data. Returned product Will Not be accepted without prior written
authorization from the factory Service Department.
Young Touchstone products have been manufactured and inspected with care by experienced crafts people. Young
Touchstone warrants your purchase to be free from defects in materials and workmanship to the original purchaser for a
period of one year from date of shipment subject to the following terms and conditions:
Warranty
Young Touchstone, hereinafter referred to as the Company, warrants that its products will be free from defects in
materials and workmanship under normal use and service for a period of one year in each case from the date of shipment
from the Companys plants.
Repair, replacement, or appropriate adjustment, at the Companys option, will be provided if, upon the Companys
inspection, the equipment is found to be properly installed, maintained, and operated in accordance with specifications to
which the equipment was manufactured. The Company shall have no liability for costs relating to removal or
reinstallation of defective components.
Any and all returns or repairs under this Warranty must be authorized in writing by the Company prior to return or repair
completion. Shipping costs for any product delivered to the Companys plant and subsequently returned to customer will
be at the customers expense. This Warranty does not apply to malfunctions caused by damage, unreasonable use,
misuse, repair or service by unauthorized persons, or normal wear and tear.
No Other Express Warranty Applies
Warranty Exclusions
*Warranty on components or accessories furnished by suppliers to the Company shall be limited to the
warranty of the respective supplier.
* Warranty shall not extend beyond the warranty offered by the end customer.
*Warranty does not apply to 1) the affects of physical or chemical properties of water/coolant used in the
equipment and 2) paint provided on the equipment or the cosmetic appearance of the equipment as this
is a maintenance issue.
*Expenses for service, labor or other matters incurred by the buyer, its customers or agents without prior
approval or authorization by the Company, will not be accepted.
*The Company shall not be liable for any contingent, incidental, punitive, or consequential damages.
Changes or repairs attempted or made in the field without written authorization from the Company void this warranty.
The Company, which is committed to continuous improvement, reserves the right to improve its products through changes
in design or material as it may deem desirable without being obligated to incorporate such changes in products of prior
manufacture.
Form 2000 October, 1986/Revised 6/00 This form is shipped with product.
OCS Maintenance & Warranty Instructions.Doc PAGE 2 OF 2

Young Touchstone
2825 Four Mile Road, Racine, WI 53404 PH : 262-639-1010 Fax : 262-639-1013
Instrucciones para el Recivimiento de Enfriadores de Aceite OCS
#1
Inspeccion:
Examinar el equipo y verificar que no tenga daos especialmente el panal (core) antes de
abrir la caja.Jire el ventilador que deberia rotar libremente. Atencion,una hoja(aspa) del
ventilador esta asegurada con un alambre(en algunos modelos) para embalaje.Quitar este
alambre del ventilador.
Manejo del Embalaje:
Tener cuidado en mover el equipo para evitar dao del panal. Todos los equipos estan
embalados de tal manera para facilitar uso del monta carga(camion).Usar respectivos
huecos(agujeros) de la caja para cargar el equipo.
Almacenaje:
Los equipos usualmente tienen una mano de pintura gris con esmalte(enamel paint),una
segunda mano de pintura debe ser aplicada al exterior,incluyendo partes de fierro,al
menos que el equipo sea guardado en los interiores donde no lo afecte el medio
ambiente.Atencion, no pintar el panal,esto afectaria la fluidez del aire a traves de
el,afectando la transferencia de calor.Todas las aberturas estan celladas con tapones
respectivos(incluyendo tapas de bridas).Verificar que estos esten en su sitio.
Formulario 2952-1 revisado Junio 1997(este formulario es enviado con producto)

Young Radiator Company
Instrucciones para Instalar Enfriadores de Aceite OCS
Pagina 1 de 2
#2
Ubicamiento:
Asegurar que nada impida que fluya el aire en la entrada y salida del panal. Si el equipo
va ser instalado en la pared asegurar que el aire pueda fluir libremente .La entrada del
aire debe ser ubicada de tal manera que reciba el aire fresco (frio) del viento o medio
ambiente.Esto es para aprovechar el enfriamiento maximo posible y evitar el
recirculamiento que bloquea el efecto de enfriamiento.Esto es muy beneficioso en el
verano.Ductos(partes) aadidas a la entrada de aire contribuye a la resistencia al flujo de
aire lo cual produce mas trabajo para el ventilador. Los ductos deben ser mas grandes en
area que la entrada de aire del panal.Y debera tener solo paletas ,rectas,paralelas al flujo
de aire.El equipo no debe ser ubicado en ambientes corrosivos para evitar la oxidacion de
las partes expuestas a ello,esto acortaria la vida del equipo y necesitaria cambio de piezas
antes del tiempo original diseado.
Base y Ensamblaje:
Las conexiones hechas para el montaje del panal deben ser flexibles ,de tal manera que
permita el movimiento al expandirse el panal con cambios de temperatura. Estas
conexiones deben poder absorber la vibracion del equipo.Tambien evitar poner peso
innecesario encima del equipo.Tuberias deben tener el tamao requerido por el diseo
(debido a cambios de Presion) y no del tamao de la conexion.Un filtro(o colador) debe
ser instalado delante del panal dependiendo del servicio requerido para atrapar tierra ,
polvo e impuresas del medio ambiente.
Una valvula de alivio(by pass relief valve) con la ayuda de un termostato instalada
delante del enfriador ayudara a calentar el sistema en climas frios al encendido y aliviara
el sistema de presiones ecsesivas,como tambien,controlar la temperatura del aceite en
ciertas instalaciones.Estos accesorios adicionales deben ser considerados en los computos
originales de extraccion de calor.
Enfriadores de Aceite(Young OCS Oil Coolers)estan diseadas para maxima presion de
aceite de 200psi y una temperatura maxima de 400`F.
Enfriadores Tipo D(Direct Drive Coolers)
Conectar motor solamente al voltage y caracteristicas requeridas por ello(caracteristicas

escritas sobre el motor en una placa).Para motores de una velocidad seguir instrucciones
adjuntas al motor.Para motores con multiples velocidades seguir instrucciones adjuntas a
los controles.Antes de prender los motores verificar la rotacion libre del
ventilador,asegurar que gire(rote) libremente y no este daada.Observar detenidamente
el funcionamiento despues de encender el motor.
Pagina 2 de 2
Enfriadores Externos Tipo E(External Drive Coolers)
Si el ventilador requiere fajas(correas) , verificar que esten bien templadas, para asegurar
que transmitan todo el poder al ventilador(sin patinar/resbalar) y evitar desgaste
innecesario de la correa y rodajes. Tambien alinear las calzas(sheave).Ubicar la calza de
la polea loca al mismo lado de la correa colgante(sin templar).
Tapas y protectores para las fajas(correas) vienen incluidas de fabrica solo para los
enfriadores pequeos.Para los enfriadores grandes el dueo(comprador) es responsable
por comprarlos e instalarlos.
Para ensamblar las calzas y/o ventiladores que usan conector conico de seguridad(Taper
lock bushings), necesita de una superficie limpia y alineamiento apropiado a la conexion
del la calza y/o ventilador.Inicialmente ajusta levemente los pernos de extraccion(pull-up
bolts),verificando que calze correctamente.Ahora apreta los pernos con una llave de
torque de manera alternativa a la medida indicada a continuacion.Usar si es necesario,un
martillo lijero,para golpear levemente los pernos para asegurar que tenga el torque
adecuado.
Diametro Perno Torque(lb-ft)

#10 5
9
5/16 15
3/8 30
60
9/16 75
5/8 135
225
7/8 300
1 450
1-1/8 600
1-1/4 750
Instrucciones para el Mantenimiento de Enfriadores de Aceite OCS
#4
Lubricacion:
Lubricar motor de acuerdo con las instrucciones que vienen adjuntas al motor.
Inspeccion General:
Inspeccionar el equipo regularmente por pernos sueltos , conexiones , oxido, corrocion,

tierra acumulada y suciedad en el panal.
Limpieza Externa:
Tierra y suciedad en el panal reduce la capacidad de enfriamiento .Ventiladores sucios

producen(crean) mas resistencia en la fluidez del aire, tambien, desbalanceo en el
ventilador que incrementa el trabajo del motor.Suciedad en el motor reduce la ventilacion
del motor causando calentamiento y posible dao al motor.
Al menos una vez al ao limpiar polvo y grasa depositadas en el ventilador, motor y
panal. Usar una escobilla o aire a presion o una solucion organica alkalina para limpiar
polvo y depositos de grasa.
No doblar ni daar panal.Precausion debe ser tomada para no daar las cuchillas(paletas /
aspas) del ventilador .Un mal uso de este podria causar el desbalanceamiento del
ventilador,produciendo vibraciones,daos a los rodajes del motor y posible fundicion del
motor por calentamiento.
Para limpiar depositos pesados alrededor del panal, sacar el panal y tanque ,tapar todos
los orificios abiertos y remojar en una solucion alkalina organica(leve),por ejemploFine
Organics 2223 o Keychem 06000, a 10% de concentracion con agua y calentando a
160-180`F para incrementar los efectos.Tambien agitar panal en la solucion para ayudar a
disolver depositos.Tambien puede ser utilizado un equipo de ultrasonidos.El tiempo que
requiere la limpieza es proporcional a la suciedad que tenga. No usar una solucion
caustica(muy fuerte) para evitar posible dao a las hojas(paletas) del panal.
Limpieza Interior:
Una vez al ao las tuberias deben ser desconectadas y una solucion(agente desengrasante)
introducida para enjuagar la suciedad e impuresas para mantener el equipo a su maxima
capacidad.Algunos ejemplos de solvents :Fine Organics 2223 o Keychem06000
pueden ser utilizados .Una bomba de agua y sistema de filtracion puede ser utilizada para
circular los liquidos usados para enjuagar.Idealmente la solucion debe ser circulada
(bombeada) en direccion opuesta a la direccion normal de circulacion.Si el producto de
limpieza recomendado es usado , otra producto de enjuague (aceite de enjuague) debe
ser utilizado para extraer el primer producto de limpieza para evitar oxidacion de la
superficie de fierro.Una limpieza profunda y detallosa es recomendable para evitar dejar
impuresas.EL filtro(o colador) tambien debe ser cuidadosamente limpiado lo cual
ayudara a tener el equipo en optimas condiciones.
Garantias para Enfriadores de Aceite OCS
#5
Comunicarse con los representantes autorizados de la compania a travez del representante
local de Young Radiator.Incluye los datos de las placas (numero de serie,etc).Productos
no seran aceptados sin previa autorisacion de los representantes autorizados.
Garantias :
Young Radiator company,desde ahora en adelante referido como la compania garantiza

sus productos, comerciales e industriales, contra defectos materiales, defectos producidos
durante uso normal y servicio por el tiempo de un ao desde la fecha de embarque de la
planta(fabrica) donde fue ensamblada(producida).
Todas las obligaciones y responsabilidades bajo esta garantia estan sujetas a una
reparacion o remplazo a discrecion de la compania.Los supuestos productos defectuosos
deben ser enviados con el flete pre-pagado a la fabrica original designada por la
compania.Todas las reparaciones o remplazos seran inspeccionados por la compania en la
planta.La compania no es reponsable por los gastos de desmontaje o montaje(armar o
desarmar) del equipo.
Accesorios adicionales adquiridos de otras companias tendran las garantias de sus
respectivas companias de origen.
Si el cliente requiere de la visita personal de un representante autorizado de la compania
y la falla es determinada ser no de la compania, el cliente sera responsable de pagar por el
tiempo y gastos del representante autorizado. Pagos, por servicios rendidos por el
representante autorizado no seran reenbolsados sin previa autorisacion de la compania.
Estas garantias no incluyen fallas producidas durante la instalacion del equipo ,ni fallas
por corrosion y oxidacion.Los productos de la compania no estan empaquetados ni
protegidos para estar almacenados mucho tiempo en ambientes corrosivos.Cambios y
reparaciones hechas en vuestra planta sin la autorisacion escrita de la compania
automaticamente pierde la garantia.
Las polizas de la compania estan en constante arreglo y reserva el derecho de mejorar sus
productos cambiando diseos y materiales segun sea conveniente sin ser obligados a
incorporar dichos cambios en productos hechos en el pasado.
INDEX MDS-O-0001
TOSHIBA INTERNATIONAL CORPORATION
SHEET NO. 1 of 3
Industrial Division / Houston Motor Plant
ISSUED 01/24/96
SUPERSEDES NEW
Motor Operation Procedure
REVISION 0
REFERENCE USE ONLY WHEN ISSUED BY MOTOR MKTG. WRITTEN BY I. MARQUEZ
APPROVED BY J. Bugbee
Motor Lubrication
Dist: Mktg.
QC 1. SCOPE
To give recommended guidelines for electric motor relubrication.
2. START UP
Toshiba motors are properly greased at the time of manufacture. It is recommended that
if a motor has been stored for a period of six months or more, it should be lubricated prior
to starting (See Fig. 1) using a standard hand held grease gun.
Fig. 1 FRAME SIZE QUANTITY of PUMPS

143 ~ 256 2 to 3 strokes
284 ~ 405 4 to 5 strokes
444 and Larger 6 to 10 strokes
It should be noted that grease leakage around the shaft hole could indicated over-
packing. Excess grease should be purged out by operating the motor temporarily with
the relief open.
Lubrication of electric motors should be done as a part of a planned maintenance

program.
Before greasing, be sure fittings are clean and free from dirt. Always relubricate using
grease that is fresh and free from contamination.
Toshiba motors may be equipped with an automatic grease relief fitting, grease plug or
grease cover plate for the outlet.
It should be noted that it may be necessary to remove an automatic type fitting due to
hardening of grease. Motors utilizing a grease plate may require the scraping out of old
grease a minimum of once every two years.
3. STANDARD SERVICE
1. Select the proper service condition from Fig. 2.
2. Select the frequency and volume from Fig. 3.
3. Before greasing be sure fittings are clean and free from dirt.
INDEX MDS-O-0001
SHEET NO. 2 of 3
ISSUED 01/24/96
SUPERSEDES NEW
3. STANDARD SERVICE (-cont.)
5. Remove relief plug or plate and using a low pressure hand held grease gun, pump the required
amount of grease.
6. For Frames 143T to 365T allow motor to run for 20 to 30 minutes and for Frames 405T and
larger allow motor to run for 30 to 60 minutes before replacing hardware.
7. Grease may not relieve from drain. Use volumes recommended to avoid overgreasing.
Fig. 2 SERVICE CONDITIONS

Standard Duty Eight hours per day;
Light to normal loading;
Clean condition, free from dust.
Severe Duty 24 hours per day;

Light to normal shock loading, vibration;
Exposure to dirt or dusty conditions.
Very Severe Duty 24 hours per day;

High ambient;
Normal to high shock loading, vibration;
Dusty conditions;
Confined mounting conditions
4. RECOMMENDED GREASES:
Confirm if the motor nameplate has specified the grease used.
Standard, Severe Duty and 841 motors greased at the factory will use:
Grease Name: Chevron SRI
Manufactured By: Chevron U.S.A., Inc.
Operating Ambient Temp.: -30C to 50C
5. RECOMMENDED GREASES for STANDARD APPLICATIONS
Use the following greases listed for the given temperature range, unless otherwise shown by the motors
grease nameplate:
Operating Ambient Temp. -30C to 50C

Chevron SRI Chevron U.S.A., Inc.
Exxon Unirex #2 Exxon Corp.
Exxon Polyrex Exxon Corp.
Shell Dolium R Shell Oil Co.
Polystar RB 2 Texaco
INDEX MDS-O-0001
SHEET NO. 3 of 3
ISSUED 01/24/96
SUPERSEDES NEW
Fig. 3 TYPE OF SERVICE
SYNC. RPM FRAME SIZE STANDARD SEVERE VERY SEVERE

RANGE DUTY DUTY DUTY
3600 143T-256T 8 Mos. 4 Mos. 1 Mo.
1800 ~ 900 143T-256T 30 Mos. 12 Mos. 4 Mos.
Bearing Size Periodic Grease Amount
6205/6206 3 Grams
6207/6208/6305 5 Grams
6306 10 Grams
6308/6309 20 Grams
3600 284T-365T 8 Mos. 4 Mos. 1 Mo.
1800 ~ 900 284T-365T 24 Mos. 12 Mos. 4 Mos.
6211 10 Grams
6309 20 Grams
6310/6312 30 Grams
6314 50 Grams
3600 404T-447T 8 Mos. 4 Mos. 1 Mo.
1800 ~ 900 404T-447T 18 Mos. 8 Mos. 3 Mos.
6216 20 Grams
6313/NU317 30 Grams
NU318/NU320 50 Grams
6317/6318 80 Grams
6320/6322/6324 80 Grams
NOTES:
1. When relubricating roller bearings divide the monthly service time by two.
2. See Fig. 2 for definitions of Service Conditions.
3. Gram quantity when using a typical low pressure hand grease gun equals
(4 pumps = 5 grams)
6. RECOMMENDED GREASES FOR SPECIAL APPLICATIONS
The following greases are recommended for special applicaitons only and should be used only for motors
specifically built for such conditions.
Minimum Ambient Temp. -60C

Beacon 325 Exxon Corp.
Maximum Ambient Temp. 90C
DOW Corning 44 DOW Corning Corp.
Exxon Unirex S2 Exxon Corp.
WARNING: In general it is not recommend to mix greases of different brands. The mixing of different types of thickeners may destroy the
composition and physical properties of the grease. In the event that a different grease is required by the end user, the following steps can
be taken. Using the instructions for lubrication, open grease outlet and purge the system as much as possible of the old or unwanted
grease. Repeat this same operation after 1 week of service. Consult TOSHIBA/HOUSTON Engineering for further recommendations on
grease compatibility.
13131 W. Little York Rd.
Houston, Texas 77041
Phone: 713-466-0277
Fax: 713-466-8773
STORAGE INSTRUCTIONS
Short Term Storage

If the equipment is not put into immediate use it should be stored in a clean, dry location.
Care should be taken to keep the equipment covered when moving from a cold location
to a warm location, otherwise condensation may occur. If condensation does occur, and
the equipment is moist, allow it to dry thoroughly before applying power.
Long Term Storage

1. Cover machined metal parts with weatherproof cover, but leave ventilating area
exposed.
2. Make certain unpainted portions are covered and retouch any scratches or flaked
areas.
3. If condensate plugs or drain plugs have been used, make sure they are operative.
4. Cover completely with plastic cover and insert silica-gel bags inside the cover for
moisture control.
5. If motor is equipped with space heaters make sure space heaters are properly
connected and operative. The motor interior temperature should be maintained
approximately 5.6 C ( 10 F) above ambient.
6. A systematic inspection and maintenance schedule should be established. If rotating

apparatus is to be stored for 6 months or longer, it should, in addition to the minor
precautions above, be given a megger test every 3 to 6 months. A minimum reading
of 10 megohoms is recommended. A record of insulation values, temperature, time,
humidity and length of voltage application should be recorded to show winding
conditions prior to start up.
7. If windings are designed for outdoor operation, they will not be affected by extreme
or sudden temperature changes or inclement weather in general. However a weather
proof cover with provisions for adequate ventilation should be used to guard against
intrusion of salt, dust, or other abrasive or corrosive material.
8. It is recommended that the rotor be turned every month to redistribute the lubricant in
the bearings and oil or grease be added every 6 six months.
9. Preferably, storage would be in a warehouse or enclosed building but the same

precautions should be followed.
FULFLO SPECIALTIES COMPANY . . .
Pioneers in Fluid Power

Established in 1912, FULFLO was incorporated in largest manufacturing centers. Blanchester is served
1933 under its present name and trademark. Patents by air from Greater Cincinnati Airport and alternately
for the original guided piston, direct-acting relief from Dayton Municipal Airport.
valve were obtained in 1935, coincident with the From Cincinnati, travel Interstate 71 north to
onset of fluid power systems. The need for providing Interstate 275, east to US 28 and northeast to
large flows without excessive bulk was subsequently Blanchester.
met by the pilot-valve-controlled relief valve, a patent
on which was issued to FULFLO in 1943 (U.S. Patent From Dayton, travel Interstate 75 south to Route 123
No. 2,333,522). and southeast to Blanchester.
FULFLO is located in Blanchester, Ohio just 30 miles If you plan to visit FULFLO, advise us of your
northeast of Cincinnati, close to some of the states itinerary and we will be happy to assist with
transportation and hotel arrangements.
TERMS AND CONDITIONS

Product Information. Please include complete Prices. F.O.B. Blanchester, Ohio. Prices are subject
product data as described in the catalog. Note: All to change without notice.
valves will be set midrange pressure of the spring, Terms. Net 30 days to buyers with approved credit:
unless otherwise specified. all other shipments are C.O.D.
Shipping Information. Please include purchasers Invoicing. Buyers will be invoiced by Fulflo
name, complete address and requested routing. Specialties, 459 E. Fancy Street, Blanchester, Ohio
Product many be shipped via U.P.S., insured parcel 45107.
post or commercial motor freight.
Delivery. Deliveries are scheduled after receipt of
Guarantee. Fulflo products are guaranteed against orders which should include all required technical
defects in workmanship or material for one year after information. Shipping dates are estimated based on
date of shipment. Fulflo is not liable for any damages conditions prevailing at the time of quotation, but are
resulting from misuse or misapplication of its not guaranteed. Fulflo shall not be liable for delays in
product. delivery due to causes beyond its reasonable
Specifications. For continued improvement of our control. Fulflo shall not be liable for any special or
product line, we reserve the right to change product consequential damages caused by or resulting from
specifications without prior notice. delay, failure to manufacture or deliver.
Cancellations. Charges are based on work Minimum Order. Minimum order charge required is
accomplished prior to the receipt of cancellation. $25.00.
Returned Material. An RGA (Return Goods Expediting Fee. Orders may be subject to a 15%
Authorization) Number must be issued before expediting fee.
returning any product. Change Order Fee. There is a $25.00 change order
Restocking. Product returned is subject to a fee, per order.
restocking charge. Restocking fee is 25% of List
Price on standard product line. Special products are
subject to additional charges. DUE TO ENGINEERING UPGRADING, THE
DIMENSIONS AND SPECIFICATIONS ARE
SUBJECT TO CHANGE, BUT ARE CORRECT
HERE AT TIME OF PRINTING.
The Fulflo Specialties Company, 2001
2
CONTENTS
OUR MISSION STATEMENT: Fulflo Specialties will strive to be the world leader in
the valve manufacturing industry. Our mission is to achieve and sustain through
FULFLO continuous improvement, the highest quality of product and services. Fulflo will
ensure that every employee, vendor, and subcontractor share a common goal of
quality and reliability at an affordable price.
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Terms & Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ENGINEERING DATA
Valve Design Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Valve Sizing-Use of Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Pipe Sizing-Use of the Nomograph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Application Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Spring Material & Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
ENGINEERING Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
SAE O-Ring Boss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
DATA Socket Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Standard Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
ASTM/ASME Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Material Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
O-Ring and Pad Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Max Temp. Max Pressure
Orifice Area & Piston/Body Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Flange and Drilling Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
V-SERIES VALVE
V-SERIES Application and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Valve Setting Maintenance Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Assembly Number Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
VALVES Standard Spring Pressure Range Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Dimensions and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-15
VJ, VB, VS, VSS, VJ-SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-15
VJF, VBF, VSF, VSSF, VJF-SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-15
HVJ, HVB, HVS, HVSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-17
HVJ-P, HVB-P, HVS-P, HVSS-P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-17
HVJF, HVBF, HVSF, HVSSF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-17
HVJF-P, HVBF-P, HVSF-P, HVSSF-P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-17
Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-19
FV-SERIES VALVE
FV-SERIES Application and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Assembly Number Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
FVJ, FVB, FVS, FVSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23-24
FVJF, FVBF, FVSF, FVSSF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23-24
A-SERIES VALVES
A-SERIES Application and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Model Number and Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Direct Acting Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
AAD, ACD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-31
AADF, ACDF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-31
Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Internal Pilot Operated Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-35
AAP, ACP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-35
AAPF, ACPF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-35
Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
SVB-SERIES VALVES (Underwriter Listed)
SVB Application and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Maintenance Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Valve Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
SERIES Model Number and Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Standard Spring Pressure Range Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
VALVES Dimensions and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
APPLICATIONS
APPLICATIONS Typical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
SPECIALTY Please contact Fulflo direct for special applications. We provide special valves or modified
valves to meet your application.
VALVES
3
VALVE SIZING...Use of Performance Charts
ENGINEERING
FULFLO GUIDED PISTON VALVES valve equal in size to the pipe to which it is connected.
A larger or smaller valve may be used to suit individual
DATA
The trademark FULFLO expresses the basic principle requirements, depending on the permissible amount of
that the relief valve must have flow capacity equal to over-pressure. Assume we have selected a 3/4 valve
that of the pipe lines to which it is connected. The sliding for 17 GPM flow and a cracking pressure of 325 PSI. By
piston concept and internal design contours of FULFLO referring to the pressure range chart, we find that we
valves provide unique flow and stability characteristics may use either a YS or a ZS spring.
for reliable performance without chatter. Assuming a YS spring, draw a line horizontally at 17
FULFLO valves are designed to operate reliably at GPM in the 3/4 valve chart, to intersect the slanted line
pressures as low as 2 PSI and as high as 1000 PSI. The marked YS and drop a vertical line to the over-
FULFLO valve reduces velocities through all but the pressure scale to read an over-pressure of 44 PSI. The
controlling interface of the valve thereby minimizing 17 GPM will be discharged at a pressure of 325 + 44 or
system power loss. 369 PSI. The percentage of over-pressure would be
44/325 X 100 or 13.5%.
Unlike ordinary direct acting relief valves, FULFLO
guided piston valves are less responsive to transient If a ZS spring is used, extend the horizontal line to the
pressure surges thereby eliminating the tendency to ZS slope and the over-pressure is 70 PSU. The
pound, squeal or chatter. Quiet, stable, efficient pressure to pass 17 GPM would be 325 + 70 or 395 PSI
performance is assured in both load regulation and and the over-pressure would be 21.5%. If the over-
system protection applications. pressure is higher than desired for the particular
application, the procedure may be repeated for the next
FULFLO valves operate effectively with all types of larger size valve.
liquids in the full range of viscosities including hydraulic
oils, water, solvents and chemicals. In some cases, maximum flow through a valve at a
given pressure is specified. To determine the cracking
FULFLO valves are not designed to be positive shut off, pressure, assume a 3/4 valve is to pass 12 GPM at 50
and will pass a minimal amount of leakage before the PSI. A horizontal line drawn from the 12 GPM capacity
set pressure. to the intersection with the WS spring line results in an
FULFLO valves are NOT designed for use with air, gas over-pressure of 14 PSI, therefore the cracking
or steam. pressure must be 50 14 or 36 PSI, and the
Since the FULFLO relief valve is a flow-modulating percentage of over-pressure of only 9 PSI, but the
device, pressure flow characteristics are completely cracking pressure would be 14/36 x 100 or 38.8%. The
different from spring loaded poppet or ball check valves. use of a US spring would produce an over pressure of
Both types remain substantially tight up to cracking only 9 PSI but the cracking pressure would then be 50
pressure. When this pressure is exceeded, the 9 or 41 PSI, which would exceed the rating of the US
conventional valve pops open with a pressure drop at spring.
very low flow and an exponential pressure rise as the For sizing valves for higher viscosity than 500 SSU, the
flow increases. following formula is used:
In contrast the FULFLO valve causes a pressure rise, 4 V2 x area of valve for 150 SSU
over-pressure, as soon as flow starts; pressure V1
increases almost proportionally with flow. Springs and
areas on FULFLO valves are carefully designed to V1 = 150 SSU
minimize this over-pressure. V2 = higher viscosity
Both pressures are important in sizing a valve. Cracking Assume we have the following application,
pressure must be selected high enough to permit GPM = 10
system operation at its maximum rated pressure and
Viscosity = 12,000 SSU
flow. Over-pressure is limited by the systems capability
to withstand the additional pressure and the motors Normally for 10 GPM a 1/2 valve would be used.
ability to sustain the pump output at the increased Referring to the orifice area chart on page 9, to find the
pressure for the required time interval. area of a 1/2 valve. The area is .305.
The over-pressure to produce a certain flow is a
4 12000 = 4 80=2.99
function of valve size and spring constant and can be 150
determined with the aid of the over-pressure charts 2.99 x .305=.9120 area needed to pass 10 GPM
given for the different valve sizes. The valve
performance charts are based on tests made with oil of Again referring to the orifice area chart, we find that the
150 SSU viscosity at 100 F and may be used with area of 11/4 valve is 1.224. Therefore a 11/4 valve
reasonable accuracy within the conventional range of would be used. To find the over-pressure refer to the
oil viscosities from 30 to 500 SSU. For operation with performance chart for a 11/4 valve.
high viscosity fluids, consult FULFLOs engineering Performance charts based on actual test results are
department. available on request. For additional information contact
In sizing a valve, the first attempt should be to select a THE FULFLO SPECIALTIES CO.
4
PIPE SIZING...Use of the Nomograph
ENGINEERING
The flow velocity, which must first be determined, is Note the different weights or piping are grouped under
DATA
dependent on the viscosity of the fluid and the various schedule numbers. Approximate pressure for
permissible flow resistance in the piping. Lower each schedule number may be computed from the
velocities are for higher viscosity fluids and/or lower formula.
pressure drops; higher velocities are for less viscous Pressure = S x schedule number
fluids and cases where higher pressure drops can be 1000
tolerated. In all cases, allowable suction velocities are S is the permissible stress to which the pipe is
much lower and the lowest velocities should be used for subjected. Thus, for a stress of 10,000 psi, the allowable
the more viscous fluids and/or higher suction lifts. pressure is equal to ten times the schedule number.
Suction velocities are much more critical than discharge Higher pressures may be carried if higher stresses are
velocities. Too high a discharge velocity may only result allowed.
in excessive power loss but an excessive suction In the example, a schedule 40 pipe is more than
velocity may make the system inoperative or cause adequate for 250 psi. Twice the wall thickness of a 3/4
damage to the pump and system. schedule 40 pipe of 0.226 or 0.976. Since the actual
After the velocity has been selected, the nomograph outside diameter of a 3/4 schedule 40 pipe is 1.05, the
chart is used to determine the inside diameter of the selection of a 3/4 pipe is adequate.
pipe at a given flow rate. For example, assume a flow of A 3/4 Fulflo relief valve should be selected. Operational
17 gpm and a velocity of 12 fps for the discharge pipe characteristics of this valve, that is cracking pressure
is required. Draw a line from the 12 fps point on the and overpressure, may be determined from the
velocity scale through the 17 gpm point on the flow rate performance chart precisely in the manner explained in
scale and the extended line intersects the pipe inside the example. The maximum discharge pressure of 285
diameter scale at 0.76 inches. This inside diameter psi is still well below the safe carrying capacity of the
applies to either pipe or tubing. pipe. The design of the Fulflo valves is such that if used
The correct pipe or tube size also depends on the within their rating and with properly selected springs,
pressure it must carry. The conversion chart for pipe the overpressure is not sufficient to endanger system or
sizes and schedules facilitates this section. system components.
VELOCITY
FEET PER SECOND
NORMAL SUCTION NORMAL MAX. DISCHARGE VELOCITY

VELOCITY IN PIPES IN VALVES
MAXIMUM DISCHARGE VELOCITY

IN PIPES
FLOW RATE
GALLONS PER MINUTE
PIPE SIZE
INSIDE DIAMETER IN INCHES
5
APPLICATIONS
SYSTEM 1 SYSTEM 2
TO SYSTEM TO SYSTEM
FULFLO VALVE FULFLO VALVE
OPEN TANK PUMP CLOSED TANK PUMP
OPEN TANK CLOSED TANK

VALVE SET PRESSURE EQUALS TANK PRESSURE + VALVE SET PRESSURE
SYSTEM OPERATING PRESSURE EQUALS SYSTEM OPERATING PRESSURE
SYSTEM 3 SYSTEM 4
TO SYSTEM
TO SYSTEM
FULFLO VALVE
PUMP
SUCTION
SUCTION FULFLO VALVE
PUMP
PUMP INTERNAL RELIEF

FOR PUMPS WITH (2) SUCTION PORTS
CLOSED LOOP AND (2) DISCHARGE PORTS
SUCTION PRESSURE + VALVE SET PRESSURE SUCTION PRESSURE + VALVE SET PRESSURE
EQUALS SYSTEM OPERATING PRESSURE EQUALS SYSTEM OPERATING PRESSURE
6
SPRING MATERIAL
& TEMPERATURE CHART
ENGINEERING
MATERIAL MAX TEMP. ASTM SPEC. MATERIAL MAX TEMP. ASTM SPEC.
DATA
CHROME SILICON
CHR. VANADIUM
CHR. VANADIUM
VALVE SIZE
VALVE SIZE
A581 COND. A
A581 COND. A
PART NO.
PART NO.
313 TYPE 631
313 TYPE 631

MUSIC WIRE
OIL TEMP.
OIL TEMP.
17-7PHSS
17-7PHSS
18-8SS
18-8SS
A 231
A 231
650 F
550 F
425 F
250 F
650 F
550 F
425 F
250 F
229
228
229
228
207-AS 607-AS
207-US 607-US
207-WS 607-WS
207-XS 607-XS
207-YS 607-YS

1/4
11/4
207-ZS 607-ZS
207-RS 607-A
207-TS 607-U
207-A 607-W

3/8
207-U 607-Y
207-W 607-Z
207-X 607-R
207-Y 707-AS
207-Z 707-US
207-RS 707-WS
207-TS 707-XS
307-AS 707YS
307-US 707-ZS
11/2
307-WS 707-A
307-XS 707-U
307-YS 707-W
307-ZS 707-X
307-RS 707-Y

1/2
307-TS 707-Z
307-A 707-R
307-U 807-AS
307-W 807-US
307-X 807-WS
307-Y 807-XS
307-Z 807-YS
307-RS 807-ZS
2
307-TS 807-A
407-AS 807-U
407-US 807-W
407-WS 807-X
407-XS 807-Y
407-YS 807-Z
3/4
407-ZS A0960D
407-U A0961C
21/2
407-W A0970D
407-X A0971C
407-Y A0980D
407-Z A1060D
507-AS A1061C
3
507-US A1070D
507-WS A1071C
507-XS A1080D
507-YS A1160D
4
507-ZS A1170D
1
507-A A1181D
507-U
507-W
4 3 21/2
507-X A1190D
507-Y
507-Z
507-R
7
SAE O-RING BOSS CONNECTIONS
ENGINEERING
VALVE SAE NUMBER

SIZE 5 6 8 10 12 16 20 24 32
DATA
3/8 X X X
1/2 X X X
3/4 X X
1 X X X
11/4 X X
11/2 X
2 X
SAE (Society Automotive Engineers)
B
THD. A
FIG.F
DIMENSIONS (INCHES)
C SAE
NO. A B C D E
5 1/2-20 .937 .547 .550 12F
6 9/16-18 1.000 .609 .616 12F
8 3/4-16 1.218 .688 .811 12F
10 7/8-14 1.375 .781 .942 15F
12 11/16-12 1.656 .906 1.148 15F
16 15/16-12 2.000 .906 1.398 15F
DIA. D 20 15/8-12 2.312 .906 1.713 15F
24 17/8-12 2.562 .906 1.962 15F
.010 32 21/2-12 3.192 .906 2.587 15F
.005 R
100
E FIG. F
45 + 5
VALVE SAE MATERIAL

SIZE NO. CAST IRON BRASS STEEL STAINLESS
5 SVJ-2039 SVB-2039 SVS-2039 SVSS-2039
3/8 6 SVJ-2036 SVB-2036 SVS-2036 SVSS-2036
8 SVJ-2042 SVB-2042 SVS-2042 SVSS-2042
6 SVJ-3065 SVB-3065 SVS-3065 SVSS-3065
1/2 8 SVJ-3066 SVB-3066 SVS-3066 SVSS-3066
10 SVJ-3051 SVB-3051 SVS-3051 SVSS-3051
10 SVJ-4041 SVB-4041 SVS-4041 SVSS-4041
3/4
12 SVJ-4049 SVB-4049 SVS-4049 SVSS-4049
12 SVJ-5084 SVB-5084 SVS-5084 SVSS-5084
1 16 SVJ-5071 SVB-5071 SVS-5071 SVSS-5071
20 SVJ-5083 SVB-5083 SVS-5083 SVSS-5083
11/4 20 SVJ-6065 SVB-6065 SVS-6065 SVSS-6065
24 SVJ-6066 SVB-6066 SVS-6066 SVSS-6066
11/2 24 SVJ-7050 SVB-7050 SVS-7050 SVSS-7050
2 32 SVJ-8047 SVB-8047 SVS-8047 SVSS-8047
8
SOCKET WELD & STANDARD MATERIALS
ENGINEERING
BB
SOCKET WELD
VALVE MODEL NUMBER AA
DATA
SIZE BB
STEEL STAINLESS MIN. MAX.
3/8 SVS-2033 SVSS-2033 .685 .690 .312
1/2 SVS-3037 SVSS-3037 .850 .855 .437
3/4 SVS-4038 SVSS-4038 1.060 1.065 .562 AA
1 SVS-5024 SVSS-5024 1.325 1.330 .625
11/4 SVS-6058 SVSS-6058 1.670 1.675 .750
11/2 SVS-7067 SVSS-7067 1.910 1.915 .812
2 SVS-8070 SVSS-8070 2.410 2.415 .875
ASTM/ASME SPECIFICATIONS
Adjusting Screws Locknuts, Retainers Bodies
Stop Rings, Glands, Bonnets Steel ASTM 108-79 Cast Iron ASTM A126-42 Class A
Brass ASTM B16 Stainless Steel ASTM A582 Class 303 Brass ASME B62
Steel ASTM 108-79 Brass ASTM B16 Steel ASTM A 216 Grade WCB
Stainless Steel ASME ASME SA479 Class 316 Stainless Steel ASTM A 351 CF8M
Caps Pistons Material Codes

Cast Iron 401 thru 801 ASTM A 126-42 Class A Hardened Steel ASTM 108-79 (Unless Otherwise Specified)
Brass 201-B thru 501-B ASTM B16 416 Stainless Steel ASTM A 582 Cond. A A 416 Stainless Steel
Brass 601B thru 801-B ASME B62 303 Stainless Steel ASTM A 582 Class 303 J Cast Iron (No Part # Suffix)
Steel All models ASTM 108-79 B Brass
Stainless Steel All models ASME SA479 Class 316
S Steel
SS Stainless Steel
O-RING & PAD MATERIAL SPECIFICATIONS

SUFFIX COMPOUND TEMP. RANGE ASTM
MATERIAL CODE SPEC.
MIN. MAX.
BUNA R B 46 -40F 257F D2000
ETHYLENE-PROPYLENE EPR E 50 -67F 302F D2000
VITON RV V 14 -31F 437F D2000
SILICONE RS S 71 -103F 482F D2000
TEFLON RT -423F 500F D2000
NEOPRENE RN -67F 284F D2000
AFLAS RA -25F 450F D2000
MAXIMUM ALLOWABLE
MAXIMUM TEMP. OF BODIES WORKING PRESSURE
MATERIAL TEMPERATURE CAST IRON 1500 PSI
CAST IRON 400F BRASS 1500 PSI
BRASS 400F STEEL 2000 PSI
STEEL 600F STAINLESS STEEL 2000 PSI
STAINLESS STEEL 600F
ORIFICE AREA & PISTON/BODY TOLERANCES DIMENSIONS IN INCHES

VALVE PISTON DIA. AREA BODY GO BODY NO GO
SIZE +.000-.0003 IN 2 RC 3 FIT RC 3 FIT
1/4 .4985 .195 .4993 .4999
3/8 .4985 .195 .4993 .4999
1/2 .6235 .305 .6243 .6249
3/4 .7485 .440 .7493 .7499
1 .9985 .783 .9993 1.0003
11/4 1.2485 1.224 1.2495 1.2507
11/2 1.4985 1.764 1.4995 1.5007
2 1.9985 3.167 1.9997 2.0011
21/2 2.6500 5.515 2.6517 2.6527
3 3.1235 7.663 3.1247 3.1261
4 4.1222 13.346 4.1250 4.1262
9
FLANGE AND
DRILLING DIMENSIONS (INCHES)
ENGINEERING
D TO FLANGE
THICKNESS
DATA
E F
C
A REF.
CLASS 150 (BRASS CAST IRON STEEL STAINLESS STEEL)
A B C D E F G
Valve Flange Thickness Number
Flange Bolt Circle Bolt Holes Raised Face Raised Face Spotface of Bolts
Size Diameter Diameter Diameter Diameter Height Diameter
Brass Cl/Steel
1 41/4 3/8 9/16 31/8 5/8 2 1/16 1.12 4
11/4 45/8 13/32 1/2 31/2 5/8 21/2 1/16 1.12 4
11/2 5 7/16 9/16 37/8 5/8 27/8 1/16 1.12 4
2 6 1/2 5/8 43/4 3/4 35/8 1/16 1.37 4
21/2* 7 N/A 11/16 51/2 3/4 41/8 1/16 1.37 4
3* 71/2 N/A 3/4 6 3/4 5 1/16 1.37 4
4* 9 N/A 15/16 71/2 3/4 63/16 1/16 1.37 8
Note: Brass flanges conform to 150# ANSI B 16.24 except with raised face. Cast iron and steel flanges conform to 150# ANSI B 16.5 steel specifications.
*Available in Cast Iron & Steel only. 125-250 AARH flange finish (Steel & Stainless Steel only)
CLASS 250 (CAST IRON)
A B C D E F G Number
Valve Flange Flange Bolt Circle Bolt Holes Raised Face Raised Face Spotface
Size Thickness of Bolts
Diameter Diameter Diameter Diameter Height Diameter
1 47/8 11/16 31/2 3/4 211/16 1/16 1.37 4
11/4 51/4 3/4 37/8 3/4 31/16 1/16 1.37 4
11/2 61/8 13/16 41/2 7/8 39/16 1/16 1.56 4
2 63/4 7/8 5 3/4 43/16 1/16 1.37 8
Note: Cast iron flanges conform to 250# ANSI B 16.2 steel specifications.
CLASS 300 (BRASS STEEL STAINLESS STEEL)
A B C D E F G Number
Valve Flange Flange Bolt Circle Bolt Holes Raised Face Raised Face Spotface
Size Thickness of Bolts
Diameter Diameter Diameter Diameter Height Diameter
1 47/8 11/16 31/2 3/4 2 1/16 1.37 4
11/4 51/4 3/4 37/8 3/4 21/2 1/16 1.37 4
11/2 61/8 13/16 41/2 7/8 27/8 1/16 1.56 4
2 63/4 7/8 5 3/4 35/8 1/16 1.37 8
21/2 73/4 1 57/8 7/8 41/8 1/16 1.56 8
3 81/2 11/8 65/8 7/8 5 1/16 1.56 8
4 10 11/4 77/8 7/8 63/16 1/16 1.56 8
Note: Available in steel and cast iron only. Brass flanges conform to 300# ANSI B 16.24 except with raised face.
Steel flanges conform to 300# ANSI B 16.5 steel specifications. 125-250 AARH flange finish (Steel & Stainless Steel only)
CLASS 600 (CAST IRON STEEL STAINLESS STEEL

A B C D E F G
Valve Flange Flange Bolt Circle Bolt Holes Raised Face Raised Face Spotface Number
Size Diameter Thickness Diameter Diameter Diameter Height Diameter of Bolts
1 47/8 11/16 31/2 3/4 2 1/4 1.37 4

11/4 51/4 13/16 37/8 3/4 21/2 1/4 1.37 4
11/2 61/8 7/8 41/2 7/8 27/8 1/4 1.56 4
2 61/2 1 5 3/4 35/8 1/4 1.37 8
21/2 73/4 11/8 57/8 7/8 41/8 1/4 1.56 8
3 81/2 11/4 65/8 7/8 5 1/4 1.56 8
4 103/4 11/2 81/2 1 63/16 1/4 1.78 8
Note: Cast iron and steel flanges conform to 600# ANSI B 16.5 steel specifications. 125-250 AARH flange finish (Steel & Stainless Steel only)
Note: Special Flanges With Drilling On Or Off Center And Smooth Or Raised Face Are Available Upon Request.
10
V-SERIES VALVES
V-SERIES
VALVES
Standard Standard Stainless Steel Handwheel Handwheel
with Screw with Flange with Screw with Screw with Flange
Connections Connections Connections Connections Connections
APPLICATION Widely used in a variety of applications, the V

series valves are ideally suited in hydraulic and
The Fulflo V Series range in size from 1/4 lubricating systems for load regulation and
through 2 and operate efficiently with liquids of system protection. Special trim or packings are
any viscosity at pressures from 2 to 1000 P.S.I. available for use with fire resisting fluids and
The V series valves are available in flange or other liquids of this type. Unusual applications
screw type...cartridge or handwheel in a choice and special requirements should be referred to
of brass, cast iron, steel and stainless steel. our engineering staff for recommendation.
INSTALLATION should be piped back to the tank. Care must be

taken to have the discharge well below the oil
Fulflo valves can be mounted in any position. A level in the tank to prevent air entrainment and
tee may be inserted in the pump discharge line erratic operation.
to mount the valve. The correct size of valve
should be installed, preferably matching the Only if the valve is used as safety or overload
pump discharge line. Screw the valve into the relief and operates infrequently may its
nipple in the tee, or in the case of the flange discharge be piped back into the pump suction
style, bolt the valve to the companion flange line. Frequent or continuous operation under
screwed into the nipple. When the valve is used these conditions will cause excessive heating of
for frequent bypassing of oil pressure, its outlet the oil and possible damage.
11
V-SERIES
SETTING VALVES having a flow meter in the pump discharge line must
be available. With a valve adjusted for cracking
Valves may be set with a hydraulic hand pump for pressure as above, continue closing bypass until the
cracking pressure. If a test stand is available, valve required flow registers on the flow meter and observe
should be connected to the discharge header with the pressure. Readjust pressure, if necessary, to obtain
pump bypass open, and the bypass gradually closed desired pressure at desired flow.
until the desired pressure registers on the gauge.
Adjust valve adjusting screw until valve slightly bleeds
at the set bypass pressure and lock adjusting screw. MAINTENANCE
Fulflo valves are not designed to be positive shut-off, Fulflo valves provide reliable chatter-free operation
and will pass a minimal amount of leakage before the when the system is free of abrasives and foreign
V-SERIES
VALVES
set pressure. If a valve is required to bypass a given matter. Continuous filtration of the liquid used is
amount of fluid at a given pressure, a test stand strongly recommended.
TYPICAL DISASSEMBLY OF STANDARD TYPE VALVE
To dismantle valve for inspection or cleaning:

G 1. Remove cap B
2. Remove O-Ring E
3. Remove lock nut F
B
I 4. Remove adjusting screw C
5. Remove retainer D
E H 6. Remove spring G
7. Remove piston I
F 8. Remove stop ring H (Not Recommended)
A (Special tooling is required to install new stop ring.)
C Inspect valve bore and piston for wear and scoring. Replace
broken or damaged parts. Clean all parts thoroughly and
re-assemble by reversing the above procedure.
D
TYPICAL DISASSEMBLY OF HANDWHEEL TYPE VALVE

To dismantle the valve for inspection or cleaning:
1. Release spring tension by backing off handwheel as far as it
will go.
2. Remove lock nut A or set screw and take off handwheel B
3. Remove lock nut D
4. Unscrew and remove gland E
5. Unscrew and remove bonnet F
J 6. Remove O-Ring H
A
F 7. Remove adjusting screw C (turn clockwise and pull out from
B bottom of bonnet F)
D K 8. Remove O-ring packing G
9. Remove spring J
E H 10. Remove piston K
11. Remove stop ring L (Not Recommended)
G L (Special tooling is required to install new stop ring.)
Inspect valve bore and piston for wear or scoring. Replace broken
C or damaged parts. Clean all parts thoroughly and re-assemble by
reversing the above procedure.
I
12
V-SERIES
ASSEMBLY NUMBER IDENTIFICATION CHART
Symbol No. Designation Code Description
1 Style None Standard Model
H Handwheel Model
2 Series V
3 Material J Cast iron
B Brass
S Steel
SS 316 Stainless Steel
4 Connections None Screw Connections
F Flange Connections 300# Flange Class Standard (250# Flange Class - Cast Iron Standard)
V-SERIES
VALVES
5 Size -1 1/4
-2 3/8
-3 1/2
-4 3/4
-5 1
-6 11/4
-7 11/2
-8 2
6,7,8 ASA None 300# Flange Standard (no designation required)
Flange -150
Rating -600
9 Flange A Raised Face, Staggered Bolt Centers (standard on all Flange rating)
Style B Smooth Face, Staggered Bolt Centers
150# & 600# C Raised Face, Bolts on Valve Centerline
Only D Smooth Face, Bolts on Valve Centerlne
10 O-Ring R Buna O-Ring Cap Seal (standard)
Material RV Viton O-Ring Cap Seal
RS Silicone O-Ring Cap Seal
RT Teflon O-Ring Cap Seal (standard on VSS Series)
RA Aflas O-Ring Cap Seal
11 Options SP Steel Parts (used on cast iron only)
P Panel Mount on Handwheel Series
12 Piston /HS Hardened Steel
Material /SS 416 Stainless Steel
/3SS 303 Stainless Steel
13 Spring AS
US
WS
XS
YS
ZS
14 Setting Desired Pressure Setting
EXAMPLES:
VJ-1RVSP/HS/WS VJF-5R/HS/WS VJF-5-150AR/HS/WS
V J -1 RV SP /HS WS V J F -5 R /HS WS V J F -5 -150 A R /HS WS
Series Cast Iron 1/4 Viton O-Ring Steel Parts H.S. Piston WS Spring Series Cast Iron Flanged 1 Buna O-Ring H.S. Piston WS Spring Series Cast Iron Flanged 1 Rating Style Buna O-Ring H.S. Piston WS Spring
NOTE: Stainless steel pistons are supplied on brass valves, unless hardened steel is specified. Hardened steel pistons are supplied on cast iron or steel unless stainless steel is
specified. Buna O-Rings are supplied as standard unless other material is specified.
STANDARD PRESSURE RANGE CHART

Valve Valve SPRING PRESSURE AND IDENTIFICATION NO.
Pipe Flange BLACK-AS RED-US GREEN-WS YELLOW-XS WHITE-YS BLUE-ZS PURPLE-TS BROWN-RS
Size Size
Low High Low High Low High Low High Low High Low High Low High Low High
1/4 3 15 7 35 30 100 60 175 150 350 300 500 400 600 550 750
3/8 3 15 7 35 30 100 60 175 150 350 300 500 400 600 550 750
1/2 3 15 7 35 30 100 60 175 150 350 300 500 400 600 550 750
3/4 3 15 7 35 30 100 60 175 150 350 300 500
1 1 3 15 7 35 30 100 60 175 150 350 300 500
11/4 11/4 3 15 7 35 30 100 60 175 150 350 300 500
11/2 11/2 3 15 7 35 30 100 60 175 150 350 300 500
2 2 3 15 7 35 30 100 60 175 150 350 250 600
13
VJ VB Brass
V-SERIES VS
Cast Iron
Steel VSS Stainless Steel VJ-SP Cast Iron with Steel Parts
DIMENSIONS Valve
Size
AA BB CC DD
1/4 5 / 11
32 1 /
11
32 1 /
11
32 13/8
J B 3/8 511/32 111/32 111/32 13/8
C 1/2 6 /163
1 /16
11
1 /16
7
17/16
F 3/4 615/16 115/16 113/16 111/16
1 87/32 29/32 29/32 21/16
K E
D 11/4 99/16 29/16 29/16 21/2
FULFLO
V-SERIES
AA REF.
G 1 /2 1
11 /16 1
2 /16
11
2 /16
11
27/8
VALVES
CAP A 2 13 3 3 31/4
(GASKET SEAL) I
PIPE SIZE
OUT
DD
REF
BB
H IN
CC
PIPE SIZE
DD
REF
PARTS LIST
1/4 3/8 1/2 3/4 1 11/4 11/2 2
VJ, VJ-SP 100 200 300 400 500 600 700 800
VB 100-B 200-B 300-B 400-B 500-B 600-B 700-B 800-B
A BODY VS 100-S 200-S 300-S 400-S 500-S 600-S 700-S 800-S
VJ, VJ-SP 201-SR 201-SR 301-SR 401-R 501-R 601-R 701-R 801-R
CAP VB 201-BR 201-BR 301-BR 401-BR 501-BR 601-BR 701-BR 801-BR
B (O-RING SEAL) VS 201-SR 201-SR 301-SR 401-SR 501-SR 601-SR 701-SR 801-SR
VSS 201-SSR 201-SSR 301-SSR 401-SSR 501-SSR 601-SSR 701-SSR 801-SSR
VJ, VB 202-B 202-B 302-B 402-B 502-B 602-B 702-B 802-B
C ADJUSTING VS, VJ-SP 202-S 202-S 302-S 402-S 502-S 602-S 702-S 802-S
SCREW VSS 202-SS 202-SS 302-SS 402-SS 502-SS 602-SS 702-SS 802-SS
VJ, VB 203-B 203-B 303-B 403-B 503-B 603-B 703-B 803-B
D RETAINER VS, VJ-SP 203-S 203-S 303-S 403-S 503-S 603-S 703-S 803-S
VJ, VJ-SP, VB, VS 204-* 204-* 304-* 404-* 504-* 604-* 704-* 804-*
E O-RING VSS 204-RT 204-RT 304-RT 404-RT 504-RT 604-RT 704-RT 804-RT
VJ, VJ-SP, VB, VS 205-S 205-S 305-S 405-S 505-S 605-S 705-S 805-S
F LOCK NUT VSS 205-SS 205-SS 305-SS 405-SS 505-SS 605-SS 705-SS 805-SS
G SPRING ALL MODELS 207-** 207-** 307-** 407-** 507-** 607-** 707-** 807-**
VJ, VB 208-B 208-B 308-B 408-B 508-B 608-B 708-B 808-B
H STOP RING VS, VJ-SP 208-S 208-S 308-S 408-S 508-S 608-S 708-S 808-S
HARDENED STEEL 206 206 306 406 506 606 706 806
I PISTON 416 STAINLESS STEEL 206-A 206-A 306-A 406-A 506-A 606-A 706-A 806-A
CAP VJ, VJ-SP 201-S 201-S 301-S 401 501 601 701 801
J VB 201-B 201-B 301-B 401-B 501-B 601-B 701-B 801-B
(GASKET SEAL)
VS 201-S 201-S 301-S 401-S 501-S 601-S 701-S 801-S
VJ, VB 204 204 304 404 504 604 704 804
K GASKET 204-S 204-S 304-S 404-S 504-S 604-S 704-S 804-S
VS, VJ-SP

14
V-SERIES
6
VALVES
5 XS
4 Rated Capacity WS 10 XS
3 G.P.M.
3 Rated Capacity
5 G.P.M.
WS
2 US 5
GALLONS PER MINUTE
RS
GALLONS PER MINUTE

AS 4 US RS
TS
3
1 ZS AS TS
.8 2 ZS
YS PRESSURE RANGE IN P.S.I. PRESSURE RANGE IN P.S.I.
.6 207-AS = 3-15 207-AS = 3-15
207-US = 7-35 YS 207-US = 7-35
207-WS = 30-100 207-WS = 30-100
.4 207-XS = 60-175 1 207-XS = 60-175
207-YS = 150-350 207-YS = 150-350
207-ZS = 300-500 207-ZS = 300-500
207-TS = 400-600 207-TS = 400-600
207-RS = 600-750 207-RS = 600-750
.2 .5
1 2 4 6 8 10 20 40 60 80 100 150 1 2 4 6 8 10 20 40 60 80 100 150

307-AS = 3-15
307-US = 7-35
307-WS = 30-100
307-XS = 60-175 40
307-YS = 150-350
307-ZS = 300-500 30
307-TS = 400-600
25 307-RS = 600-750
20 Rated Capacity
20 16 G.P.M.
15 15
Rated Capacity
11 G.P.M. WS ZS
GALLONS PER MINUTE
GALLONS PER MINUTE
10 10 US
XS YS
AS
RS
5 WS XS
5
4 US TS 4
3 AS ZS 3 407-AS = 3-15
407-US = 7-35
407-WS = 30-100
2 YS 2 407-XS = 60-175
407-YS = 150-350
407-ZS = 300-500
1 1
1 2 4 6 8 10 20 40 60 80 100 150 1 2 4 6 8 10 20 40 60 80 100 150
18
1 VALVE TESTS 11/4 VALVE TESTS

507-AS = 3-15 607-AS = 3-15
507-US = 7-35 607-US = 7-35
507-WS = 30-100 607-WS = 30-100
507-XS = 60-175 607-XS = 60-175
V-SERIES
507-YS = 150-350 607-YS = 150-350
VALVES
507-ZS = 300-500 120 607-ZS = 300-500
60 507-R = 500-900 607-R = 500-800
50 100
40 80
Rated Capacity Rated Capacity
30 25 G.P.M.
60 50 G.P.M.
20 ZS
GALLONS PER MINUTE
GALLONS PER MINUTE

WS 40 WS
ZS
US US YS
YS
10 AS R 20 XS
8 XS 16 AS
6 12
R
4 8
21 2 4 6 8 10 20 40 60 80 100 150 41 2 4 6 8 10 20 40 60 80 100 150

11/2 VALVE TESTS 2 VALVE TESTS

707-AS = 3-15 807-AS = 3-15
707-US = 7-35 807-US = 7-35
707-WS = 30-100 807-WS = 30-100
707-XS = 60-175 807-XS = 60-175
707-YS = 150-350 807-YS = 150-350
707-ZS = 300-500 807-ZS = 250-600
707-R = 500-900
200
160 200 Rated Capacity
150 G.P.M.
120 Rated Capacity 150
80 G.P.M.
80 100
GALLONS PER MINUTE
GALLONS PER MINUTE
R
WS ZS
40 AS
50
32 US YS ZS 40
WS XS
24 AS 30 US
16 XS 20 YS
8 10
1 2 4 6 8 10 20 40 60 80 100 150 1 2 4 6 8 10 20 40 60 80 100 150
19
U N I V E R S A L
R
FLOW MONITORS
Flow Monitor Installation and

Maintenance Instructions
for Vane and Piston Style
Variable Area Flow Monitors
UNIVERSAL FLOW MONITORS INC.

1755 E. Nine Mile Road
Hazel Park, MI 48030-0249
Ph. 810-542-9635 / Fax 810-398-4274
Area code changing mid 1997, new numbers are:
Ph. 248-542-9635 / Fax 248-398-4274
1 GENMAN-200.5M 3/97
Installation and Instruction Manual for Universal Flow Monitors, Inc. Flow Monitors
The following manual includes the installation and maintenance instructions for flow meters manufactured by Universal Flow
Monitors Inc. All flow monitors are individually calibrated for use with a specific fluid requested in the order entry process.
Different fluids should not be used without first consulting the factory to verify compatibility of materials and flow parameters,
such as viscosity and specific gravity for liquids, or operating pressure, temperature and specific gravity for gases, of the new
application. Meter designs are of the variable-area type and operate with a relatively low, pressure drop. The flow elements
are either a swinging vane or a repositioning piston.
INDEX
How Vane and Piston Flow Meters work............2
Special Use Meters.............................................3
Construction Materials and Engineering Data.....4
Readout Specifications........................................5-8
Periodic Maintenance........................................10
Calibration Notes...............................................11
Dimension Information.....................................12-16
Replacement Parts Kits...................................17-33
Return Authorization Information..................34-37
How the swinging-vane design works
Fluid enters at A, passes around the semi-circular vane F

B, exits at outlet C. The vane resists the flow because
of the spring D. The further the vane is pushed the C
larger the passageway E becomes. This minimizes the
increase in pressure drop. The vane shaft turns to A D
operate the pointer F and remote signal devices such as B
the switch G. The shaft can also turn switch cams and
transducers to actuate any remote readout devices
present. E
How the piston design works
Fluid flow causes a spring-loaded piston A having a

E
circular opening at its center B to move along the axis of
A a precision-tapered shaft C. This creates a variable
D orifice in direct proportion to the flow rate. The equilib-
C B rium position of the piston is mechanically linked to the
readout pointer D, and the strong force developed as
fluid pressure acts on a large piston area that easily
actuates the readout device E. Pressure drop increases
over rated flow range, averaging 3 PSI.
GENMAN-200.5M 3/97 2
Special Use Meters
Universal Flow Monitors has several special use flow meters for specific applications such as air, lube and water. These
meters are constructed of materials that are known to be compatible with the particular service intended. To select a seal,
gasket, cover, readout, or dial assembly kit for any of these models requires conversion of the model prefix to that of a
standard line meter. Additionally, accurate conversion of your specific use meter requires identification of size and seal
materials. Use the following tables to select your correct standard model prefix, housing size and seal material:
MODEL PREFIX:
AS (svh) -use- SN-ESF
AM (mvh) -use- MN-ESF
AL (lvh) -use- LN-ESF
O (svh) -use- SN-ASB
O (mvh) -use- MN-ASB
OK (svh) -use- SN-BSF
OK (mvh) -use- MN-BSF
OO (ph) -use- LL-ABPSB
WB (svh) -use- SN-BSE
WB (mvh) -use- MN-BSE
WB (lvh) -use- LN-FSE
WP (ph) -use- LL-BBPSE
WVS (svh) -use- SN-BSE
WVM (mvh) -use- MN-BSE
WVL (lvh) -use- LN-FSE
WW (ph) -use- LL-BBPSE
WW (svh) -use- SN-BSE
WW (mvh) -use- MN-BSE
WW (lvh) -use- LN-FSE
Others consult factory
(ph=piston housing, svh=small vane housing,

mvh=medium vane housing, lvh=large vane housing).
Note: Other manuals are available for Vortex,
Sensor Manifold, FlowStream, Mensah, Octopus,
Insite and Transmitter
3 GENMAN-200.5M 3/97
Construction Materials and Engineering Data
Prior to installation always double check the system pressure, temperature, wetted parts compatibility, electrical
ratings, and all other requirements to verify that the flow meter supplied is appropriate for the application.
HOUSINGS SN SM SH SX MN MM MH MX ML LN LE XHF LL** LP** LH**
HOUSING MATERIAL and WEIGHT (lb)

4-in 70
Aluminum 4 4 9 9 65 6-in 78 4 4
8-in 100
Aluminum/Nylon Bowl 3 7 7
Aluminum/Hard Coat 4 4 9 9
Brass 6 6 16 16 135 10
4-in 200
Aluminum Bronze 6-in 220
8-in 260
Brass/Nylon Bowl 5 13 13
Cast Iron 6 6 7 19 19 30 120 10 10
Cast Iron/Nylon Bowl 5 13
Cast Iron/Nickel Plated/Teflon 6 6 7 19 19 30 120 10 10
Impregnated
4-in 200
Carbon Steel 6 6 7 21 21 30 120 120 6-in 220 12 12 14
8-in 260
Carbon Steel/Nickel Plated 7 30 120
Naval Bronze 6 6 16 16 135
Naval Bronze/Nylon Bowl 5 13
Polypropylene 12
Polysulphone 1.75 6
PVC 1.75 6 12
Teflon 12
Tefzel 1.75 6
4-in 200
316 Stainless Steel 6 6 7 21 21 30 120 120 6-in 220 12 12 14
8-in 260
MAXIMUM FLUID TEMPERATURE (F)
200 (Optional 300 & 400 F)
100 for PVC and PP, 200 for Others *

MAXIMUM OPERATING PRESSURE LIQUIDS/GASES (PSIG)
300/125 (PSIG)
500/125
500/200
1000/167
1500/375
2000/500 Iron & Steel
2000/500, 1200/450 Stainless Steel
*100 PVC, 150 Tefzel, 200

Polysulphone
*100 PVC, 200 Tefzel & Polysulphone
*100, 50 Teflon
150 Plastic, 300 Metal Cap/125 Metal

Cap
* Liquids only
Add 2 pounds for control boxes other than A.
**Piston and cap material. Polysulfone plastic cap can be used in LL units up to 150 PSI (liquid), metal cap (same as housing) is used for all other units.
Installation
These are in-line devices that can be mounted in any position without affecting performance. First, attach the meter at the
port marked in by the appropriate means (threaded or flanged) ensuring the flow goes into that port. When threading
pipe into a cast iron meter, do not use teflon tape to seal the pipe threads. Then connect the meter at the out port.
The installation diagrams on pages 10-13 give the critical mounting dimensions. To insure maximum accuracy, install
control valves downstream of the flow meter. If this is a gas application, back pressure must be maintained on the meter
equal to the calibrated pressure. Units may have visual indication of flow only, or use a variety of switches,
potentiometers, transmitters, or pneumatic switches.
GENMAN-200.5M 3/97 4
Switch Specifications
Option 1,2 1B,2B 3,4 61,62 71,72 53,54 7, 7C*, 18 17, 17C*, 19 30,31
(SYMBOL)
SPDT High-Vibration SPDT High-Temp Gold-Contact Hermetically-
SPDT DPDT SPST
Switch Type
3-Wire SPDT 4-Wire SPDT SPDT Sealed SPDT
3-Wire 3-Wire Proximity
3-Wire 3-Wire 3-Wire 3-Wire
UL/CSA UL/CSA UL/CSA UL/CSA/ UL/CSA/
Rated By UL/CSA/CE UL/CSA/CE (CE Pending) (CE Pending) (CE Pending) MIL-S-8805 *CENELEC *CENELEC UL/CSA
15A-125,250, or 15A-125,250, or 15A-125,250, or 15A-125,250, or 15A-125,250, or

480 VAC 480 VAC 480 VAC
1A-125 VDC, 480 VAC 480 VAC
2A-600 VAC 2A-600 VAC 2A-600 VAC, 2A-600 VAC, 11A, 1/4 hp, 11A, 1/4 hp,
1/2A-250 VDC 5A res., 3A ind., 125/250 VAC; 125/250 VAC;
1/2A-125 VDC, 1/2A-125 VDC, 1/2A-125 VDC 1/2A-125 VDC 115 VAC, 0.5A,
1/4A-250 VDC 1/4A-250 VDC 1/4 HP-125 VAC, 5A res., 5A res.,
Rating 1/4A-250 VDC, 1/4A-250 VDC, 400 Hz 20-250
1/8 HP-125 VAC, 1/8 HP-125 VAC, 1/2 HP-250 VAC 1/8 HP-125 VAC 1/8 HP-125 VAC 28 VDC
28 VDC; 28 VDC; VAC/VDC
1/4 HP-250 VAC 1/4 HP-250 VAC 3A Resistive & 0.5A res., 0.5A res.,
2.5A Inductive- 1/4 HP-250 VAC, 1/4 HP-250 VAC,
6A Resistive & 6A Resistive & 6A Res. & 5A Ind.- 6A Res. & 5A Ind.- 125 VDC 125 VDC
5A Inductive- 5A Inductive- 48 VDC
24 VDC= 24 or 48 VAC VDC 24 or 48 VAC VDC
24 or 48 VDC 24 or 48 VDC
6A Res. & 5A Ind.
General General General High- General General and Hazardous Hazardous Hazardous
Use
Purpose Purpose Purpose Temperature Purpose Corrosive Use Location Location Location
Deadband 7% 1 7% 1 7% 1 7% 1 7% 1 7% 1 15% 1 15% 1 10% 1

(Not to exceed) 7% 2 7% 2 7% 2 7% 2 7% 2 7% 2 25% 2 25% 2 15% 2
1
Flow rates 15 GPM/56 LPM with exception of piston style. 2
Flow rates 14 GPM/52 LPM including piston style.
The above chart shows each switch pictorially, details it by option number and switch type,
and describes its rating and the rating agency, its use and deadband.
PIN IDENTIFICATION FOR B-H TYPE CONNECTORS
3-POSITION CONNECTOR (PC3) 5-POSITION CONNECTOR (PC-5) 6-POSITION CONNECTOR (PC6)

For 4-20 mA loop For a 3-wire For a 4-wire For a two 3-wire switches
GRN/1-GRD switch switch (DC) ORN/1-NO1 WHT/4-NO2
RED/2-NEG RED/1-COM BLU/1-NC1 BLU/2-NC1 RED/5-NC2
RED/3-POS RED/2-N.C. BLU/2-NO1 BLK/3-COM1 GRN/6-COM2
GRN/3-GRD GRN/3-GRD
RED/4-N.O. BLU/4-NO2
4-POSITION CONNECTOR (PC4) RED/5-N/U BLU/5-NC2 8-POSITION CONNECTOR (PC8)
For a 3-wire switch For a two 4-wire switches
BLK/1-N.O. For a 4-wire switch (AC) ORN/1-NC1 (1) WHT/5-NC1 (2)
WHT/2-N.C. RED/1-NC1 GRN/3-GRD BLU/2-NC2 (1) RED/6-NC2 (2)
RED/3-COM RED/2-NO1 RED/4-NO2 WHT-BLK/3NO1 (1) GRN/7-NO1 (2)
GRN/4-GRD GRN/3-GRD RED/5-NC2 BLK/4-NO2 (1) RED-BLK/8-NO2 (2)
5 GENMAN-200.5M 3/97
Setting Single Electrical Switches
Usually the switches are set at the factory as indicated in the model code on the nameplate, or as indicated on an
attached paper tag. To reset the switch point for common switch options 1, 1B, 3, 11, 53, 61, and 71, proceed as follows.
Warning: Shut off the electric power to the control box before opening it.
1. Remove the nameplate, window, and gasket from the control box.
2. The cam that actuates the switch is located just under the pointer. The position of the cam dictates the flow rate at
which the cam will trip the switch.
3. Turn the pointer so that it points at the desired flow rate on the scale. Against low spring forces you can do this by
grasping the pointer itself (and holding it in position while you adjust the cam).
NOTE: Some flow meters with higher spring forces (medium, large, and extra large vane style) have an extended shaft
which provides a means of manually moving the vane and simulating flow. A wrench (supplied with those units) is used to
turn an extension of the shaft located at the back of the unit, opposite from the control box.
Flow meters with very high spring force and no extended shaft (typically MN, MM, MH, series) can be handled by *remov-
ing the bowl (under the housing).
WARNING: Isolate meter from process and be sure to bleed off any remaining pressure, as well as purge the line
of any hazardous chemical prior to removing the bowl.
To maintain factory calibration accuracy, mark the bowl mounting orientation and replace the bowl in the same position
after the cam is properly adjusted. The vane is then grasped and turned. To get the edge of the vane out of its recessed
seat, use a socket head screw wrench as a lever, inserting it into one of the vane set screws to rotate the vane. To
properly set the cam, the set point must be approached from the normal flow condition. I.E., a low flow contact is set for
decreasing flow by moving the indicator above the low flow set point and adjusting the cam to activate or deactivate the
switch just as it arrives at the low flow setting. To set the cam for an increasing set point, the cam is adjusted to activate/
deactivate the switch as it approaches the set point from zero.
4. While holding the pointer/shaft/vane in the desired position, depress the cam ring fully (approx. 1/16 inch) and rotate it
until the switch actuates (clicks). Release your downward pressure and the cam ring will lock at that position.
5. If you cant hear the switch click, you can determine contact closure with an ohmmeter connected across the switch
terminals. Connect to the common and normally open or normally close on the switch.
6. To check the setting, direct the pointer again to the desired flow rate, noting where the switch actuates. Make adjust-
ments as necessary. If the bowl was removed please place on guide roll pins and firmly tighten, in a X motion.
7. Its much easier to set the switch point if you can do it with actual flow present. Adjust the flow to the desired point
where you want a signal to occur and turn the cam to actuate the switch as outlined above.
8. Replace window, nameplate, and gasket before turning on electric power.
Gasket
Window
Name Plate
Scale
Switch
* NOTE: It is recommended that all

DO NOT Teflon bowl seals be replaced
LOOSEN DIAL when bowl is removed. This is
SCREW!! symbol T found in model code.
Cam Ring (ex. MN-IIT-ect.)
Control Box
Dial Allen Screws
Spring
Pointer
Exploded View O Ring
Single switch assembly Cam Retainer
Pointer Screw
GENMAN-200.5M 3/97 6
Setting Dual Electrical Switches
Cam Set Screw Adjustment

For switch options 2, 2B, 4, 7, 7C, 17, 17C, 18, 18C, 19, 19C, 30, 31, 54, 62, and 72, cams are supplied with set screws
for adjustment. Dual switch units have two independent cams, stacked one on top of the other.
WARNING: Shut off electric power to control box before removing control box cover.
1. Remove the nameplate, window, and gasket from the control box.
2. With a 5/16 nut driver remove upper switch from control box.
3. Using a 1/8" hex wrench*, loosen lower cam screw just enough to rotate cam.
4. Turn the pointer so that it points at the desired flow rate on the scale. Against low spring forces you can do this by
using a screwdriver and turning the pointer screw (and holding it in position while you adjust the cam).
NOTE: Some flow meters with higher spring forces (medium, large, and extra large vane style) have an opening on the
opposite side of the meter from the control box. A wrench (supplied with those units) can be used to turn an extension of
the shaft. Flow meters with very high spring force and no extended shaft (medium) can be changed by removing the bowl
(under the housing).
WARNING: Isolate meter from process and be sure to bleed off any remaining pressure, as well as purge the line
of any hazardous chemical prior to removing the bowl.
To maintain factory calibration accuracy, mark the bowl mounting orientation and replace the bowl in the same position
after the cams are properly adjusted. The vane is then grasped and turned. To get the edge of the vane out of its
recessed seat, use a socket head screw wrench as a lever, inserting it into one of the vane set screws to rotate the vane.
To properly set the cam, the set point must be approached from the normal flow condition. I.E., a low flow contact is set
for decreasing flow by moving the indicator above the low flow set point and adjusting the cam to activate or deactivate
the switch just as it arrives at the low flow setting. To set the cam for an increasing set point, the cam is adjusted to
activate/deactivate the switch as it approaches the set point from zero.
5. While holding the pointer, shaft and vane in the desired position, rotate the bottom cam until it actuates the bottom
switch (switch will click). Still holding the pointer, shaft and vane in the desired position, tighten the cam screw with a
hex wrench.
NOTE: If you cannot hear the switch click, you can determine contact closure with an ohmmeter connected across the
switch terminals. The lower switch is now set.
6. To check the setting, move the pointer again to the desired flow rate, noting where the switch actuates. Make adjust-
ments as necessary.
7. Its much easier to set the switch point if you can do it with actual flow present. Adjust the flow to the desired point
where you want a signal to occur and turn the cam to actuate the switch as outlined above.
8. Place upper switch back into position in control box.
9. Again using a 1/8" hex wrench loosen upper cam just enough to rotate on dial.
10. Repeat steps 4 through 6.
11. Replace the gasket, window and nameplate before turning electrical power on.
*Due to control box space constraints, the supplied 1/8 inch hex wrench has been modified by grinding down the
short end of the wrench. Additional modified wrenches can be obtained through UNIVERSAL FLOW MONITORS,
consult factory.
2.12
3/4 NPT
ELECTRICAL
1.44 CONNECTION
CENTER
4.25 LINE OF
FLOW 2.88
Exploded View
5.38
Dual switch assembly
6
7 GENMAN-200.5M 3/97
WARNING: Instrument to AC power lines constitute a Pneumatic Switch Option
potential electric shock to users. Make certain that the Universals pneumatic switch option gives you reliable
branch circuit is disconnected from the power supply air-operated remote signalling. The switch is available
before touching anything inside the control box. on all Universal flow monitors. The unit is actually a
cam-operated 5-port multi-purpose 4-way valve with
Electric Switch Wiring Diagrams flow paths that can be optionally connected, to supply
Make connections according to the appropriate diagram ON-OFF signals.
below. (Switches may be removed to facilitate wiring The valve has a hardened stainless steel packless spool
them.) sliding in an electronics nickel plated body. The unit is
best used with instrument air. In any case, the air must
be clean and dry.
Connection is simplified with its push-on type barb tube
NC F
connectors. No tubing inserts, ferrules, collars, seals, or
threads are required. (Tubing should be 1/8" I.D.)
3-Wire SPDT INCREASING
C The unit comes mounted in the standard flow monitor
control box.
NO
Switch options 1, 1B, 2, 2B, 53, 54, 61, 62, 71, 72 Operation
The operation of this switch is the same as directional
valves commonly used to direct flow to air cylinders,
motors, and similar devices. The function of the switch
is to provide air control signals to activate a remote and/
4-Wire SPDT or pilot-operated signalling device, or as part of a logic
circuit.
NO 1 NC 1
ON-OFF Signalling
NO 2 NC 2
For simple ON-OFF operation of the valve, to signal a
Switch options 3,4 low-flow condition, just three ports are utilized. (See
simplified fluid power symbol.) Port 3 is the IN port,
port 4 is the OUT port, and port 5 is the Exhaust port.
The unit is cam operated with a spring return. When the
Switch options 7, 7C, 17, 17C, 18, 18C, 19, 19C, 30 and cam is not actuating it, the spring controls the valve
31 are all CSA and UL rated for use in hazardous spool. In the spring controlled position, port 3 is con-
locations DIV. 1, Class 1, Groups A, B, C & D, Class 2, nected to port 4. In the cam-controlled position, port 3 is
Groups E, F & G (switches with a suffix of "C" are connected to port 5 the exhaust port.
CENELEC rated). When flow is above the minimum level required (above
The explosion-proof switches come with color coded leads the switch point), the valve is held in the cam-controlled
as follows: RED
position, routing the air to exhaust . So the control box
BLUE
is purged with instrument air during normal operation.
When flow falls below the switch point, the valve shifts
RED BROWN to the spring-controlled position. Port 3 to 4 is then
PURPLE connected, completing the circuit to the signalling
BLUE
device.
BROWN
YELLOW
GREEN BLACK 2 4 2 4
SPDT
GREEN
DPDT
Switch options 7, Switch options 17,
7C, 18, 18C 17C, 19, 19C
LOAD
BLK 1 3 5 1 3 5
Vs CAM SPRING
RED
Switch options 11
ALTERNATE LOAD
LOCATION
Cam-controlled position shown at left, spring-controlled
position at right.
EXPLOSION-PROOF PROXIMITY
Switch options 30,31
GENMAN-200.5M 3/97 8
Air Logic Circuits
Wiring a transmitter (in control boxes RT, TT and
This multi-purpose valve offers a number of circuiting
TTL)
possibilities. Operation is illustrated in the symbols
RT, TT and TTL boxes contain a transmitter (and driving
shown here. When the cam is not actuating it, the spring
potentiometer) that provide a two wire 4-20 mA DC
controls the valve spool. The air logic symbols for the
linear output signal proportional to flow.
valves spring-controlled position are shown. Care
The transmitter comes factory calibrated for the fluid
should be taken that unused ports are not blocked, as
and application specified in the ordering process.
these act as exhaust ports. When flow is above the
Recalibration is only necessary if the transmitter is
switch point, the valve is held in the cam-controlled
replaced or installed in a different flow meter. Connect a
position. When flow falls below the switch point, the
shielded twisted pair of wires (not provided) to the
valve shifts to the spring-controlled position, changing
terminals marked + and - in the left hand junction box of
the condition of the flow paths.
the control box. The wire must be between AWG size 22
and 12. (see chart below).
(UFM STD.) OPTIONAL Wire Length Chart

Wire Gauge Maximum Signal Wire Length*

22 AWG 1000 Feet

20 AWG 1500 Feet

18 AWG 2500 Feet
2 connections 3 connections 4 connections 16 AWG 3000 Feet
3-4 1-2-4 1-2-4-5 14 AWG 3500 Feet
12 AWG 4000 Feet
* Based on using instrument grade twisted shielded signal cable
Engineering Data and adhering to wire separation guide line.
Pressure Rating: vacuum to 125 PSIG. Fully balanced.
Cv=0.12, when tubed with 1/8" I.D. polyurethane tubing. An electrical ground connection must be made to the
Leakage: no greater than .002 SCFM when supplied ground screw provided in the box. The twisted wire pair
with 50 PSIG pressure. Fittings: 10-32 to 1/8" I.D. push- connects the transmitter and all receiving equipment in
on barbs. a loop. Supply power (typical 24 VDC at 30mA) must be
supplied by one of the receiving units or by a separate
power supply. Several receivers (such as recorders or
Wiring a Potentiometer (options RP and TP) controllers) may be connected in series, but only one
RP and TP boxes contain a potentiometer that will give power supply source should be used. NOTE: The loop
a varying voltage with flow. Our standard pot is 10k should be grounded, at only one point in the loop.
ohms with an output of less Than 2k ohms. Power Refer to: RT, TT, TTL manuals for additional information
rating is 1 watt. These may be ordered with or without on transmitters.
the switches described previously. They should be
wired as shown below. Note: resistance of wiring Calibration
should not exceed 2 ohms. When ordering a remote All flow meters are individually calibrated (for a specific
transmitter for the purposes of keeping the transmitter fluid) before leaving the factory. Scales are therefore not
out of a hazardous location, there must be a barrier on interchangeable. Be sure any scale removed is put back
each of the three branches. (Consult factory for in the same meter.
additional instructions). (For additional information see separate transmitter
manual RT, TT, TTL)
3 1
3
2
1 2 WIPER
C.C.W. 1 3 C.W.
CLOCKWISE
10k POTENTIOMETER
9 GENMAN-200.5M 3/97
Periodic Maintenance
Periodic maintenance (Vane type meters) Periodic Maintenance (Piston type meters)
Check the meter function by varying flow though it and In the piston design, individual springs cannot be
observing if the flow indications are tracking. If not, there changed. All internal parts are contained in a
may be an obstruction around the flow sensing element. replaceable capsule, including a piston, piston seal, and
stainless steel spring. The capsule is easily removed to
CAUTION: Shut off flow to the meter and bleed off correct a malfunction or to change the flow range, as
pressure prior to disassembly. The meter may also follows:
have to be purged if it is metering hazardous
materials. CAUTION: Shut off flow to the meter and bleed off
pressure prior to disassembly. The meter may also
Mark position of bowl on both the body and bowl to ensure have to be purged if it is metering hazardous
reassembly in the proper position. Open the flow chamber materials.
as show in the diagram. Check for obstructions and
remove any. If the vane is in good condition (not pitted or Loosen the four cap screws from the lower end cap, and
corroded), and the spring is intact, it is likely the original pull the end cap and attached flow sensing capsule out
calibration is still good. Reassemble the meter, matching of the housing. The capsule may be cleaned by flushing
the marks previously made on the bowl and meter body, in a liquid, or by a blast of compressed air. However, we
and continue the operation, Actual verification of flow do not recommend disassembly of the capsule.
accuracy requires a flow prover or calibration flow test Before installing a cleaned or replacement capsule,
stand. clean the interior of the housing with a rag or brush. The
tell-tale arm that controls the motion of the pointer must
be held out of the way while the capsule is installed.
VANE STYLE This is done by removing the name plate from the
control box, and moving the pointer, by hand, in the
direction of maximum scale reading while slipping the
capsule and end cap into position. The pointer may then
be released, the end cap tightened, and the face plate
reinstalled.
If your model number contains a Z, followed by digits,
HOUSING you have a non-standard option. Please contact the
factory for an explanation of your complete model
number.
PISTON STYLE
BOWL
Remove bowl and look for obstruction on S or M housing Remove piston by taking out 4 screws
types. * See: Caution above. and sliding it out. Check seal
condition, look for debris or coating
inner bore for LL, LP, or LH housing.
* See: Caution above.
If there is no sign of corrosion or blockage and the flow
element is still frozen in place, it is likely that the O-rings
have been chemically attacked. If the attack is not likely to
be repeated, then replacement O-rings can be ordered as
a seal kit. If the chemical attack is due to a permanent
change in fluid conditions, then the meter must be rebuilt
using new O-rings of a different material. Please consult
the factory when making this selection. It is also possible
that gaskets, switches, control box mechanical moving
parts and O-rings may become damaged and need
replacement. Select these parts kits from page 12-28
according to the flow meter model number.
GENMAN-200.5M 3/97 10
Calibration Notes
If the flowmeter will be used to measure flows at varying pressures (as in applications for
portable meters) a standard unit calibrated for 90 psig @ 70oF is supplied, and correction
factors from Table 1 are applied against the readings to get actual SCFM.
If the flowmeter is to measure air at a constant and repeatable pressure, it will be factory
calibrated to read directly in actual SCFM, with air temperature assumed to be 70oF.
Readings taken with air at other than 70oF can be corrected by using the correction factors
in Table 2.
Table 1 Pressure
PSIG 10 20 30 40 50 60 70 80 90 100 110 120
Factor .49 .58 .65 .72 .79 .84 .90 .95 1.0 1.05 1.09 1.13
Table 2 Temprature
Temp oF 30 50 70 90 120 150 200 250 300 350
Factor 1.04 1.02 1.00 0.98 0.96 0.93 0.90 0.86 0.84 0.81
14.7 . 14.7
14.7 + 90.0 . 14.7 + X
X = System Pressure
11 GENMAN-200.5M 3/97
Dimensional information
A Style Control Box 2.12

3/4 NPT
ELECTRICAL
1.44 CONNECTION
CENTER
4.25 LINE OF
FLOW 2.88
5.38
6
M Style Control Box 1.75 2.75
4.25
1.68
1/2 NPT
ELECTRICAL
.75 1.38 CONNECTION
R Style Control Box 3.31
CENTER
LINE
3.813R OF FLOW
1.31
3/4 NPTF 7.62

TO GAGE
3.81
T Style Control Box .65
.719 .005 CORE THRU

*2 DRAFT PER SIDE
2PLACES AS SHOWN
1/2-14 NPTF TAP
2 PLACES TO GAGE
7.75 3.88
5.38 FLOW 2.62
CENTER
LINE
.12
4.25
3.25
X Style Control Box 2.44 2.50
PRIMARY
5.12 SWITCH
4.75
SECONDARY
9.62
SWITCH
FLOW CENTER 7.75
LINE
6.00
3/4 NPT 3.44

ELECTRICAL
CONNECTION
(2 PLACES)
6.50
2.94 7.50
NOTE: Dimensional information on these drawings are for general reference only. Please request certified drawings with your order when installation dimensions are critical.
GENMAN-200.5M 3/97 12
5.50
3.75
DIM R1
SWING RADIUS
(TO CONTROL BOX)
1.31
5.75
2.62 LH
5.25
DIM R2
SWING RADIUS
(TO CONTROL BOX)
.25
CONTROL BOX STYLE

Piston Body A M R T X
BOX BOX BOX BOX BOX
DIM R1 5.62 5.06 7.25 7.00 8.38
DIM R2 5.06 5.68 6.68 6.50 6.75
Shown with A/Box
4.38 (HIGH PRESSURE)

Shown with A/Box
3.88 3.50 PORT TO PORT
2.25 Small Body
3.00
.75
2.44
DIM R
SWING RADIUS
(TO CONTROL BOX)
CONTROL BOX STYLE
A M R T X
BOX BOX BOX BOX BOX
DIM R 5.00 5.62 8.62 7.00 7.12
13 GENMAN-200.5M 3/97
4.25 DIM. A
2.20 3.50 PORT TO PORT
.75
2.38
DIM B
SWING RADIUS
(TO CONTROL)
CONTROL BOX STYLE FITTING DIM A

STYLE SIZE (NPTF)
A M R T X
BOX BOX BOX BOX BOX MALE 1/4 6.00
DIM B 5.00 5.56 8.62 7.00 7.12 1/2 6.25
3/4 6.50
SX Body 1 6.50
FEMALE ALL 5.50
Shown with A/Box
8.31 (DUAL SPRING & MANUAL OVERRIDE)

8.06 (MANUAL OVERRIDE)
7.44 (DUAL SPRING)
6.69
5.25 PORT TO PORT
2.88
Shown with A/Box
DIM C
DIM A
Medium Body
DIM B
DIM R
SWING RADIUS
(TO CONTROL BOX)
1/2" TO
1-1/2" 2" CONTROL BOX STYLE
A M R T X
DIM A 1.44 1.75 BOX BOX BOX BOX BOX
DIM B 4.38 4.75
DIM R 5.75 6.44 9.50 7.81 8.12
DIM C 3.75 4.00
GENMAN-200.5M 3/97 14
6.25 WITH ADAPTOR
5.75
5.25
2.98
1.75
6.38
DIM C
SWING RADIUS
(TO CONTROL BOX)
14.5
CONTROL BOX STYLE
A M R T X
BOX BOX BOX BOX BOX 6
DIM C 6.00 6.75 9.50 8.00 7.62

MX Body
Shown with A/Box
5.69 MANUAL OVERRIDE Shown with A/Box

5.56 DUAL SPRING & MANUAL OVERRIDE
4.75 MH Body
4.00 5.25
3.06 3.06
1.88
7.25
DIM B
SWING RADIUS
CONTROL BOX STYLE (TO CONTROL BOX)
A M R T X
BOX BOX BOX BOX BOX
DIM B 6.12 7.56 9.62 8.25 8.25
15 GENMAN-200.5M 3/97
17.55 (DUAL SPRING)
15.19
5.88
CONTROL
BOX 2.15
10.81
10.25
WRENCH PORT
TO JOG
SWINGING VANE
DIM C 6.00
10.25
Large Body CONTROL BOX STYLE

R T X
BOX BOX BOX
DIM C 3.38 3.88 3.00
Shown with R/Box
10.81 13.25
6.62
Shown with R/Box
XHF Body
CONTROL
BOX
22.25
15.25
DIM C 9.48
WRENCH PORT
(TO JOG SWINGING VANE)
CONTROL BOX STYLE

R T X
BOX BOX BOX
DIM C 10.69 10.31 11.25
GENMAN-200.5M 3/97 16
Replacement Parts
Select replacement part kits from the following charts using the model code stamped on the name plate of the flow meter. Model
code descriptions can be found on all UFM specification sheets. The first two digits will define the correct flow monitor series. (NOTE:
See page 2 for special use meters, if you do not find your particular series listed.)
How to order a Dial Assembly Kit: Pg. 18-22
How to order a Readout Kit: Pg. 23-25
How to order a Cover Assembly Kit: Pg. 26-28
How to order a Gasket Kit: Pg. 29-30
How to order a Seal Kit: Pg. 31-33
17 GENMAN-200.5M 3/97
HOW TO ORDER A DIAL ASSEMBLY KIT: (DAK)
The meters in this manual are all mechanical in nature. The flow elements are connected to the control boxes via a shaft that
rotates with changing flow rates. The parts that are attached to this shaft and that reside inside the control box are referred to
as the Dial Assembly. If any of these parts are damaged, the replacement parts are sold as a kit. All Dial Assembly kit
part numbers begin with DAK. The remainder of the part number is derived from the model code of the meter. The kit
numbers correlate to the model codes as follows:
MN-BSB30GM-8-32V1.0-A1NR
DAK-MN-A-1
EX. DAK - MN - A - 1
GENERAL SERIES BOX READOUT FLOW
DESIGNATOR TYPE DIRECTION
DAK LL* A 0 L
LP* M 1, 1B R
LH* R 2, 2B U
SH* T 3 D
SN* X 4
SM* 61
SX* 62
ML 53
MN 54
MX 71
MM 72
MH 7, 7C
LN 18, 18C
LE 17, 17C
XHF 19, 19C
30
* Flow direction required for 31
these models only.
11
The following kit diagrams are subsets of the main parts assembly. The accompanying diagrams will clarify which
parts are included for each meter series.
Single Switch Assy. Single Switch Assy.
EX. DAK - LL - A - 1 - R EX. DAK - MN - A - 1

GENERAL SERIES BOX READOUT FLOW GENERAL SERIES BOX READOUT
DESIGNATOR TYPE DIRECTION DESIGNATOR TYPE
DAK LL A 1, 1B L DAK MN A 1, 1B
LP R 3 R MM R 3
LH T 61 U MH T 61
SN M 53 D MX M 53
SM 11 ML 11
SH 71 71
SX
GENMAN-200.5M 3/97 18
Single Switch Assy. Double Switch Assy.
EX. DAK - LN - R - 1 EX. DAK - LL - A - 2 - R

GENERAL SERIES BOX READOUT GENERAL SERIES BOX READOUT FLOW
DESIGNATOR TYPE DESIGNATOR TYPE DIRECTION
DAK LN R 1, 1B DAK LL A 2, 2B L
LE T 3 LP R 4 R
XHF 61 LH 62 U
53 SN 54 D
11 SM 72
71 SH
SX
Double Switch Assy. Double Switch Assy.
EX. DAK - MN - R - 2 EX. DAK - LN - R - 2

GENERAL SERIES BOX READOUT GENERAL SERIES BOX READOUT
DESIGNATOR TYPE DESIGNATOR TYPE
DAK MN A 2, 2B DAK LN R 2, 2B
MM R 4 LE 4
MH 62 XHF 62
MX 54 54
ML 72 72
19 GENMAN-200.5M 3/97
EX. DAK - LL - X - 7 - R EX. DAK - MN - X - 7

DAK LL X 7, 7C L DAK MN X 7, 7C
LP 17, 17C R MM 17, 17C
LH U MH
SN D MX
SH ML
SX
EX. DAK - LN - X - 7 EX. DAK - LL - X - 30 - R

GENERAL SERIES BOX READOUT GENERAL SERIES BOX READOUT FLOW
DESIGNATOR TYPE DESIGNATOR TYPE DIRECTION
DAK LN X 7, 7C DAK LL X 30 L
XHF 17, 17C LP R
LH U
SN D
SH
SX
GENMAN-200.5M 3/97 20
EX. DAK - MN - X - 30 EX. DAK - LN - X - 30

DAK MN X 7, 7C DAK LN X 7, 7C
MM 17, 17C XHF 17, 17C
MH 30 30
MX
ML
EX. DAK - LL - X - 31 - R EX. DAK - MN - X - 18

DAK LL X 31 L DAK MN X 18, 18C

LP R MM 19, 19C
LH U MH 31
SM D MX
SN ML
SH
SX
21 GENMAN-200.5M 3/97
Double Switch Assy.
EX. DAK - LN - X - 18
GENERAL SERIES BOX READOUT
DESIGNATOR TYPE
DAK LE X 18, 18C

LN 19, 19C
XHF 31
GENMAN-200.5M 3/97 22
HOW TO ORDER A READOUT KIT: (ROK)
The meters in this manual are all mechanical in nature. The flow elements are connected to the control boxes via a shaft
that rotates with changing flow rates. The parts that are actuated by this mechanical action that reside inside of the control
box are called the Readout. If any of these parts are damaged, the replacement parts are sold as a kit. All Readout
Assembly kit part numbers begin with ROK. The remainder of the part number is derived from the model code of the
meter. The part numbers correlate to the model codes as follows:
MN-BSB30GM-8-32V1.0 -A1NR
ROK-MN-A-1
EX. ROK - MN - A - 1 - HT
GENERAL SERIES BOX READOUT OPTIONS
DESIGNATOR TYPE
ROK LL A 0
LP M 1, 1B
LH R 2, 2B
SN T 3 CE
SM X 4
SH 61 HT
MN 62
MM 53
MH 54
LN 71
LE 72
XHF 7, 7C
SX 18, 18C
MX 17, 17C
ML 19, 19C
30
31
11
The following kit diagrams are subsets of the main parts assembly. The accompanying diagrams will clarify which parts are
included for each flow meter series.
Single Switch Assy. Double Switch Assy.
Insulator used Insulator used

with R box & with R box.
T Box.
EX. ROK - LL - A - 1B - CE EX. ROK - LL - A - 2B - CE
GENERAL SERIES BOX READOUT OPTIONS GENERAL SERIES BOX READOUT OPTIONS
ROK ALL A 1, 1B CE ROK ALL A 2, 2B CE

R 3 HT R 4 HT
T 61 54
M 53 62
71 72
23 GENMAN-200.5M 3/97
EX. ROK - LL - X - 7 EX. ROK - LL - X - 30

ROK LL X 7, 7C ROK ALL X 30

LP 17, 17C
LH
SN
SM
SH
MN
MM
MH
LN
LE
XHF
ML
EX. ROK - XHF - X - 19 EX. ROK - LL - X - 31

ROK MN X 18*, 18C* ROK ALL X 31*

MM 19*, 19C*
MH
LN
LE
XHF
ML
GENMAN-200.5M* 3/97
Includes 2 switch assemblies. 24 * Includes 2 switch assemblies.
Single switch
Single Pneumatic Switchassy.
for All Series
EX. ROK - LL - A - 11
GENERAL SERIES BOX READOUT
DESIGNATOR TYPE
ROK ALL A 11
25 GENMAN-200.5M 3/97
HOW TO ORDER A COVER ASSEMBLY KIT: (CAK)
that changes angle with changing flow rates. If any of these parts are damaged, the replacement parts are sold as a kit.
All Cover Assembly Kits part numbers begin with CAK. The remainder of the part number is derived from the model
code of the meter. The part numbers correlate to the model codes as follows:
MN-BSB30GM-8-32V1.0-A1WR-HT
*
CAK-MN-A-H
How to order a Cover Assembly Kit:

EX. CAK - LL - A - W - HT
GENERAL SERIES BOX ENCLOSURE OPTIONS

DESIGNATOR TYPE TYPE
CAK LL LN A N,W,X HT
LP LE M W or X C
LH XHF R W or X TG
SN SX T W or X CE
SM MX X W or X
SH ML RTZ W or X
MN TTZ W or X
MM
*
HT Option at the end of the model code requires an HT designator in the kit part number for high temperature
applications (not available with N type control boxes, SX, MX, or ML meters).
NOTE: Model number and UFM # must be supplied with order to stamp new name plate.
The following kit diagrams are subsets of the main assembly. The accompanying diagrams will clarify which parts are
included.
A Box (Vane Style) A Box (Piston Style)
C.
IN
S,
OR0
NIT4803
5
3
1
OR
AT MO MI
DIC W Park,
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IN
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SA IV. Nine
IV
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55 4-96
35
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17 52
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31
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ITE
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M
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NU C. LN
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17 52
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IV
UN
EX. CAK - SN - A - W - HT EX. CAK - LL - A - N - HT

GENERAL SERIES BOX ENCLOSURE OPTIONS GENERAL SERIES BOX ENCLOSURE OPTIONS
DESIGNATOR TYPE TYPE DESIGNATOR TYPE TYPE
CAK SN A N C CAK LL A N C
SM W HT LP W HT
SH X TG LH X TG
MN CE CE
MM
MH
SX
MX
ML
Flow Any Direction Flow Any Direction

GENMAN-200.5M 3/97 26
R Box (Flow to right) R Box (Flow to Left)
OR
ICAT
IND
TE
RA
W
O
FL
C. A
L
IN S
S, 0
5
3 R
1
E
OIR4803 IV
NIT
N
M U
rk,
MzeOl Pa
OW, Ha 35
FL ad 96
L ile Ro524-
SAne M 313-
ER Ni
IV55 E.
UN 17 5
3
1
.
NO
M
ITE
0 .
1 NO ER
2 M MB
4
3 ITE L NU
DE .
MO NO
AL
ER RS
MB IVE
UN
L NU
DE . PE

MO NO TY
AL
C.
RS
IVE
UN
IN
S, 0
OIR4803
PE 1
0
TY
NIT
2
3
M
rk,
4
MzeOl Pa
OW, Ha 35
FLRoad4-96
L ile 52
SAne M 313-
R
O
A
T
ERE. Ni
D
IC
U NIV55
17
IN
TE
RA
OW
FL
RS AL
UNIVE
EX. CAK - LL - R - X - HT EX. CAK - LN - R - W - HT

CAK ALL R W C CAK LN R W C

EXCEPT: RP X HT LE RP X HT
LN RT TG XHF RT TG
LE
XHF * RTZ CE RTZ CE
* LEFT TO RIGHT - UP or DOWN FLOW ONLY

NOTE : HT = HIGH TEMPERATURE OPTION.
X Box
C.
IN
S,
OR0
NIIT4803
MO
rk,
M
OWl Pa
FL, Haze
AL ad 5
RS ile Ro
3
1
IVENine
M
UN
55
E. 9635
17 524-
3-
31
0
1 .
2 NO
ITEM
3
4
R
MBE
NU
EL
MOD .
L NO
SA
IVER
UN
R
TO
CA
DI
IN
TE
RA
OW
FL
L
SA
IVER
UN
EX. CAK - SN - X - X - C
CAK SN X X C
SM HT
SH TG
MN
MM
MH
SX
ML
MX
LN
LE
XHF
27 GENMAN-200.5M 3/97
T Box (Flow to right) T Box (Flow to left)
5
3
1
R
TO
CA
INDI
TE
RA
OW
FL
L
SA
IVER
UN
.
NO
1
0
M
. 2 ITE
NO 3
M 4
ITE
ER
R 3
5
MB
TO 1
L NU
ER INDI
CA DE . C.
MB
MO NO , IN
L NU RA
TE
RS
AL
RS
DE . OW IVE ITO030
MO
L NO L
FL
UN
ON
Mrk, MI
48
SA
IVER
SA
. PE OWl Pa
IVER
INC
TY
UN FL, Haze
UN
S, AL ad
OR0 RSMile Ro
IVE
PE e
NIT4803
TY
UN Nin 35
MO
E.
MI 55 -96
17 24
OWl Pa
rk, 3-5
31
FL Haze
AL ad,
RSMile Ro
0
1
IVE
2
Nine
3
UN
4
E. 35
55 -96
17 24
3-5
31
EX. CAK - LL - T - X - HT EX. CAK - LN - T - X - HT

CAK ALL T X C CAK LN T X C

EXCEPT: HT LE HT
TG XHF TG
LN
LE *
XHF
* LEFT TO RIGHT, UP OR DOWN FLOW ONLY FLOW RIGHT TO LEFT ONLY
M Box
INDICATOR
FLOW RATE
UNIVERSALPATENT PENDING
AL
UNIVERS INC.
NITORS,
FLOW MO Mile Road
1755 E. Nine 48030
, MI
Hazel Park
313-524-9635
ER
MODEL NUMB
ITEM NO.
NO.
UNIVERSAL
TYPE
AL HAZARD
: ELECTRIC RE SERVICING
WARNING
CT POWER BEFO
DISCONNE
EX. CAK - LL - M - W - C
CAK LL M W C
LP HT
LH
SN
SM
SH
SX
MX
MN
MH
MM
Any Direction 3/97
GENMAN-200.5M 28
HOW TO ORDER A GASKET ASSEMBLY KIT: (GAK)
that changes angle with changing flow rates. The various parts of the meters are sealed from the atmosphere by gaskets.
If any of these gaskets are damaged, the replacement parts are sold as a kit. All Gasket Assembly kit part numbers
begin with GAK. The remainder of the part number is derived from the model code of the meter. The part numbers
correlate to the model codes as follows:
*
GAK-MN-A-W-H
How to order a Gasket Kit:
EX. GAK - LL - T - W - HT

DESIGNATOR PRESSURE TYPE TYPE
GAK LL A N HT
LP M W
LH R X
SN T
SM
SH
MN
MM
MH
LN
LE
XHF
SX
MX
ML
HT option at the end of the model code requires an HT designator in the kit part number for high temperature applica-
*
tions (not available with N type control boxes, SX, MX, or ML meters).
The following kit diagrams are subsets of the main assembly.
The accompanying diagrams will clarify which parts are included.
A Box Gasket Assy. M Box Gasket Assy.
* *
EX. GAK - MN - A - W - HT EX. GAK - MN - M - W - HT

GAK *LL MN A N HT GAK *LL MN M N HT
*LP MM W *LP MM W
*LH MH X *LH MH
*SN *SX *SN *SX
*SM MX *SM MX
*SH ML *SH ML
* Not part of kit
29 GENMAN-200.5M 3/97
HOW TO ORDER A GASKET ASSEMBLY KIT: (GAK)
R Box Gasket Assy. T Box Gasket Assy.
* *
EX. GAK - MN - R - W - HT EX. GAK - MN - T - W - HT

GAK *LL MM R W HT GAK *LL MM T W HT
*LH MH X *LP MH X
*SN LN *LH LN
*SN LE
*SM XHF
*SM XHF
*SH *SX *SH *SX
MN MX MN MX
ML ML
* Not part of kit * Not part of kit
X Box Gasket Assy.
EX. GAK - MN - X - X - HT
GAK *LL MM X W HT
*LP MH X
*LH LN
*SN LE
*SM XHF
*SH *SX
MN MX
ML
* Not part of kit
GENMAN-200.5M 3/97 30
HOW TO ORDER A SEAL ASSEMBLY KIT: (SAK)
The meters in this manual are all mechanical in nature. The flow elements are connected to the control boxes via a shaft that
rotates with changing flow rates. The fluid is prevented from leaking out of the flow meter body by O-rings acting as seals. If
any of these seals are damaged, the replacement parts are sold as a kit. All Seal Assembly kits part numbers begin with
SAK. The remainder of the part number is derived from the model code of the meter. The part numbers correlate to the
model codes as follows:
SAK-MN-B-A
EX. SAK - MN - B - A - G
GENERAL SERIES SEAL BOX AIR OR
DESIGNATOR MATERIAL TYPE GAS UNIT
SAK LL B A G
LP E M (No
LH F R Symbol
SN J T for
SM T X Liquids)
SH K
MN H
MM A
MH
LN
LE
XHF
SX
MX
ML
The following kit diagrams are subsets of the main parts assembly kit. The accompanying diagrams will clarify which parts are
included for each flow meter series.
This seal included in SAK with SH

EX. SAK - SN - B - S - R - G housings only.
Thrust Bearing for SH housing
GENERAL SERIES SEAL INTERNALS BOX AIR OR
only.
DESIGNATOR MATERIAL TYPE GAS UNIT
SAK SN B S A G
*
SM E I M (No
SH F T R Symbol The glydring is
*SX J H RT for added to this parts
T L RP Liquids) list for transmitting *
K C T and air or gas units.
H R X It is standard on SM
A P & SH Series
monitors
,yy,y,y,y,y,y,y,y,y,y,y,y,y,y,
y, y, y, y, y,
Small Vane Style

NOTE: SHAFT IS INCLUDED IN SMALL SERIES (SN,SM,SH,SX) ONLY.
* SX Series requires additional static seals for port adaptors.
31 GENMAN-200.5M 3/97
Medium Vane Style

EX. SAK - MN - B - R - G
DESIGNATOR MATERIAL TYPE GAS CAL. **
SAK MN B A G
MM E* M (No
MH F R Symbol
ML J RP for The glydring is
MX T RT Liquids) added to this parts **
K T list for transmitting
H X and air or gas units.
A It is standard on
MM ,MH, & ML
Series monitors
,yy,y,y,y,y,y,y,y,y,
y,y,y,y,y,y,y,y,y,y,
y, y, y, y, y,
*EPR O-Rings swell when in contact with oil, grease or petroleum
based fluids. The shaft seals will have one Buna-N seal
substituted for the EP o-ring for use in the "spring pocket".
** MX Series with port adaptors require static seals.
(See drawing to right)
Piston Style
EX. SAK - LL - F - T - G
,yy,y,y,y,y,y,y,y,y,y,y,y,y,
DESIGNATOR MATERIAL TYPE GAS CAL.
SAK LL B A G
LP E M (No
LH F R Symbol
J RT for
T RP Liquids)
K T
H X
The glydring is
standard on all piston
style monitors.
GENMAN-200.5M 3/97 32
Large Vane Style

EX. SAK - LN - B - R - G
DESIGNATOR MATERIAL TYPE GAS CAL.
SAK LN B M G
LE E R (No
F RP Symbol
J RT for
T T Liquids)
K X
H
A
The glydrings are a
standard part, and
is used for both
liquids and gases.
The glydrings are a

EX. SAK - XHF - B - R - G standard part, and
is used for both
GENERAL SERIES SEAL BOX AIR OR liquids and gases.
DESIGNATOR MATERIAL TYPE GAS CAL. ,yy,y,y,y,y,y,y,y,y,
SAK XHF B M G y,y,y,y,y,y,y,y,y,y,
E R (No
F RT Symbol
J RP for
T T Liquids)
K X
H
A
XHF Vane Style
33 GENMAN-200.5M 3/97
NOTICE
RETURN MATERIAL AUTHORIZATION
Please read the following UFM policy information carefully. By following the guidelines outlined
below you will assist in providing a timely evaluation and response regarding the status of your flow
meter. UFM evaluates all AUTHORIZED RETURNED MATERIALS in a timely manner and will promptly
provide notification regarding the status of the related materials and/or a written quotation indicating
the total charges and description of the necessary repairs.
1. All returns must have a RMA form completed by the customer.

2. Any meter returned that was previously in service must have the OSHA requirements completed and
a MSDS included where applicable.
3. An RMA number will only be issued when UFM has received a copy of the completed RMA form and
any applicable MSDS.
4. A "Return Goods" shipping label (located in the back of the Instruction Manual) must be used for
returning materials to UFM.
5. A purchase order must accompany all returns to cover the cost of the repair evaluations.
6. Returned goods must be shipped prepaid or they will be rejected.
REPAIRABLE MATERIAL
Written authorization to proceed with the repair under the assigned Purchase Order, must be received within
30 days of repair quotation. If the unit(s) are repaired, the $90.00 evaluation charge will be applied to the
quoted repair costs. If no repairs are authorized within this 30 day period, the customer will be billed $90.00
plus shipping charges and the materials will be returned to the customer.
NON-REPAIRABLE MATERIAL
A written notice that the material is not repairable will be provided to the customer by UFM. If no disposition
to scrap or return the material is received from the customer within 30 days, unrepairable material will be
scrapped and the customer will be billed the $90.00 evaluation charge. If a UFM replacement unit is pur-
chased within 30 days of non-repairable condition notice, the $90.00 evaluation fee will be waived. The return
of non-repairable materials may be ordered by customer Purchase Order providing for shipping and handling
charges.
RETURN FOR RESTOCK

All goods returned for restock adjustment must be:
A. New and unused.
B. Returned to the factory within ONE YEAR of date of original shipment.
C. Returned through the distributor where the goods were originally purchased.
This material will also be subject to an evaluation charge of $90.00 and must be accompanied by a Purchase
Order.
The customer will be advised of the restocking adjustment for all restockable goods. Upon acceptance of the
restocking adjustment, by the customer, the $90.00 evaluation fee will be waived and a credit issued by UFM
against the assigned Purchase Order. The customer will be advised of any non-restockable goods and will
be charged the $90.00 evaluation fee plus any shipping charges if returned to the customer.
If no disposition is received by UFM within 30 days, the goods will be scrapped and the $90.00 evaluation fee
will be billed.
WARRANTY RETURNS
Warranty returns must be accompanied by a Purchase Order and must be shipped prepaid to UFM. UFM will
review the goods and advise the customer of the evaluation and validity of the warranty claim. Valid warranty
claims will be repaired or replaced at no charge. No evaluation fee will be charged to repairs made under
valid warranty. Return shipping costs will be prepaid by UFM. Should UFM determine the returned material
is not defective under the provisions of UFM's standard warranty, the customer will be advised of needed
repairs and associated costs. All materials returned without a valid warranty will be subject to the "Repair-
able Material" policy outlined above.
Form RMAP-100
GENMAN-200.5M 3/97 34
U N I V E R S A L RETURN MATERIAL AUTHORIZATION
(RMA) REQUEST FORM
FAX TO: UFM Repair Department
FLOW MONITORS (810) 398-4274
IMPORTANT: This form must be filled out completely and faxed to UFM Repair Department prior to UFM issuing a RMA #
Customer: Product Information Qty:

Ship To: Model Code:
Universal #:
Operating Temp: Max Temp:
Operating Pressure: Max Pressure:
Contact Name: Viscosity Specific Gravity
Return P.O.# Date Purchased: Date Installed:
Phone#
FAX#
Reason for return: (Please be detailed as possible. Lack of Information may increase labor charges.)
Mechanical Electronics
Meter leaks No signal
Pointer sticks Inaccurate signal
Pointer is not accurate (calibration off) Remote Readout
Alarm switch does not work (MENSAH ) Digital Display
Other (describe below) Signal at no flow
Other (describe below)
Details:
Note: There will be a minimum evaluation charge of $90.00 for all units returned (excluding units covered under warranty).
Units WILL NOT be accepted without a valid UFM Return Material Authorization Number (RMA#). A Material Safety Data
Sheet on the process fluid must be received by UFM when applicable, prior to the RMA# being issued.
* OSHA Requirements: (to be filled out by customer) NO EXCEPTIONS!!

Process Fluid:
Meter must be flushed to remove all process fluids.
I hereby certify that the material being returned has been properly flushed and cleaned of all hazardous
materials and does not require any special handling.
Print or Type Name Signature:
Title Date:
Distributor Information INTERNAL USE ONLY

Company Name RMA#
Contact Name Authorized by
P.O. # Date
Phone# FAX#
Document #: 1400.8 Revision #: 2 Revision Date: 1/18/95 Approved By: Approval Date:
Distribution: GENMAN, VORTEX, INSITE, OCTOPUS, MENSAH 140, MENSAH 145, TRANSMITTER, GDN, GDNL
35 GENMAN-200.5M 3/97
DO NOT REMOVE THIS PAGE.
PLEASE COPY RMA FORM.
GENMAN-200.5M 3/97 36
FROM:
REMINDER: PLEASE INCLUDE MSDS INFORMATION
TO:
UNIVERSAL FLOW MONITORS, INC.
ATTN: RETURNS/REPAIRS DEPT.
1755 EAST NINE MILE ROAD
HAZEL PARK, MI 48030-0249
U.S.A.
CUSTOMER:
RMA#:
RUSH DELIVERY REQUIRED: (CIRCLE ONE) YES NO
FROM:
TO:
U.S.A.
CUSTOMER:
RMA#:
FROM:
TO:
U.S.A.
CUSTOMER:
RMA#:
37 GENMAN-200.5M 3/97
GENMAN-200.5M 3/97 38
Notes
UNIVERSAL FLOW MONITORS, INC. U N I V E R S A L

1755 East Nine Mile Road
P.O. Box 249, Hazel Park, MI 48030-0249
(810)542-9635 / FAX (810) 398-4274 FLOW MONITORS
39 GENMAN-200.5M 3/97
U N I V E R S A L
R
FLOW MONITORS

Ph. 810-542-9635 / Fax 810-398-4274
Area code changing mid 1997, new numbers are:
Ph. 248-542-9635 / Fax 248-398-4274
GENMAN-200.5M 3/97 40
Litho in USA
U N I V E R S A L
FLOW MONITORS
Instrucciones de Instalacin de
monitores de flujo e
Instrucciones de Mantencin para
Monitores de flujo de area variable
Tipo paleta y tipo piston

Fono. 248-542-9635 / Fax 248-398-4274
Direccin Email: ufm@flowmeters.com
Sitio Web: http://www.flowmeters.com
1
SPGENMAN-200.1 10/4/2000
Manual de Instalacin e instruccin para monitores de flujo Universal Flow Monitors, Inc.
El siguiente manual incluye las instrucciones de instalacin y mantencin para medidores de flujo fabricados por
Universal Flow Monitors Inc. Todos los monitores de flujo son individualmente calibrados para uso con un fluido
especifico requerido en el proceso de ingreso de la orden. No deberan ser usados fluidos diferentes, sin primero
consultar a la fabrica, para verificar la compatibilidad de materiales y los parmetros de flujo, tales como la viscosidad y
la gravedad especifica para los lquidos, o la presin de operacin, temperatura y gravedad especifica, para los gases de
la nueva aplicacin. El diseo de los medidores, es del tipo rea variable y operan con una relativa baja perdida de
presin. Los elementos de medicin de flujo pueden ser ya sea una paleta mvil o un pistn en movimiento.
INDICE
Como trabajan los medidores de flujo tipo paleta y tipo pistn ........ 2
Medidores para uso especial ........................................................... 3
Materiales de construcciones y especificaciones de ingeniera ....... 4
Especificaciones de Lectura ......................................................... 5-8
Matencin peridica ....................................................................... 10
Notas de calibracin ....................................................................... 11
Informacin de dimensional ...................................................... 12-16
Juego de partes de remplazo .................................................... 17-33
Informacin para autorizacin de retorno ................................. 34-37
Como funciona el diseo de paleta mvil
El fluido entra en A, pasa alrededor de la paleta semicircu-

lar B, sale finalmente en la salida C. La paleta resiste el
flujo a causa del resorte D. Mientras ms se empuja la
F
paleta, tanto mas se abre el pasaje E. Esto minimiza el C
aumento de la perdida de carga. El eje de la paleta se
mueve para operar el puntero F y los aparatos de seal A D
remotos tales como el interruptor G. El eje puede tambin
activar los interruptores de leva y transductores, para actuar
B
cualquier artefacto de lectura remota presente. La perdida
de carga aumenta sobre el rango de flujo medido, E
promediando 2 PSI. Perdidas de carga mas altas pueden
ser alcanzadas en medidores de capacidades mayores.
Como funciona el diseo de Pistn
El flujo de fluido causa la compresin del resorte A, el

medidor tiene una apertura circular en su centro B que
E mueve a lo largo de su eje una vara torneada a precisin C.
A Esto crea un orificio variable, que varia en directa
D proporcin al rango de flujo. La posicin de equilibrio del
C B pistn esta mecnicamente unida al puntero indicador D, y
la fuerte fuerza desarrollada por la presin del fluido que,
acta en una gran rea de pistn, que fcilmente acta el
aparato lector E. La perdida de carga aumenta con el rango
de flujo indicado, promediando 3 PSI.
2
SPGENMAN-200.1 10/4/2000
Medidores para usos especiales
Universal Flow Monitors tiene varios medidores de flujo para usos especiales para aplicaciones especificas tales
como aire, aceite y agua. Estos medidores son construidos de materiales que son claramente conocidos, por ser
compatibles con el servicio particular para el que son necesarios. Para seleccionar un sellos, empaquetadura,
cubierta, escala indicadora, o juego de piezas para la escala para cualquiera de estos modelos se requiere un cambio
en el prefijo del modelo de un medidor de flujo de la lnea estndar. Adicionalmente, una conversin precisa su
medidor de uso especifico requiere identificacin de el tamao y materiales de los sellos del medidor. Use las
siguientes tablas para seleccionar su correcto prefijo de modelo estndar, el tamao de la caja y el material de los
sellos:
PREFIJO PARA LOS MODELOS
AS (svh) -use- SN-ESF

AM (mvh) -use- MN-ESF
AL (lvh) -use- LN-ESF
O (svh) -use- SN-ASB
O (mvh) -use- MN-ASB
OK (svh) -use- SN-BSF
OK (mvh) -use- MN-BSF
OO (ph) -use- LL-ABPSB
WB (svh) -use- SN-BSE
WB (mvh) -use- MN-BSE
WB (lvh) -use- LN-FSE
WP (ph) -use- LL-BBPSB
WVS (svh) -use- SN-BSB
WVM(mvh) -use- MN-BSB
WVL (lvh) -use- LN-FSB
WW (ph) -use- LL-BBPSE
WW (svh) -use- SN-BSE
WW (mvh) -use- MN-BSE
WW (lvh) -use- LN-FSE
Otros diferentes, consulte a la fbrica
(ph= cmara para el pistn, svh= cmara para paleta pequea, mvh=
cmara para paleta mediana, lvh= cmara para paleta grande).
Nota: Otros manuales estn disponibles para los sensores tipo Mani-
fold, FlowStream, Mensah, Octopus, Insite y Transmisores.
3
SPGENMAN-200.1 10/4/2000
Materiales de Construccin e informacin de Ingeniera
Antes de la instalacin siempre vuelva a revisar la presin del sistema, la temperatura, la compatibilidad de las partes
hmedas de su medidor, los valores de parmetros elctricos, y todos los requerimientos de su aplicacin, para verificar
que el medidor suministrado es apropiado para la aplicacin.
CAJAS SN SM SH SX MN MM MH MX ML LN LE XHF LL** LP** LH**
MATERIAL DE LA CAJA Y PESO (lb)
4-in 70
Aluminio 4 4 9 9 65 6-in 78 4 4
8-in 100
Aluminio/deposito de Nailon 3 7 7
Aluminio/Cubierta Dura 4 4 9 9
Latn 6 6 16 16 135 10
4-in 200
Bronce Aluminio 6-in 220
8-in 260
Latn/deposito de Nailon 5 13 13
Hierro fundido 6 6 7 19 19 30 120 10 10
5 13
Hierro fundido/deposito de Nailon.
Hierro fundido/Niquelado 6 6 7 19 19 30 120 10 10
Electroplateado/Impregnado con Tefln
4-in 200
Acero Carbono 6 6 7 21 21 30 120 120 6-in 220 12 12 14
8-in 260
Acero Carbono/Niquelado 7 30 120
Electroplateado
Bronce Naval 6 6 16 16 135
Bronce Naval/Deposito de Nailon 5 13
Polipropileno 12
Polisulfono 1.75 6
PVC 1.75 6 12
Tefln 12
Tefzel 1.75 6
4-in 200
Acero Inoxidable tipo 316 6 6 7 21 21 30 120 120 6-in 220 12 12 14
8-in 260
MAXIMA TEMPERATURA DEL FLUIDO (F)
200 (Opcional 300 y 400 F)
100 para PVC y PP, 200 para Otros

*
MAXIMA PRESION DE OPERACIN PARA LIQUIDOS/GASES (PSIG)
300/125 (PSIG)
500/125
500/200
1000/167
1500/375
2000/500 Hierro y Acero
2000/500, 1200/450 Acero Inoxidable
*100 PVC, 150 Tefzel, 200

Polisulfono
*100 PVC, 200 Tefzel y Polisulfono
*100, 50 Tefln
150 Plstico, 300 tapa
Metlica/125 Tapa Metlica
* Lquidos solamente
Sumar 2 Libras para cajas de control diferentes a la caja A.
**Pistn y material de la tapa. Tapa plstica de Polisulfono puede ser usada en las unidades LL hasta 150 PSI (lquidos), tapa metlica (lo mismo que la caja)
se usa para todas la otras unidades.
Instalacin
Estos son aparatos que van puestos en lnea y que pueden ser montados en cualquier posicin sin afectar el rendimiento. Primero,
junte el medidor por la entrada marcada in usando la conexin adecuada para eso (hilada o enflanchada) asegurndose que el flujo va
hacia esta entrada. Cuando este atornillando la caera en un medidor de Hierro fundido, No use Tefln para sellar los hilos de la
caera. Despus conecte el medidor en la salida marcada out. Los diagramas de instalacin en las pginas 10-13 dan las
dimensiones criticas de montaje. Para asegurar mxima precisin, instale las vlvulas de control aguas abajo del medidor de flujo. Si
esta es una aplicacin de gas, la presin de salida debe ser mantenida en el medidor igual a la presin calibrada. Las unidades pueden
tener indicacin visual de flujo solamente, o usar una variedad de interruptores, potenciometros, transmisores, o interruptores
neumticos.
4
SPGENMAN-200.1 10/4/2000
Especificaciones de los interruptores
Opcin
1,2 1B,2B 3,4 61,62 71,72 53,54 7, 7C*, 18 17, 17C*, 19 30,31
(SIMBOLO)
Alta-Vibracin Alta-Temp Contactos de Oro Hermticamente-
Tipo de SPDT SPDT SPDT DPDT SPST
Interruptor
SPDT SPDT SPDT Sellados SPDT
3-Alambres 4-Alambres 3-Alambres 3-Alambres Proximidad
3-Alambres 3-Alambres 3-Alambres 3-Alambres
Aprobado UL/CSA UL/CSA UL/CSA UL/CSA/ UL/CSA/
UL/CSA/CE UL/CSA/CE MIL-S-8805 UL/CSA
por (CE Pendiente) (CE Pendiente) (CE Pendiente) *CENELEC *CENELEC
15A-125,250,
15A-125,250, 15A-125,250, 15A-125,250, 15A-125,250,
480 VAC
480 VAC 480 VAC 480 VAC 480 VAC
1A-125 VDC,
2A-600 VAC 2A-600 VAC 2A-600 VAC, 2A-600 VAC, 11A, 1/4 hp, 11A, 1/4 hp,
1/2A-250 VDC
1/2A-125 VDC, 1/2A-125 VDC, 1/2A-125 VDC 1/2A-125 VDC 5A res., 3A ind., 125/250 VAC; 125/250 VAC;
1/4 HP-125 VAC, 0.5A,
1/4A-250 VDC 1/4A-250 VDC 1/4A-250 VDC, 1/4A-250 VDC, 115 VAC, 5A res., 5A res.,
Capacidades 1/8 HP-125 VAC, 1/8 HP-125 VAC, 1/2 HP-250 VAC 1/8 HP-125 VAC 1/8 HP-125 VAC 400 Hz 28 VDC; 28 VDC;
20-250
3A Resistivos y VAC/VDC
1/4 HP-250 VAC 1/4 HP-250 VAC 1/4 HP-250 VAC, 1/4 HP-250 VAC, 28 VDC 0.5A res., 0.5A res.,
2.5A Inductivos-
6A Resistivos y 6A Resistivos y 6A Res. y 5A Ind.- 6A Res. y 5A Ind.- 125 VDC 125 VDC
48 VDC
5A Inductivos- 5A Inductivos- 24 o 48 VAC VDC 24 o 48 VAC VDC
24 VDC=
24 o 48 VDC 24 o 48 VDC
6A Res. y 5A Ind.
Propsitos Propsitos Propsitos Alta- Propsitos Uso General y Localizacin Localizacin Localizacin
Uso
Generales Generales Generales Temperatura Generales Corrosivo Peligrosa Peligrosa Peligrosa
Banda
7% 1 7% 1 7% 1 7% 1 7% 1 7% 1 15% 1 15% 1 10% 1
Muerta
(No exceder) 7% 2 7% 2 7% 2 7% 2 7% 2 7% 2 25% 2 25% 2 15% 2
1
Rangos de Flujo >15 GPM/56 LPM con excepcin del tipo Pistn.
2
Rangos de Flujo <14 GPM/52 LPM Incluyendo el tipo Pistn.
La tabla mostrada arriba muestra cada interruptor grficamente, detalla este por numero de opcin y tipo de interruptor y
describe su capacidad y aprobacin por agencia correspondiente, su uso y su banda muerta.
IDENTIFICACION DE TERMINAL PARA LOS CONECTORES TIPO B-H
CONECTOR DE 3-POSICIONES (PC3) CONECTOR DE 5 POSICIONES (PC-5) CONECTOR DE 6-POSICIONES (PC6)

Para lazo de 4-20 mA Para un Interruptor Para un interruptor de Para un Interruptor doble de 3-alambres
GRN/1-GRD de 3-alambres 4-alambres (C.C)
RED/2-NEG RED/1-COM BLU/1-NC1 ORN/1-NO1 WHT/4-NO2
RED/3-POS RED/2-N.C. BLU/2-NO1 BLU/2-NC1 RED/5-NC2
GRN/3-GRD GRN/3-GRD BLK/3-COM1 GRN/6-COM2
RED/4-N.O. BLU/4-NO2
RED/5-N/U BLU/5-NC2
CONECTOR DE 4-POSICIONES (PC4) Para un interruptor de 4-alambres (C.A) CONECTOR DE 8-POSICIONES (PC8)
Para un interruptor de 3-alambres RED/1-NC1 GRN/3-GRD Para un interruptor doble de 4-alambres
BLK/1-N.O. RED/2-NO1 RED/4-NO2
WHT/2-N.C. GRN/3-GRD RED/5-NC2 ORN/1-NC1 (1) WHT/5-NC1 (2)
RED/3-COM BLU/2-NC2 (1) RED/6-NC2 (2)
GRN/4-GRD WHT-BLK/3NO1 (1) GRN/7-NO1 (2)
BLK/4-NO2 (1) RED-BLK/8-NO2 (2)
5
SPGENMAN-200.1 10/4/2000
Seteando Interruptores elctricos simples
Usualmente los interruptores son seteados en la fabrica como se indica en cdigo del modelo sobre la placa de
identificacin, o como es indicado en un pedazo de papel adjunto al medidor. Para resetear el interruptor de punto a un
interruptor comn, opciones 1, 1B, 3, 11, 53, 61 y 71, prosiga como sigue.
Advertencia: Desconecte la alimentacin elctrica a la caja de control antes de abrirla.
1. Saque la placa de identificacin, ventana y la empaquetadura de la caja de control.
2. La leva que acta el interruptor esta localizada justo debajo del puntero. La posicin de la leva dicta el porcentaje de
flujo en el cual la leva actuara el interruptor.
3. Mueva el puntero de forma que este apunte el deseado rango de flujo en la escala. Usted puede hacer esto moviendo
el puntero en contra de las bajas fuerzas del resorte, tomando el puntero mismo y movindolo (y mantenindolo en esta
posicin, mientras ajusta la leva).
NOTA: Algunos medidores de flujo resortes mas fuertes (tipo paleta media, grande y extra grande) tienen un eje o barra
extendida la cual provee los medios para mover manualmente la paleta y simular el flujo. Una llave (suministrada con
esas unidades) se usa para girar una extensin de el eje localizada en la parte de atrs de la unidad, al lado opuesto de
la caja de control.
Medidores de flujo con gran fuerza en el resorte y sin el eje extendido (tpicamente las series MN, MM, MH) pueden ser
manejados *removiendo el deposito (debajo de la caja).
ADVERTENCIA: Asle el medidor del proceso y asegurase de purgarlo completamente de cualquier presin
remanente, tambin purgue la lnea de cualquier qumico peligroso antes de quitar el deposito.
Para mantener la precisin de calibracin de fabrica, marque la orientacin de montaje del deposito y reinstale el
deposito en la misma posicin despus que la leva es adecuadamente ajustada. La paleta es despus tomada y girada.
Para sacar el borde de la paleta de su prolongado asentamiento, use la cabeza de una llave como palanca, insertndola
en uno de los tornillos de seteo de la paleta para rotar la paleta. Para setear apropiadamente la leva, el punto de seteo
debe ser alcanzado desde una condicin de flujo normal. Ej.: un contacto de bajo flujo es seteado para flujo decreciente
moviendo el indicador de flujo sobre el punto de seteo de bajo flujo y ajustando la leva para activar o desactivar el
interruptor justo cuando este llega al punto de seteo de bajo flujo. Para setear la leva para un punto de seteo en incre-
mento de flujo, la leva se ajusta para activar/desactivar el interruptor cuando este llega al punto de seteo desde cero
(flujo).
4. Mientras mantiene el puntero/eje/paleta en la posicin deseada, alivie el anillo de leva completamente

(aproximadamente. 1/16 pulgada) y rtelo hasta que el interruptor acte (clic). Alivie su presin descendente y el anillo
de leva se asegurara en esa posicin.
5. Si usted no puede or el sonido clic del interruptor, usted puede determinar el cierre de contacto con un ohmetro
conectado a los terminales del interruptor. Conectado al comn y al normal abierto o normal cerrado en el interruptor.
6. Para chequear el seteo, lleve el puntero en contra de el flujo deseado, notando que acta el interruptor. Haga ajustes
as sea necesario. Si el deposito fue sacado, por favor colquelo en los terminales guiados y firmemente apritelos, en un
movimiento en X.
7. Es muy fcil setear punto de accionamiento del interruptor, usted puede hacerlo con flujo real presente en el medidor.
Ajuste el flujo al punto deseado donde usted quiere que ocurra una seal y que se mueva la leva para actuar el
interruptor como se dibuja abajo.
8. Reinstale la ventana, placa de identificacin y la empaquetadura antes de conectar la energa elctrica.
6
SPGENMAN-200.1 10/4/2000
Empaquetadura
Ventana
Placa de indentificacin
Escala
Interruptor * NOTA: Es recomendable que todos

los sellos del deposito de Tefln sean
reemplazados cuando el deposito es
sacado. Esto es smbolo T
NO SUELTE
LOS TORNILLOS mostrado en el cdigo de modelo.
DEL SINTONIZADOR!! (ej.: MN-IIT-etc)
Caja de control Anillo de leva
Sintonizador de flujo Tornillos Allen

Resorte Puntero
Anillo
Retenedor de Leva
Tronillo del puntero
Vista Detallada
Armado de Interruptor Simple
Seteando interruptores elctricos duales
Ajuste de tornillos de Leva

Para opciones de interruptor 2, 2B, 4, 7, 7C, 17, 17C, 18, 18C, 19, 19C, 30, 31, 54, 62 y 72, son suministradas levas con
tornillos de seteo para su ajuste. Las unidades de interruptor dual tienen dos levas independientes, apiladas una encima
de la otra.
ADVERTENCIA: Desconecte la energa elctrica a la caja de control antes de sacar la tapa de la caja.
1. Saque la placa de identificacin, ventana y empaquetadura de la caja de control.
2. Con un llave de tuerca de 5/16 saque el interruptor superior de la caja de control.
3. Usando una llave hexagonal * de 1/8", suelte el tornillo de leva localizado mas debajo, solo lo suficiente para rotar la
leva.
4. Gire el puntero de forma que este apunte en el flujo deseado sobre la escala. Usted puede hacer esto usando un
atornillador y moviendo el tornillo del puntero en contra de las bajas fuerzas de resorte (y mantenindolo en posicin
mientras ajusta la leva).
NOTA: Algunos medidores de flujo resortes mas fuertes (tipo paleta media, grande y extra grande) tienen una entrada en
el lado opuesto de la caja de control del medidor. Una llave (suministrada con esas unidades) se usa para girar la
extensin del eje. Medidores de flujo con gran fuerza en el resorte y sin el eje extendido (Mdium) pueden ser cambiados
removiendo el deposito (debajo de la caja).
ADVERTENCIA: Asle el medidor del proceso y asegurase de purgarlo completamente de cualquier presin
remanente, tambin purgue la lnea de cualquier qumico peligroso antes de quitar el deposito.
7
SPGENMAN-200.1 10/4/2000
Seteando interruptores elctricos duales
Para mantener la precisin de calibracin de fabrica, marque la orientacin de montaje del deposito y reinstale el
deposito en la misma posicin despus que la leva es adecuadamente ajustada. La paleta es despus tomada y girada.
Para sacar el borde de la paleta de su prolongado asentamiento, use la cabeza de una llave como palanca, insertndola
en uno de los tornillos de seteo de la paleta para rotar la paleta. Para setear apropiadamente la leva, el punto de seteo
debe ser alcanzado desde una condicin de flujo normal. Ej.: un contacto de bajo flujo es seteado para flujo decreciente
moviendo el indicador de flujo sobre el punto de seteo de bajo flujo y ajustando la leva para activar o desactivar el
interruptor justo cuando este llega al punto de seteo de bajo flujo. Para setear la leva para un punto de seteo en incre-
mento de flujo, la leva se ajusta para activar/desactivar el interruptor cuando este llega al punto de seteo desde cero
(flujo).
5. Mientras sujeta el puntero, eje yt la paleta en la posicin deseada rote la leva inferior hasta que acte el interruptor
inferior (ste har clic). Aun sujetando el puntero, el eje y la paleta en la posicin deseada, apriete el tornillo de leva con
una llave hexagonal.
NOTA: Si usted no puede or el sonido clic del interruptor, usted puede determinar el cierre de contacto con un ohmetro
conectado a los terminales del interruptor. El interruptor inferior esta ahora seteado.
5. Para chequear el seteo, lleve el puntero en contra de el flujo deseado, notando que acta el interruptor. Haga ajustes
as sea necesario.
6. Es muy fcil setear punto de accionamiento del interruptor, usted puede hacerlo con flujo real presente en el medidor.
Ajuste el flujo al punto deseado donde usted quiere que ocurra una seal y que se mueva la leva para actuar el
interruptor como se dibuja abajo.
8. Coloque el interruptor superior de vuelta en su posicin en la caja de control.
9. De nuevo usando una llave hexagonal de 1/8" suelte la leva superior solo lo suficiente para rotar el sintonizador de
flujo.
10. Repita los pasos 4 al 6.
11. Reinstale la ventana, placa de identificacin y la empaquetadura antes de conectar la energa elctrica.
*Debido a lo restringido del espacio en la caja de control, la llave de 1/8 pulgada suministrada ha sido modificada
esmerilando el extremo corto de la llave. Llaves modificadas adicionales pueden ser solicitadas a UNIVERSAL
FLOW MONITORS, consulte a fbrica o a su representante local.
Empaquetadura
Ventana
Placa de identificacion
Escala
Interruptor
Inferior
NO SUELTE
EL TORNILLO
SINTONIZADOR!!
Tornillo de leva
Caja de Control Leva superior
Interruptor Sintonizador de flujo
Superior Puntero
Leva inferior
Tornillos de Leva
Tornillo del puntero
Vista detallada
Armado con doble interruptor
8
SPGENMAN-200.1 10/4/2000
ADVERTENCIA: Instrumentos conectados a lneas Opcin de interruptor neumtico
de alimentacin de corriente Alterna, constituyen un La opcin de interruptor neumtico de Universal le da
potencial choque elctrico para los usuarios. una confiable seal remota operada por aire. El
Asegrese completamente de que la rama de interruptor esta disponible en todos los monitores de
circuito conectada al flujometro, este desconectada flujo de Universal. La unidad es en realidad una vlvula
de la alimentacin principal, antes de tocar mutiproposito de 4 vias/5 puertas, operada por leva con
cualquier cosa dentro de la caja de control. conductos de flujo que pueden ser conectados
alternadamente, para suministrar seales ON-OFF
Diagramas de alambrado elctrico de interruptores (conectar/desconectar).
Haga las conexiones de acuerdo con el diagrama La vlvula tiene un cuerpo de acero endurecido sin
apropiado de abajo. (Los interruptores pueden ser recubrimiento, Niquelado Electroplateado. La unidad
sacados para facilitar el alambrado a ellos.) funciona mejor usando aire de instrumento. En todos
los casos, el aire debe ser limpio y seco.
NC F
SPDT 3-Alambres La conexin se facilita con tubos conectores rpidos
C EN AUMENTO tipo lengeta. No se requieren, ni existen tubos de
insercin, frulas, collares, sellos, o hilos. (El tubo
NO debera ser 1/8" Diam. Interno)
La unidad viene montada en la caja de control de flujo
Opciones de Interruptores 1, 1B, 2, 2B, 53, 54, 61, 62,
estndar.
71, 72
Operacin
La operacin de este interruptor es la misma que la de
las vlvulas direccionales comnmente usadas para
SPDT 4-Alambres
dirigir el flujo en cilindros de aire, motores y aparatos
similares. La funcin del interruptor es la de entregar las
NO 1 NC 1 seales de control de aire para activar aparatos de
seal remota y/o operados por piloto, o como parte de
NO 2 NC 2
un circuito lgico.
Opciones de Interruptores 3,4
Las opciones de interruptores 7, 7C, 17, 17C, 18, 18C, Seal ON-OFF (Activar/Desactivar)
19, 19C, 30 y 31 estn todas aprobadas por CSA y UL Para la operacin simple ON-OFF de la vlvula, para
para uso en localizaciones peligrosas DIV. 1, Clase 1, indicar condicin de bajo flujo, solo se usan 3 entradas.
Grupos A, B, C y D, Clase 2, Grupos E, F y G (Mire el smbolo simplificado de alimentacin de fluido)
(interruptores con un sufijo C estn aprobados por la entrada o puerta 3 es la puerta IN (entrada), la
CENELEC). Los interruptores a prueba de explosin puerta 4 es la puerta OUT (salida), y la puerta 5 es
vienen con los cables codificados por color, de acuerdo la puerta de escape o Exhaust. La unidad es
a lo siguiente: operada por leva con retorno por resorte. Cuando la
Rojo
leva no esta actundola, el resorte controla la vlvula
Azul
direccional. En la posicin de control del resorte, la
puerta 3 esta conectada a la puerta 4. En la posicin de
Rojo Castao control de la leva, la puerta 3 esta conectada a la puerta
Purpura 5 o salida de escape.
Azul
Castao
Cuando el flujo esta sobre el mnimo nivel requerido
Amarillo
Verde
(sobre el punto de ajuste del interruptor), la vlvula se
BLACK
mantiene en la posicin de control de la leva, guiando el
SPDT
Verde aire al escape. As la caja de control es purgada con
DPDT aire de instrumento durante la operacin normal.
Cuando el flujo cae por debajo del punto seteado del
Opciones de Interruptores Opciones de Interruptores
interruptor, la vlvula cambia a su posicin de control
7, 7C, 18, 18C 17, 17C, 19, 19C
por resorte. La puerta 3 es conectada a la puerta 4,
completando el circuito al aparato de seal.
NEGRO 2 4 2 4
CARGA
Vs
LOCALIZACION CARGA ROJO

ALTERNADA 1 3 5 1 3 5
LEVA RESORTE
Opciones de Interruptores 11
Interruptor Proximidad a Prueba de Explosion
Control de posicin por Leva mostrado a la izquierda,
Opciones de Interruptores 30,31
control de posicin por resorte mostrada a la derecha.
9
SPGENMAN-200.1 10/4/2000
Circuitos lgicos de Aire Alambrado un transmisor (en la caja de control RT,
Esta vlvula mutiproposito ofrece un sinnmero de TT y TTL)
posibilidades de conexionado. La operacin se ilustra Las cajas RT, TT y TTL contienen un transmisor (y un
en los smbolos mostrados aqu. Cuando la leva no esta potenciometro principal) que provee una salida de
actuando sta, el resorte controla la vlvula direccional. corriente continua de 4-20 mA, de 2 alambres y
Se muestran los smbolos lgicos de aire para las proporcional al flujo.
vlvulas controladas por resorte. Se debe tener cuidado El transmisor viene calibrado de fabrica para el fluido y
con que las puertas que no son usadas, no se la aplicacin especificada en el proceso de orden. Una
encuentren bloqueadas, ya que estas actan como recalibracin es solo necesaria, si el transmisor es
salidas de escape. Cuando el flujo esta sobre el punto reemplazado o instalado en un medidor de flujo
de seteo, la vlvula es mantenida en la posicin de diferente. Conecte un par de alambres apantallados y
control por leva. Cuando el flujo cae por debajo del torcidos (no provistos) a los terminales marcados + y
punto de seteo, la vlvula cambia a la posicin de en la caja de conexin asl lado izquierdo de la caja de
control por resorte, cambiando la condicin de los control. El alambre debe ser de un tamao entre AWG
controladores de flujo. 22 y 12. (mire la tabla abajo).
(UFM ESTD.) OPCIONAL
Tabla de largo de cable

Calibre Alambre Mximo largo del alambre de seal del

medidor*
2 conexiones 3 conexiones 4 conexiones
3-4 1-2-4 1-2-4-5 22 AWG 1000 Pies
20 AWG 1500 Pies
Infamacin de ingeniera 18 AWG 2500 Pies
Capacidades de Presin: Vaco hasta 125 PSIG. 16 AWG 3000 Pies
Completamente balanceadas. Cv=0.12, cuando se usa 14 AWG 3500 Pies
tubo de 1/8" de dimetro interno. Tubo de poliuretano. 12 AWG 4000 Pies
Fuga: No mayor que .002 SCFM cuando se suministra * Basado en el uso de cable de seal de instrumentacin
apropiado, torcido y apantallado y llevando los cables por un
con 50 PSIG de presin. Conectores: 10-32 a 1/8" D.I.
conducto portacables independiente
(Dimetro interno) con conectores rpidos con
lengetas.
Alambrando un potenciometro (opciones RP y TP) Una conexin elctrica a tierra debe hacerse para el
Las cajas RP y TP contienen un potenciometro que tornillo de tierra provisto en la caja. El par de alambre
variara su voltaje con el flujo. Nuestro potenciometro torcidos conecta el transmisor y todo el equipamiento
estndar es de 10k ohms con una salida de menos que de recepcin en un lazo. Alimentacin de suministro
2k ohms. La capacidad de alimentacin es de 1 watt. (tpicamente 24 VDC en 30mA) debe ser entregada por
Estos pueden ser ordenados con o sin los interruptores una de las unidades de recepcin o por una fuente de
descritos anteriormente. Deberan ser alambrados poder separada. Varios receptores (tales como
como se muestra abajo. Nota: La resistencia del registradores o controladores) pueden ser conectados
alambrado no debera exceder los 2 ohms. Cuando en serie, pero solo una fuente de poder debera ser
ordene un transmisor remoto para propsitos de usada. NOTA: El lazo debera ser tomado a tierra, en
mantener el transmisor de una localizacin peligrosa, uno de los puntos en el lazo. Refirase a: Los
debe haber una barrea en cada una de estos tres manuales de los RT, TT, TTL para informacin adicional
circuitos. (Consulte a fabrica o a su representante para sobre transmisores.
instrucciones adicionales). Calibracin
Todos los medidores de flujo son individualmente
calibrados (para un fluido especifico) antes de salir de
fabrica. Las escalas, por lo tanto, no son
intercambiables. Asegrese que la escala sacada de
2
cualquier medidor es devuelta al mismo medidor.
3 1 (Para informacin adicional revise los manuales de los
transmisores separadamente: RT, TT, TTL)
3
2
1 CONTACTO
2
DESLIZANTE
CONTRA LOS
PUNTEROS DEL RELOJ 1 3 EN DIRECCION DE
EN DIRECCION DE LOS LOS PUNTEROS DEL RELOJ
PUNTEROS DEL RELOJ
POTENCIOMETRO 10k
10
SPGENMAN-200.1 10/4/2000
Mantencin Peridica
Mantencin Peridica (Medidores tipo paleta) Mantencin Peridica (Medidores tipo Pistn)
Revise la funcin del medidor variando el flujo y observe En el diseo de medidor tipo pistn, resortes
si las indicaciones de flujo siguen a travs de la escala individuales no pueden ser cambiados. Todas las
los cambios. Si no, puede haber una obstruccin en el partes internas estn contenidas en una cpsula
elemento de censado de flujo. reemplazable, incluyendo un pistn, sello de pistn, y
resorte de acero inoxidable. La cpsula es fcilmente
PRECAUCION: Corte el flujo de fluido al medidor y removible para corregir una malfuncin o para cambiar
purgue toda la presin antes de desarmar. El el rango de flujo, como sigue:
medidor debe tambin ser purgado si esta midiendo
flujo de materiales peligrosos. PRECAUCION: Corte el flujo de fluido al medidor y
purgue toda la presin antes de desarmar. El
Marque la posicin del deposito en ambos, el medidor y medidor debe tambin ser purgado si esta midiendo
el deposito para asegurarse que se va a rearmar en la flujo de materiales peligrosos.
posicin apropiada. Abra la cmara de flujo como se
muestra en el dibujo. Revise cualquier obstruccin y Suelte los 4 tornillos de la parte de debajo de la tapa del
saque cualquiera encontrada. Si la paleta esta en medidor, y tire la tapa y la cpsula sensora de flujo
buenas condiciones (no corroda o picada), y el resorte fuera de la caja. La cpsula puede ser limpiada con un
esta intacto, es probable que la calibracin original este chorro de liquido, o por un chorro de aire comprimido.
todava buena. Rearme el medidor, juntando las marcas Sin embargo, no recomendamos el desarme de la
previamente hechas en el deposito y en el cuerpo del cpsula. Antes de instalar una cpsula limpia o nueva,
medidor, y continu la operacin, una real verificacin limpie el interior de la caja con una brocha o un trapo. El
de la precisin de flujo requiere de un probador de flujo brazo registrador que controla el movimiento del
profesional o de un aparato probador de flujo de puntero debe ser sostenido apartado del camino,
laboratorio. mientras la cpsula es instalada. Esto se hace
TIPO PALETA removiendo la placa de identificacin de la caja de
control, y moviendo el puntero, con la mano, en la
direccin de la mxima indicacin de lectura mientras
pone la cpsula y la tapa en su posicin. El puntero
puede ser entonces ser aliviado, la tapa apretada y la
cartula reinstalada.
Si su nmero de modelo contiene una letra Z seguida

CAJA DEL
de dgitos, usted tiene una opcin no estndar. Por
MEDIDOR favor contacte a la fabrica o a su representante mas
cercano para una explicacin completa de su modelo
de medidor.
TIPO PISTON
DEPOSITO DEL
MEDIDOR
Saque el deposito y revise si encuentra obstrucciones en las cajas tipo

Remueva el pistn sacando los 4 tornillos y
S o M. * Revise: Precaucin arriba
deslizndolo hacia afuera. Revise la
condicin del sello, busque desechos o
Si no hay signo de corrosin o bloqueo el medidor de recubrimientos internos pegados en las
cajas de los LL, LP, o LH. * Lea:
flujo esta todava con su lectura congelada en terreno,
Precaucin arriba
es muy probable que los anillos (O-rings) hayan sido
atacados qumicamente. Si no es probable que se repita
el ataque, entonces para reemplazar los anillos puede
ser ordenado un juego nuevo de sellos. SI hay ataque
qumico,. Este es debido al permanente cambio en las
condiciones del fluido, entonces el medidor debe ser
reconstruido usando anillos nuevos de un material
diferente. Por favor consulte a la fabrica cuando haga
esta seleccin. Es tambin posible que las
emepaquetaduras, interruptores, cajas de control, partes
mecnicas mviles y anillos (O-rings) puedan ser
daadas y necesiten reemplazo. Seleccione estos
juegos de reemplazo desde las paginas 12-28 de
acuerdo con el numero de modelo del medidor de flujo
11
SPGENMAN-200.1 10/4/2000
Notas para Calibracin.
Si el medidor de flujo ser usado para medir el flujo en presiones variantes (como en
aplicaciones para medidores de flujo porttiles) se suministra, una unidad estndar calibrada
o
para 90 psig @ 70 F y los factores de correccin de la Tabla 1 se aplican en las lecturas para
obtener los Pies Cbicos Por Minuto Estndar (SCFM).
Si el medidor se usa para medir aire en una presin constante y repetible, este ser calibrado
en fabrica para indicar directamente en Pies cbicos por minuto Actuales (ASCFM), con la
o
temperatura del aire asumida a 70 F. Las lecturas tomadas con aire a otras temperaturas
o
diferentes de 70 F pueden ser corregidas usando los factores de correccin en la Tabla 2.
Tabla 1 Presin
PSIG 10 20 30 40 50 60 70 80 90 100 110 120
Factor .49 .58 .65 .72 .79 .84 .90 .95 1.0 1.05 1.09 1.13
Tabla 2 Temperatura
Temp oF 30 50 70 90 120 150 200 250 300 350
Factor 1.04 1.02 1.00 0.98 0.96 0.93 0.90 0.86 0.84 0.81
14.7 . 14.7
14.7 + 90.0 . 14.7 + X
X = Presin del Sistema
12
SPGENMAN-200.1 10/4/2000
Dimensional information
Caja de control tipo A

2.12
3/4 NPT
CONEXION
1.44 ELECTRICA
LINEA
4.25 CENTRAL
DE FLUJO 2.88
5.38
6
Caja de control tipo M 1.75 2.75
4.25
1.68
1/2 NPT
CONEXION
.75 1.38 ELECTRICA
Caja de control tipo R 3.31
LINEA
CENTRAL
3.813R DE FLUJO
1.31
3/4 NPTF 7.62

AL MEDIDOR
3.81
Caja de control tipo T .65
.719 .005 CENTRO

*2 BORRADOR POR
COSTADO 2 POSICIONES
COMO SE MUESTRA
1/2-14 NPTF TOMA
2 POSICIONES AL MEDIDOR
7.75 3.88
5.38 LINEA 2.62
CENTRAL
DE FLUJO
.12
4.25
3.25
Caja de control tipo X 2.44 2.50
INTERRUPTOR
5.12 PRIMARIO
4.75
INTERRUPTOR
SEGUNDARIO
9.62
LINEA DE FLUJO 7.75
CENTRAL
6.00
3/4 NPT 3.44

CONEXIN
ELECTRICA
(2 POSICIONES)
6.50
2.94 7.50
NOTA: Informacin dimensional sobre estos dibujos es solo para referencia general. Por favor pida diagramas certificados con su orden, cuando las
dimensiones de instalacin son criticas.
13
SPGENMAN-200.1 10/4/2000
5.50
3.75
DIM R1
RADIO MOVIL
(A LA CAJA 1.31
DE CONTROL)
5.75
2.62 LH
5.25
DIM R2
RADIO MOVIL
(A LA CAJA
.25
DE CONTROL)
TIPO DE CAJA DE CONTROL

Cuerpo de Pistn CAJA CAJA CAJA CAJA CAJA
"A" "M" "R" "T" "X"
DIM "R1" 5.62 5.06 7.25 7.00 8.38
DIM "R2" 5.06 5.68 6.68 6.50 6.75
Mostrado con una caja/A
Mostrado con caja/A
4.38 (ALTA PRESION)

Cuerpo pequeo
3.88 3.5 PUERTA A PUERTA
.75
2.44
DIM "R"
RADIO MOVIL
(A LA CAJA DE CONTROL)
TIPO DE CAJA DE CONTROL

CAJA CAJA CAJA CAJA CAJA
"A" "M" "R" "T" "X"
DIM "R" 5.00 5.62 8.62 7.00 7.12
14
SPGENMAN-200.1 10/4/2000
4.25 DIM. A
3.50
2.20
PUERTA A PUERTA
.75
2.38
DIM B
RADIO MOVIL
(A CONTROL)
Cuerpo SX TIPO DE CAJA DE CONTROL TIPO

TAMAO
DIM "A"
CONECTOR (NPTF)
CAJA CAJA CAJA CAJA CAJA MACHO 1/4 6.00
1/2 6.25
"A" "M" "R" "T" "X" 3/4 6.50
1 6.50
DIM "R" 5.00 5.62 8.62 7.00 7.12 TODOS
HEMBRA 5.50
8.31 (DOBLE RESORTE Y OPERADOR MANUAL)

8.06 (OPERADOR MANUAL)
7.44 (DOBLE RESORTE)
6.69
5.25 PUERTA A PUERTA
2.88
Cuerpo Mediano
DIM C
DIM A
DIM B
DIM R 1/2" A 2
RADIO MOVIL TIPO DE CAJA DE CONTROL
(A LA CAJA DE CONTROL) 1-1/2"
CAJA CAJA CAJA CAJA CAJA DIM "A" 1.44 1.75
"A" "M" "R" "T" "X"
DIM "B" 4.38 4.75
DIM "R" 5.75 6.44 9.50 7.81 8.12
DIM "C" 3.75 4.00
15
SPGENMAN-200.1 10/4/2000
6.25
CON ADAPTADOR
5.75
5.25
2.98
1.75
6.38
DIM C
RADIO MOVIL
(A LA CAJA DE CONTROL)
TIPO DE CAJA DE CONTROL 14.5

"A" "M" "R" "T" "X"
6
DIM "C" 6.00 6.75 9.50 8.00 7.62
Cuerpo MX
Mostrado con caja/ A
5.69 Mostrado con caja/A

OPERADOR MANUAL
5.56 RESORTE DOBLE Y
OPERADOR MANUAL
4.75
Cuerpo MH
4.00 5.25
3.06 3.06
1.88
7.25
DIM B
RADIO MOVIL
TIPO DE CAJA DE CONTROL (A LA CAJA DE CONTROL)

A M R T X
DIM B 6.12 7.56 9.62 8.25 8.25
16
SPGENMAN-200.1 10/4/2000
17.55
(DOBLE RESORTE)
15.19
5.88
CAJA DE
CONTROL 2.15
10.81
10.25
ENTRADA DE LLAVE
PARA MOVER LA
PALETA DESLIZANTE
Cuerpo Grande DIM C 6.00
10.25
TIPO DE
CAJA DE CONTROL
CAJA CAJA CAJA

"R" "T" "X"
DIM "C" 3.38 3.88 3.00
Mostrado con caja/R
10.81 13.25
6.62
Mostrado con caja/R
Cuerpo XHF
CAJA DE
CONTROL
22.25
15.25
DIM C 9.48
ENTRADA DE LLAVE
(PARA MOVER LA
PALETA DESLIZANTE)
TIPO DE
CAJA DE CONTROL
CAJA CAJA CAJA
"R" "T" "X"
DIM "C" 10.69 10.31 11.25
17
SPGENMAN-200.1 10/4/2000
Partes de Reemplazo
Seleccione los juegos de partes de reemplazo desde las siguientes tablas usando el numero de modelo puesto en sus placa
de identificacin en el medidor de flujo. Descripciones de cdigo de modelo pueden ser encontradas en todas las hojas de
especificaciones de UFM. Los primeros 2 dgitos definirn la serie correcta del medidor. (NOTA: Si usted no encuentra su serie
listada, revise la pagina 2 para los medidores para usos especiales).
Como ordenar un juego nuevo de cartula: Pag. 18-22
Como ordenar un juego de indicacin: Pag. 23-25
Como ordenar un juego de armado de tapa o cubierta: Pag. 26-28
Como ordenar un juego de empaquetaduras: Pag. 29-30
Como ordenar un juego de sellos Pag. 31-33
18
SPGENMAN-200.1 10/4/2000
COMO ORDENAR UN NUEVO JUEGO DE ARMADO DE CARATULA: (J.A.C D.A.K)
Los medidores mostrados en este manual son todos de naturaleza mecnica. Los elementos de flujo estn conectados a
las cajas de control va un eje que rota con los rangos de flujos cambiantes. Todas las partes que estn unidas a este
eje y residen dentro de la caja de control son lo que se llama el armado de cartula. Si cualquiera de estas partes se
daa, las partes de reemplazo son vendidas como un juego de repuesto. Todos los armados de cartula comienzan
con la sigla DAK. El resto del numero de parte viene del cdigo de modelo del medidor. El numero de juego correlativo
al cdigo de modelo, sigue as:
DAK-MN-A-1
EX. DAK (JAC) - MN - A - 1
DESIGNADOR SERIES TIPO DE INDICACION DIRECCION DE
GENERAL CAJA FLUJO
DAK LL* A 0 L
LP* M 1, 1B R
LH* R 2, 2B U
SH* T 3 D
SN* X 4
SM* 61
SX* 62
ML 53
MN 54
MX 71
MM 72
MH 7, 7C
LN 18, 18C
* Direccin de flujo LE 17, 17C
requerida para estos XHF 19, 19C
modelos solamente. 30
31
11
Los siguientes diagramas de juegos son el resultado del ensamble de las piezas principales. Los diagramas que los
acompaan aclararan cuales partes se incluyen en cada una de las series de medidores.
Armado de interruptor Simple Armado de interruptor Simple
EX DAK (JAC) - LL- A - 1 - R EX. DAK (JAC) - MN - A - 1

DESIGNADOR SERIES TIPO DE INDICACION DIRECCION DE DESIGNADOR SERIES TIPO DE INDICACION
GENERAL CAJA FLUJO GENERAL CAJA
DAK LL A 1, 1B L DAK MN A 1, 1B
LP R 3 R MM R 3
LH T 61 U MH T 61
SN M 53 D MX M 53
SM 11 ML 11
SH 71 71
SX
19
SPGENMAN-200.1 10/4/2000
COMO ORDENAR UN JUEGO DE ARMADO DE CARATULA: (JAC DAK)
Armado de interruptor Simple Armado de Doble Interruptor.
EX. DAK (JAC) - LN - R - 1 EX. DAK (JAC) - LL - A - 2 - R

DESIGNADOR SERIES TIPO DE INDICACION DESIGNADOR SERIES TIPO DE INDICACION DIRECCION DE
GENERAL CAJA GENERAL CAJA FLUJO
DAK LN R 1, 1B DAK LL A 2, 2B L
LE T 3 LP R 4 R
XHF 61 LH 62 U
53 SN 54 D
11 SM 72
71 SH
SX
Armado de Doble Interruptor. Armado de Doble Interruptor.
EX.DAK (JAC) - MN - R - 2 EX.DAK (JAC) - LN - R - 2

DESIGNADOR SERIES TIPO DE INDICACION DESIGNADOR SERIES TIPO DE INDICACION
GENERAL CAJA GENERAL CAJA
DAK MN A 2, 2B DAK LN R 2, 2B
MM R 4 LE 4
MH 62 XHF 62
MX 54 54
ML 72 72
20
SPGENMAN-200.1 10/4/2000
EX. DAK (JAC) - LL - X - 7 - R EX. DAK (JAC) - MN - X - 7

DAK LL X 7, 7C L DAK MN X 7, 7C
LP 17, 17C R MM 17, 17C
LH U MH
SN D MX
SH ML
SX
EX. DAK (JAC) - LN - X - 7 EX. DAK (JAC) - LL - X - 30 - R

DESIGNADOR SERIES TIPO DE INDICACION DESIGNADOR SERIES TIPO DE INDICACION DIRECCION DE
GENERAL CAJA GENERAL CAJA FLUJO
DAK LN X 7, 7C DAK LL X 30 L
XHF 17, 17C LP R
LH U
SN D
SH
SX
21
SPGENMAN-200.1 10/4/2000
EX. DAK (JAC) - MN - X - 30 EX. DAK (JAC) - LN - X - 30

DAK MN X 7, 7C DAK LN X 7, 7C
MM 17, 17C XHF 17, 17C
MH 30 30
MX
ML
EX. DAK (JAC) - LL - X - 31 - R EX. DAK (JAC) - MN - X - 18

DAK LL X 31 L DAK MN X 18, 18C

LP R MM 19, 19C
LH U MH 31
SM D MX
SN ML
SH
SX
22
SPGENMAN-200.1 10/4/2000
Armado de Doble Interruptor.
EX. DAK - LN - X - 18
DESIGNADOR SERIES TIPO DE INDICACION
GENERAL CAJA
DAK LE X 18, 18C

LN 19, 19C
XHF 31
23
SPGENMAN-200.1 10/4/2000
COMO ORDENAR UN JUEGO DE INDICACION NUEVO: (R.O.K)
las cajas de control va un eje que rota con los rangos de flujos cambiantes. Todas las partes que son actuadas por esta
accin mecnica residen dentro de la caja de control y son llamadas Indicacin. Si cualquiera de estas partes se daa,
las partes de reemplazo son vendidas como un juego de repuesto. Todos los juegos de armados de indicacin
comienzan con la sigla ROK. El resto del numero de parte viene del cdigo de modelo del medidor. El numero de juego
correlativo al cdigo de modelo, sigue as:
MN-BSB30GM-8-32V1.0 -A1NR
ROK-MN-A-1
EX. ROK (JAC) - MN - A - 1 - HT
DESIGNADOR SERIES TIPO DE INDICACION OPCIONES
GENERAL CAJA
ROK LL A 0
LP M 1, 1B
LH R 2, 2B
SN T 3 CE
SM X 4
SH 61 HT
MN 62
MM 53
MH 54
LN 71
LE 72
XHF 7, 7C
SX 18, 18C
MX 17, 17C
ML 19, 19C
30
31
11
Armado de interruptor Simple Armado de Doble Interruptor.
Aislador usado
con la caja R y Aislador usado con
la caja T. la caja R.
EX. ROK (JAC)- LL - A - 1B - CE EX. ROK(JAC) - LL - A - 2B - CE

DESIGNADOR SERIES TIPO DE INDICACION OPCIONES DESIGNADOR SERIES TIPO DE INDICACION OPCIONES
ROK ALL A 1, 1B CE ROK ALL A 2, 2B CE

R 3 HT R 4 HT
T 61 54
M 53 62
71 72
24
SPGENMAN-200.1 10/4/2000
EX. ROK (JAC) - LL - X - 7 EX. ROK (JAC) - LL - X - 30

ROK LL X 7, 7C ROK ALL X 30

LP 17, 17C
LH
SN
SM
SH
MN
MM
MH
LN
LE
XHF
ML
EX. ROK (JAC) - XHF - X - 19 EX. ROK (JAC) - LL - X - 31

ROK MN X 18*, 18C* ROK ALL X 31*

MM 19*, 19C*
MH
LN
LE
XHF
ML
* Incluye 2 armados de interruptor. 25 * Incluye 2 armados de interruptor.

SPGENMAN-200.1 10/4/2000
SingleSimple
Interruptor Neumatico switchpara
assy.
todas las series.
EX. ROK (JAC) - LL - A - 11

DESIGNADOR SERIES TIPO DE INDICACION
GENERAL CAJA
ROK ALL A 11
26
SPGENMAN-200.1 10/4/2000
COMO ORDENAR UN JUEGO DE ARMADO DE TAPA O COUBIERTA: (CAK)
las cajas de control va un eje que cambia su ngulo con los cambios en los rangos de flujos.
Si cualquiera de estas partes se daa, las partes de reemplazo son vendidas como un juego de repuesto.
Todos los juegos de armados de tapa o cubierta comienzan con la sigla CAK. El resto del numero de parte viene del
cdigo de modelo del medidor. El numero de parte se obtiene del cdigo de modelo del medidor. Los nmeros de parte
son correlativos a los nmeros de cdigos de modelo segn sigue:
*
CAK-MN-A-H
Como ordenar un juego de armado de tapa o cubierta:

EX. CAK (JAC)- LL - A - W - HT
DESIGNADOR SERIES TIPO DE TYPO DE OPCION

GENERAL CAJA CERCAMIENTO
CAK LL LN A N,W,X HT
LP LE M W or X C
LH XHF R W or X TG
SN SX T W or X CE
SM MX X W or X
SH ML RTZ W or X
MN TTZ W or X
MM
MH
La opcin HT en el final del cdigo de modelo requiere un designador HT en el numero de parte del juego para
*
aplicaciones de alta temperatura (no disponible con las cajas de control tipo N, SX, MX, o ML).
NOTA: El numero de modelo y el numero UFM debe ser suministrado con el numero de orden para inscribir una nueva
placa de identificacin. Los siguientes diagramas de juegos son el resultado del ensamble de las piezas principales. Los
diagramas que los acompaan aclararan cuales partes se incluyen en cada una de las series de medidores.
Caja A (Tipo Paleta) Caja A (Tipo Pistn)
C.
IN
S,
OR0
NIT4803
5
3
1
OR
AT MO MI
DIC W Park,
E
IN
LOazel
L Fd, H
T
RA
LO
W
SA Roa
L
F
ER Mile
SA IV. Nine
IV
ER UN E
55 4-96
35
UN
17 52
3-
31
.
0 NO
. NO
M
ITE
1
2 EM
3
IT 3
5
4 1
BE
R
BER
M
UM
NU C. LN
DEL O. , IN DE .
MO
SA
LN
O0 RS MO LN
O
SA
NIIT4803
ER
IV ER
UN
MO
IV
M UN
rk,
PE OWel Pa
TY FL az PE
L d, H TY OR
SA Roa AT
ERe Mile DIC
IV Nin35 IN
UN TE
0
E. 1
55 4-96
17 52
2 RA
3-
3 W
31
4
F
LO
L
SA
ER
IV
UN
EX. CAK (JAC) -SN - A - W - HT EX. CAK (JAC) - LL - A - N - HT

DESIGNATOR SERIES TIPO DE TYPO DE OPCION DESIGNATOR SERIES TIPO DE TYPO DE OPCION
GENERAL CAJA CERCAMIENTO GENERAL CAJA CERCAMIENTO
CAK SN A N C CAK LL A N C
SM W HT LP W HT
SH X TG LH X TG
MN CE CE
MM
MH
SX
MX
ML
Flujo en cualquier direccin Flujo en cualquier direccin

27
SPGENMAN-200.1 10/4/2000
Caja R (Flujo a la derecha) Caja R (Flujo a la izquierda)
OR
ICAT
IND
TE
RA
W
O
FL
C. A
L
IN S
S, 0
5
3 R
1
E
OIR4803 IV
NIT
N
M U
rk,
MzeOl Pa
OW, Ha 35
FL ad 96
L ile Ro524-
SAne M 313-
ER Ni
IV55 E.
UN 17 5
3
1
.
NO
M
ITE
0 .
1 NO ER
2 M MB
4
3 ITE L NU
DE .
MO NO
AL
ER RS
MB IVE
UN
L NU
DE . PE

MO NO TY
AL
C.
RS
IVE
UN
IN
S, 0
OIR4803
PE 1
0
TY
NIT
2
3
M
rk,
4
MzeOl Pa
OW, Ha 35
FLRoad4-96
L ile 52
SAne M 313-
R
O
A
T
ERE. Ni
D
IC
U NIV55
17
IN
TE
RA
OW
FL
RS AL
UNIVE
EX. CAK (JAC) - LL - R - X - HT EX. CAK (JAC) -LN - R - W - HT

CAK ALL R W C CAK LN R W C

EXCEPT: RP X HT LE RP X HT
LN RT TG XHF RT TG
RTZ CE RTZ CE
LE
XHF *
* IZQUIERDA A DERECHA FLUJO ARRIBA o ABAJO
SOLAMENTE
NOTA : HT = OPCION DE ALTA TEMPERATURA.
Caja X
C.
IN
S,
OR0
NIIT4803
MO
rk,
M
OWl Pa
FL, Haze
AL ad 5
RS ile Ro
3
1
IVENine
M
UN
55
E. 9635
17 524-
3-
31
0
1 .
2 NO
ITEM
3
4
R
MBE
NU
EL
MOD .
L NO
SA
IVER
UN
R
TO
CA
DI
IN
TE
RA
OW
FL
L
SA
IVER
UN
EX. CAK (JAC) -SN- X - X - C

DESIGNATOR SERIES TIPO DE TYPO DE OPCION
CAK SN X X C
SM HT
SH TG
MN
MM
MH
SX
ML
MX
LN
LE
XHF
28
SPGENMAN-200.1 10/4/2000
Caja T (Flujo hacia la derecha) Caja T (Flujo hacia la izquierda)
5
3
1
R
TO
CA
INDI
TE
RA
OW
FL
L
SA
IVER
UN
.
NO
1
0
M
. 2 ITE
NO 3
M 4
ITE
ER
R 3
5
MB
TO 1
L NU
ER INDI
CA DE . C.
MB
MO NO , IN
L NU RA
TE
RS
AL
RS
DE . OW IVE ITO030
MO
L NO L
FL
UN
ON
Mrk, MI
48
SA
IVER
SA
. PE OWl Pa
IVER
INC
TY
UN FL, Haze
UN
S, AL ad
OR0 RSMile Ro
IVE
PE e
NIT4803
TY
UN Nin 35
MO
E.
MI 55 -96
17 24
OWl Pa
rk, 3-5
31
FL Haze
AL ad,
RSMile Ro
0
1
IVE
2
Nine
3
UN
4
E. 35
55 -96
17 24
3-5
31
EX. CAK(JAC) - LL - T - X - HT EX. CAK (JAC)- LN - T - X - HT

CAK ALL T X C
CAK LN T X C
EXCEPT: HT
LE HT
TG
LN XHF TG
LE *
XHF
* IZQUIERDA A DERECHA, FLUJO ARRIBA O ABAJO FLUJO DE DERECHA A IZQUIERDA SOLAMENTE

SOLAMENTE
Caja M
INDICATOR
FLOW RATE
UNIVERSALPATENT PENDING
AL
UNIVERS INC.
NITORS,
FLOW MO Mile Road
1755 E. Nine 48030
, MI
Hazel Park
313-524-9635
ER
MODEL NUMB
ITEM NO.
NO.
UNIVERSAL
TYPE
AL HAZARD
: ELECTRIC RE SERVICING
WARNING
CT POWER BEFO
DISCONNE
EX. CAK (JAC)- LL - M - W - C

CAK LL M W C
LP HT
LH
SN
SM
SH
SX
MX
MN
MH
MM
Cualquier Direccin 29
SPGENMAN-200.1 10/4/2000
COMO ORDENAR UN JUEGO DE ARMADO DE EMPAQUETADURA: (GAK)
las cajas de control va un eje que cambia su ngulo con los cambios en los rangos de flujos.
Las variadas partes de los medidores estn aisladas de la atmsfera por empaquetaduras. Si cualquiera de estas
empaquetaduras se daa, las partes de reemplazo son vendidas como un juego de repuesto.
Todos los juegos de empaquetaduras comienzan con la sigla GAK. El resto del numero de parte viene del cdigo de
modelo del medidor. El numero de parte se obtiene del cdigo de modelo del medidor. Los nmeros de parte son
correlativos a los nmeros de cdigos de modelo segn sigue:
*
GAK-MN-A-W-H
Como ordenar un juego de Empaquetaduras:

EX. GAK (JAC) - LL - T - W - HT
DESIGNADOR SERIES TIPO DE TYPO DE OPCION
GAK LL A N HT
LP M W
LH R X
SN T
SM
SH
MN
MM
MH
LN
LE
XHF
SX
MX
ML
La opcin HT en el final del cdigo de modelo requiere un designador HT en el numero de parte del juego para
*
aplicaciones de alta temperatura (no disponible con las cajas de control tipo N, SX, MX, o ML).
Caja A Armado de empaquetaduras. Caja M Armado de empaquetaduras.
* *
EX. GAK (JAC) - MN - A - W - HT EX. GAK (JAC) - MN - M - W - HT

GAK *LL MN A N HT GAK *LL MN M N HT

*LP MM W *LP MM W
*LH MH X *LH MH
*SN *SX *SN *SX
*SM MX *SM MX
*SH ML *SH ML
* No es una parte del Kit
30
SPGENMAN-200.1 10/4/2000
COMO ORDENAR UN JUEGO DE ARMADO DE EMPAQUETADURA: (GAK)
Armado de empaquetaduras para la caja R. Armado de empaquetadura para la caja T.
* *
EX. GAK (JAC) - MN - R - W - HT EX. GAK (JAC) - MN - T - W - HT

GAK *LL MM R W HT GAK *LL MM T W HT
*LH MH X *LP MH X
*SN LN *LH LN
*SM XHF *SN LE
*SH *SX *SM XHF
MN MX *SH *SX
MN MX
ML ML
* No es parte del Juego * No es parte del Juego
Armado de empaquetaduras para la caja X.
EX. GAK (JAC) -MN - X - X - HT

GAK *LL MM X W HT
*LP MH X
*LH LN
*SN LE
*SM XHF
*SH *SX
MN MX
ML
* No es parte del Juego
31
SPGENMAN-200.1 10/4/2000
COMO ORDENAR UN JUEGO NUEVO DE ARMADO DE SELLOS: (SAK)
las cajas de control va un eje que rota con los cambios en los rangos de flujos. Se evita que el fluido fugue al exterior
del medidor de flujo por medio de ORings que actan como sellos. Si cualquiera de estos sellos se daa, las partes de
reemplazo son vendidas como un juego de repuesto. Todos los juegos de Sellos comienzan con la sigla SAK. El
resto del numero de parte viene del cdigo de modelo del medidor. El numero de parte se obtiene del cdigo de modelo
del medidor. Los nmeros de parte son correlativos a los nmeros de cdigos de modelo segn sigue:
SAK-MN-B-A
EX. SAK (JAC) - MN - B - A - G

DESIGNADOR SERIES MATERIAL TIPO DE UNIDAD DE
GENERAL DE SELLO CAJA AIR O GAS
SAK LL B A G
LP E M (Sin
LH F R simbolo
SN J T para
SM T X liquidos)
SH K
MN H
MM A
MH
LN
LE
XHF
SX
MX
ML
Este sello es inlcuido en el SAK
con las cajas SH solamente.
EX. SAK (JAC) - SN - B - S - R - G Rodamiento de empuje para las
DESIGNADOR SERIES MATERIAL INTERNA TIPO DE UNIDAD DE cajas SH solamente.
SAK SN B S A G *
SM E I M
SH F T R Sin
*SX J H RT simbolo
para
T
K
L
C
RP
T liquidos El sello secundario
*
H R X de Tefln estndar
A P en los monitores de
la serie SM y SH
,yy,y,y,y,y,y,y,y,y,y,y,y,y,y,
y, y, y, y, y,
Tipo de paleta pequea

NOTA: EL EJE ESTA INCLUIDO SOLAMENTE EN LAS SERIES PEQUEAS (SN,SM,SH,SX).
* Los medidores de la serie SX requieren sellos estticos adicionales para los adaptadores de puertas.
32
SPGENMAN-200.1 10/4/2000
Paleta tipo Mediana

EX. SAK (JAC) - MN - B - R - G
GENERAL DE SELLO CAJA AIR O GAS **
SAK MN B A G
MM E* M (Sin
MH F R simbolo El sello secundario
ML J RP para
MX T RT liquidos)
de Tefln es
estndar en las
**
K T series de monitores
H X MM ,MH, y ML
A
y, y, y, y, y,
*Los anillos de EPR se dilatan cuando entran en contacto con fluidos
basados en aceite, grasa o petrleo. Los sellos de eje tendrn un sello de
Buna N substituido por un anillo EP para uso en el bolsillo del resorte.
** La serie MX con adaptadores de puerta requiere sellos estticos. (Revise
el diagrama a la derecha)
Tipo Pistn
EX. SAK (JAC) - LL - F - T - G
SAK LL B A G
LP E M (No
LH F R Symbol
J RT for
T RP Liquids)
K T
H X
El sello secundario de Tefln

es estandar en todos los
monitores de tipo Pistn.
33
SPGENMAN-200.1 10/4/2000
Tipo Paleta Grande

EX. SAK (JAC) - LN - B - R - G
SAK LN B M G
LE E R (Sin
F RP simbolol
J RT para
T T liquidos)
K X
H
A
Los sellos secundarios de
Tefln son una parte
estndar y son usados para
lquidos y gases.
Los sellos secundarios

de Tefln son una parte
EX. SAK(JAC) - XHF - B - R - G estndar y son usados
DESIGNADOR SERIES MATERIAL TIPO DE UNIDAD DE para lquidos y gases.
SAK XHF B M G
E R (Sin
F RT simbolo
J RP para
T T liquidos)
K X
H
A
Paleta tipo XHF
34
SPGENMAN-200.1 10/4/2000
AVISO
AUTORIZATION RETORNO MATERIAL
Por favor lea la siguiente informacin de las clusulas y polticas de UFM cuidadosamente. Siguiendo las siguientes
instrucciones mencionadas abajo usted nos ayudar para proveerle una evaluacin y respuesta referente al estado
de su medidor de flujo, dentro de un plazo razonable. UFM evala todas las AUTHORIZED RETURNED MATERIALS
en una forma coordinada por el tiempo y entrega rpidamente la notificacin, referente al estado de los materiales
relacionados y/o una cotizacin escrita indicando los cargos totales y la descripcin de las reparaciones necesarias.
1. Todos los retornos deben tener una forma de RMA llenada por el cliente.
2. Cualquier medidor retornado que estuvo previamente en servicio debe tener la hoja de requerimientos de la OSHA
completada y si aplica una MSDS tambin.
3. Un nmero de RMA ser emitido, solo cuando UFM haya recibido una copia de la forma de RMA completada y
cualquier MSDS aplicable.
4. Una etiqueta de retorno de mercaderas Return Goods (localizada en la parte de atrs del manual de
instrucciones) debe ser usada para retornar los materiales a UFM.
5. Una Orden de compra debe ser acompaada a todos los retornos para cubrir el costo de evaluaciones de
reparacin.
6. Mercaderas retornadas deben ser embarcadas prepagadas o sern rechazadas.
MATERIAL REPARABLE
Una autorizacin por escrito debe ser recibida dentro de los primeros 30 das desde recibida la cotizacin de reparacin, para
proceder con la reparacin bajo la orden de compara designada. Si la(s) unidad (es) es (son) reparadas, ser aplicado un
costo de US$ 90.00 por evaluacin, adicional a los costos de reparacin. Si no se autoriza reparacin dentro del periodo de
30 das, el cliente ser facturado por US$ 90.00, ms los gastos de embarque. Los materiales sern retornados al cliente.
MATERIAL NO REPARABLE
Un aviso de que el material no es reparable ser entregado al cliente por UFM. Si no hay una disposicin del cliente para
desechar o retornar el material dentro de los primeros 30 das. Materiales que no pueden ser reparados sern desechados y
el cliente ser facturado por US$ 90.00, como costo de evaluacin. Si una unidad de reemplazo de UFM es comprada
dentro de los 30 dias posteriores al aviso de la condicin de NO reparable, los US$ 90.00 de cargo por evaluacin sern
obviados. El retorno de materiales no reparables puede ser ordenado por el cliente con una orden de compra, cubriendo los
cargos por embarque y tramites.
RETORNO PARA REINVENTARIO

Todos los equipos retornados para un ajuste de reinventario deben ser:
A. Nuevo y nunca usado.
B. Retornado a la fabrica dentro del periodo de un ao desde la fecha de embarque original.
C. Retornado a travs del distribuidor desde donde los equipos fueron originalmente comprados.
Este material ser tambin sujeto a una evaluacin con un cargo de US$ 90.00 y debe ser acompaado de una orden de
compra.
El cliente ser avisado del ajuste de reinventario para todos los productos que puedan ser reinventariados. Bajo aceptacin
del ajuste de reinventariado, por el cliente, el costo de US$ 90.00 por evaluacin ser obviado y un crdito ser otorgado por
UFM, a favor de la orden de compra asignada. El cliente ser avisado de cualquier producto no-reinventariable y ser
facturado por el monto de US$ 90.00, por concepto de cargo por evaluacin, mas cualquier costo por concepto de gastos de
embarque, si el material es retornado a l.
Si no se recibe una notificacin en UFM dentro de los primeros 30 das, los bienes sern desechados y el cargo por
evaluacin de US$ 90.00 ser emitido y facturado.
RETORNOS BAJO GARANTIA

Retornos bajo garanta deben ser acompaados por una orden de compra y deben ser embarcados previamente pagados a
UFM. UFM revisar los bienes y avisara al cliente de la evaluacin y de la posible validez del reclamo de garanta.
Reclamos de garanta validos sern reparados o reordenados sin cargo. No se cobrara un cargo por evaluacin, para
reparaciones hechas en caso de existir validez de garanta. Costos de retorno sern prepagados por UFM. UFM deber
determinar si el material retornado por defectos, esta bajo garanta de acuerdo con las provisiones de garanta estndares
estipuladas por UFM arriba. El cliente ser avisado de las reparaciones necesarias y de los costos asociados. Todos los
materiales retornados sin una garanta valida, estarn sujetos a la clusula de garanta Material Reparable estipulada en
los puntos anteriores.
Form RMAP-100
35
SPGENMAN-200.1 10/4/2000
U N I V E R S A L RETURN MATERIAL AUTHORIZATION
(RMA) REQUEST FORM
FAX TO: UFM Repair Department
FLOW MONITORS (248) 398-4274
IMPORTANT: This form must be filled out completely and faxed to UFM Repair Department prior to UFM issuing a RMA #
Customer: Product Information Qty:

Ship To: Model Code:
Universal #:
Operating Temp: Max Temp:
Operating Pressure: Max Pressure:
Contact Name: Viscosity Specific Gravity
Return P.O.# Date Purchased: Date Installed:
Phone#
FAX#
Reason for return: (Please be detailed as possible. Lack of Information may increase labor charges.)
Mechanical Electronics
Meter leaks No signal
Pointer sticks Inaccurate signal
Pointer is not accurate (calibration off) Remote Readout
Alarm switch does not work (MENSAH ) Digital Display
Other (describe below) Signal at no flow
Other (describe below)
Details:
Note: There will be a minimum evaluation charge of $90.00 for all units returned (excluding units covered
under warranty). Units WILL NOT be accepted without a valid UFM Return Material Authorization Number
(RMA#). A Material Safety Data Sheet on the process fluid must be received by UFM when applicable, prior
to the RMA# being issued.
* OSHA Requirements: (to be filled out by customer) NO EXCEPTIONS!!

Process Fluid:
Meter must be flushed to remove all process fluids.
I hereby certify that the material being returned has been properly flushed and cleaned of all hazardous
materials and does not require any special handling.
Print or Type Name Signature:
Title Date:
Distributor Information
Company Name
INTERNAL USE ONLY RMA#
Authorized by
Contact Name
Date
P.O. #
Phone# FAX#
Document #: 1400.8 Revision #: 3 Revision Date: 5/6/97 Approved By: Approval Date:
36
SPGENMAN-200.1 10/4/2000
NO SAQUE ESTA PAGINA.
POR FAVOR COPIE EL FORMATO

PARA RETORNO DE
MATERIALES A FABRICA
37
SPGENMAN-200.1 10/4/2000
FROM:
TO:
U.S.A.
CUSTOMER:
RMA#:
FROM:
TO:
U.S.A.
CUSTOMER:
RMA#:
FROM:
TO:
U.S.A.
CUSTOMER:
RMA#:
38
SPGENMAN-200.1 10/4/2000
Notes
UNIVERSAL FLOW MONITORS, INC. U N I V E R S A L

1755 East Nine Mile Road
P.O. Box 249, Hazel Park, MI 48030-0249
(248)542-9635 / FAX (248) 398-4274 FLOW MONITORS
39
SPGENMAN-200.1 10/4/2000
U N I V E R S A L
FLOW MONITORS

Ph. 248-542-9635 / Fax 248-398-4274
40
SPGENMAN-200.1 10/4/2000 Litho in USA
MAX FLOW SIZES FROM MAX LIQUID PRESSURE 300 PSI (20.69 BAR) MN SERIES
U N I V E R S A L
10 TO 160 GPM MAX LIQUID PRESSURE 500 PSI (34.48 BAR) MM SERIES
F L O W M O N I T O R S
(60 TO 600 LPM) MAX LIQUID PRESSURE 2000 PSI (137.93 BAR) MH SERIES
MN Series, with transmitter and
UNIVERSAL
LCD readout (control box TTL).
Flow Meters
A Medium Vane-Style
For Liquids

CSA Certified NRTL/C
NRTL/C
CE Marked (as noted)
NIST Traceable Calibration

Certificate Available
based oils, paint, some corro-

DESCRIPTION sives, solvents, and air and
gases. Meter bodies are available
These variable-area flow meters in aluminum, anodized aluminum,
have a spring-loaded vane that brass, cast-iron or nickel-plated
swings open to accomindate cast-iron, naval bronze, carbon C
F
more flow. Mounting is in-line and steel or nickel-plated carbon D
A
G
in any position. Straight pipe runs steel, and 316 stainless steel.
before or after the meter are not Aluminum, brass, and naval B
required. The all-mechanical bronze are also available with

sensing system responds quickly optional nylon orifice bowl. We E
and directly drives the pointer and offer internal moving parts in the
remote signaling devices. They following materials: 300 series
handle shocks or flow surges stainless, 316 stainless steel,
beyond their rated capacities. titanium, monel, and tantalum. Fluid enters at A, passes
Choices of materials for seals around the semi-circular vane
are: Buna N, EPR, Viton, B, exits at outlet C. The vane
Kalrez, and Teflon (Kalrez resists the flow because of
CALIBRATION
can be combined with the others). the spring D. The further the
Please consult the factory for vane is pushed the larger the
All flow meters are individually
compatibility of materials with passageway E becomes.
calibrated for fluids with the
your application. This minimizes the pressure
viscosity you specify (up to 3000
drop. The vane shaft turns to
SSU/650 centipoise). We also operate the pointer F and
compensate for your fluids remote signal devices such
specific gravity. For NIST Trace- LINE CONNECTION
as the switch G.
ability please consult factory.
Ports can be threaded or flanged.
Maintenance note: particulate
Threaded ports can be NPT (1/2
can be cleared from the
CONSTRUCTION MATERIALS to 2") or SAE straight thread (1/2
internals by removal of bowl-
to 1-1/2"). Metric threads such as
shaped part of housing, or by
The meter body, internal moving BSPP, BSPT or JIS are also
manipulating the vane using
parts, and seals are offered in a available. ANSI Flanges (1/2 to
our manual override, special
variety of materials to suit a wide 2") are standard with DIN flanges
option E.
range of applications, such as: also available.
water, synthetic and petroleum
1
HOW TO ORDER Select appropriate symbols and build a model code number, as in example shown:
EXAMPLE: MN - A S B 30 GM V - 8 - 320V.9 - A1 X R - ST - 10D
SERIES
Medium vane style
Normal pressure (300 PSI) = MN
Medium pressure (500 PSI) = MM
High pressure (1500 PSI) = MH
HOUSING MATERIAL (Series MN & MM)

Aluminum =D
Aluminum, nylon bowl = A* FLUID CHARACTERISTICS
Aluminum (hard coated) =E
Brass =F Viscosity number followed by a V (for SSU), C
Brass, nylon bowl = B* (for centipoise), or CS (for centistokes) followed
Cast iron =C by the specific gravity. (32V1.0 would mean
Cast iron, nickel plated =N water.) For dual viscosity give two numbers
Carbon steel =M separated by a slash (example: 320/500V1.0)
Carbon steel, nickel plated =J
Naval bronze =U
Naval bronze, nylon bowl = W* PORT SIZE
Stainless steel (316) =I
*Available only on Series MN NPT Flange SAE St-Thd Pipe Size Max
Symbol Symbol Symbol Inches MM GPM
4 4F 8T 1/2 12.70 25
HOUSING MATERIAL (Series MH) 6 6F 12T 3/4 19.05 50
8 8F 16T 1 25.40 70
Cast iron =C 10 10F 20T 1-1/4 31.75 75
Cast iron, nickel plated =N 12 12F 24T 1-1/2 38.10 100
Carbon steel =M 16 16F 2 50.80 150
Stainless steel (316) =I
Note: Metric threads such as BSPP, BSPT, JIS, etc. are
available, consult factory.
INTERNAL MOVING PARTS

VALVE (FLOW CONTROL) Series MN only
Stainless steel (300 series) = S*
Stainless steel (316) = I* No Symbol = No Value
Titanium (N/A in MH) =T V = Valve (brass) Restricted to port sizes to 1-inch
Monel (N/A in MH) =L and flows to 30 GPM (50 GPM in 1-1/2-inch port
Tantalum (N/A in MH) =R housings)
*MH available only in 300 and 316 Not available on carbon steel or stainless steel housings
SEAL MATERIAL SCALE CALIBRATIONS

GH = Calibrated in gallons per hour
Buna N =B
GM = Calibrated in gallons per minute
EPR =E
LH = Calibrated in liters per hour
Viton =F
LM = Calibrated in liters per minute
Kalrez =J
CMH = Cubic meters per hour
Kalrez (dynamic) and Teflon (static)
GLM = Dual scales (GPM and LPM) (consult factory)
(all metal units only) =T
DGM = Dual viscosity on GPM scale (consult factory)
Kalrez (dynamic) & Buna N (static) =A
DLM = Dual viscosity on LPM scale (consult factory)
Kalrez (dynamic) and EPR (static) =H
Kalrez (dynamic) and Viton (static) =K For specific calibrated increments and other scales consult factory.
MAX FLOW RATING LIQUIDS

These may be expressed in various engineering units as shown. Here we are selecting the maximum flow that the meter will
see. The minimum reading is about 1/10th of the maximum. There are generally 5 to 7 major increments displayed on the
analog scales (traditional mechanical pointer and inscribed scale) with that numbered roughly doubled for the high resolution
R box which allows more accurate reading. Ultimate resolution is provided by the LCD digital displays standard with some Consult factory for
transmitter selections. The following are the most commonly selected options for maximum flow rates for each engineering compatibility of
unit. More are available if you consult with the factory. construction
materials with the
GPM 10, 15, 20, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160 fluid involved.
LPM 40, 50, 60, 70, 80, 90, 100, 150, 200, 250, 300, 350, 400, 500, 600
CMH 2.25, 2.5, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30
2
SWITCH SETTING
No symbol = Lowest possible
Or, give setting(s) in GPM or LPM. Also a symbol to indicate that accuracy
is desired during increasing flow (U) or decreasing flow (D). (10D would
mean that switch should actuate when flow rate decreases to 10 GPM.)
FLOW DIRECTION Settings are field adjustable.
R = Left to right
L = Right to left SPECIAL OPTIONS
U = Up
Standard
D = Down HT = High-temp- 400F for A & R Box,
300F for transmitter options all boxes (RT, T & G)
SERVICE ST = Stainless steel ID tag for customer supplied information
PC = Pin connector (See explanation for special options.)
N = Oil and dust tight (Type 12) FL = Fault light (See explanation for special options.)
W = Weatherproof (Type 4) C = CSA enclosure / PVC window
X = Weatherproof, corrosion proof TG = Tempered glass window
E = Manual override
(Type 4X) DS = Dual spring
Z86 = Clearance vane for 16 GPM
STANDARD SPECIAL OFFERINGS

CONTROL BOX & READOUT (switches) R Box
High resolution pointer and scale for more accurate
A Box reading, optional switches
Simple indication with or without switches R = Scale & pointer only
A = Scale & pointer only R1 = One SPDT (3wire) , CE
R2 = Two SPDT (3 wire), CE
A1 = One SPDT (3wire) , CE R3 = One SPDT (4 wire)
A1B = One high vibration SPDT (3 wire), CE R4 = Two SPDT (4 wire)
A2 = Two SPDT (3 wire), CE R53 = One SPDT (3 wire) hermetically sealed
A2B = Two SPDT (3wire) , CE R54 = Two SPDT (3 wire) hermetically sealed
A3 = One SPDT (4 wire) R61 = One SPDT (3 wire) high temperature
A4 = Two SPDT (4 wire) R62 = Two SPDT (3 wire) high temperature
R71 = One SPDT (3wire) gold contact
A61 = One SPDT (3 wire) high temperature
R72 = Two SPDT (3wire) gold contact
A62 = Two SPDT (3 wire) high temperature
A71 = One SPDT (3wire) gold contact RT Box
A72 = Two SPDT (3wire) gold contact High resolution pointer and scale for more accurate
A53 = One SPDT (3 wire) hermetically sealed reading, 4-20 mA Transmitter,
A54 = Two SPDT (3 wire) hermetically sealed optional high amp mechanical switch
A11 = Pneumatic RT = Scale & pointer only
RT1 = One SPDT (3wire) , CE
X Box RT3 = One SPDT (4 wire)
RT53 = One SPDT (3 wire) hermetically sealed
Hazardous location indication and switches RT61 = One SPDT (3 wire) high temperature
X7 = One SPDT hazardous location RT71 = One SPDT (3wire) gold contact
X7C = One SPDT, CE
X17 = One DPDT hazardous location TT BOX
X17C = One DPDT, CE 4-20 mA Transmitter with pointer & scale,
X3 = One SPST hazardous location proximity optional high amp mechanical switch, separate
X31 = Two SPST hazardous location proximity junction boxes for switch & transmitter
TT = Scale & pointer only
TT1 = One SPDT (3wire) , CE
G Box TT3 = One SPDT (4 wire)
Transmitter with digital display and 2 open TT53 = One SPDT (3 wire) hermetically sealed
collectors (standard), or remote display (optional) TT61 = One SPDT (3 wire) high temperature
GTL = internal 4-20 mA transmitter with two open collector TT71 = One SPDT (3wire) gold contact
alarms TTL Box
GTLZ = intrinsically safe 4-20 mA transmitter (no alarms) 4-20 mA Transmitter with digital display,
GP = G Box with remote transmitter. This requires a remote optional high amp mechanical switch, separate
display and transmitter to be ordered as a separate junction boxes for switch & transmitter
line item. Model UT-PM-DTLCD. TTL = Scale & pointer only
Note: G Box requires W service selection (weatherproof). G Box has a TTL1 = One SPDT (3wire) , CE
terminal strip but can be used with pin connectors ordered as Special Options TTL3 = One SPDT (4 wire)
as described on next page. Select PC5M for GTL and PC3M for GTLZ or GP. TTL53 = One SPDT (3 wire) hermetically sealed
TTL61 = One SPDT (3 wire) high temperature
TTL71 = One SPDT (3wire) gold contact
M Box
Metal box for minimal indication of flow,
one alarm switch and a pin connector
M1 = One SPDT (3wire) , CE
M1B = One high vibration SPDT (3 wire), CE
M3 = One SPDT (4 wire)
M61 = One SPDT (3 wire) high temperature
Note: Micro pin connectors must be selected. See special options section.
3
ENGINEERING DATA
Maximum fluid temperature: 200F (95C)

With 150 lb R.F. flanges
(for other flanges consult factory) Optional max. fluid temperature: 300 & 400F (150 & 205C) (option HT)
Port Maximum ambient temperature: 150F (65C)
Size (inches) A Readout accuracy, full scale: 2%
1/2 3-1/2
3/4 3-7/8 Series MN max. operating pressures: (3:1 safety factor): 300 PSI (20.69 BAR)
1 4-1/4
1-1/2 5 Series MM max. operating pressures: (3:1 safety factor): 500 PSI (34.48 BAR)
2 6
Series MH max. operating pressures: (3:1 safety factor): 2,000 PSI (137.93 BAR)
12.00
[305mm]
MAX BYPASS ONLY DUAL SPRING*

A
FLOW & PRESSURE DROP FLOW Minimum Max Minimum Max
RATE Flow Pressure Flow Pressure
Units with max flows to 80 GPM GPM/LPM GPM/LPM Drop GPM/LPM Drop
(300 LPM) impose a pressure drop PSI PSI
that increases with flow from 1.9 to 3.8 90/340 20/75 4.5 10/40 6.0
PSI. Higher flow-rated models are 100/380 30/100 4.5 10/50 8.0
"Flow up" or "flow down" dimensions
are the same. Scale numbers are made possible by having either a 110/400 30/100 5.0 20/90 6.8
turned 90 to be right reading. partial bypass (which raises minimum 120/450 40/150 5.8 20/90 6.8
130/500 40/150 5.8 20/90 6.8
indicated flow), dual springs (which
140/550 50/170 6.5 20/90 6.8
raises the pressure drop), or both. The 150/570 50/170 6.5 30/100 6.8
table shows minimum flow rates and 160/600 50/170 6.5 30/100 7.5
pressure drops (PSI) (at max flow
rates) for models rated from 100 to *When dual-spring is ordered you must specify
special option DS. Some dual-spring units also
160 GPM. have partial bypass to achieve high flow ranges.
SPECIAL OPTIONS
High temperature: (option HT) for the number of pins required for your tempered-glass window is employed
requires all-metal construction of control box selection and current type. where airborne solvents or high-
housing/orifice cover with seals of Insert the number of pins in the code ambient temperatures are common.
Viton, EPR, Kalrez or Teflon (compat- PC__ for a mini connector or PC__M
ible with fluid). A thermal barrier (heat- for a micro connector. For example, a Manual override: (option E) provides
resistant cloth) is added between the PC5 would be a 5 pin mini and PC5M an extended shaft you can manipulate
housing and the control box, which would be a 5 pin Micro. to clear debris, simulate flow, adjust
must be used with service option "W" switch settings, etc. Same material as
Fault light: (option FL) a red LED in internals specified.
(weatherproof) or "X" (corrosion
the nameplate to indicate when a flow
resistant). A metal scale is provided. CE marked switches: (option CE)
limit has been reached by internal
Identification tag: (option ST) cus- switch contact. Helpful with multiple SPDT 3-wire switch for general
tomer-supplied information is stamped meters. Add to end of symbol: 1 (1 purpose use. Standard on switches 1,
on a stainless steel tag that is attached light), 2 (2 lights), A (AC), D (DC), i.e. 1B, 2 and 2B.
to the nameplate. FL2D. Only available with service Clearance vane: (option Z86) the swing
option "W" weatherproof enclosures or vane is modified to pro-vide extra
Multi-pin connector: Pin connectors
"X" corrosive service. For optional LED clearance for liquids that contain
(option PC) are available for rapid field
colors, consult factory. particulate. Available for maximum flow
installation. Meters are provided with
the male half of either a micro or a mini Tempered-glass window: (option TG) range of 16 GPM or greater, this reduces
pin connector. Check the chart below replaces the standard window. A the turndown to a minimum of 4 GPM.
Number of pins required for various combinations of current type, box type and switch option.
AC switch options 1, 1B, 61, 71 3 53
DC switch options 0 1, 1B, 61, 71 3 2, 2B, 54, 62, 72 53
A 3 4 6 5 3 4
M 3 4 5
Box R 3 4 6 5 3 4
RT 3
TT 3 3 4 3 4
TTL 3 3 4 3 4
GTL* 5
GTLZ* 3
GP* 3
*This box allows micro pin connectors only. Eg. PC3M or PC5M.
4
DIMENSIONS
MN & MM SERIES (approximate) in inches MH SERIES
STANDARD OFFERING: Control Box A

8.16 STD. SPRING W/ OVERRIDE
[207mm]
7.98 DUAL SPRING OVERIDE
[203mm]
7.54 DUAL SPRING
[192mm] 8.16 STD. SPRING W/ OVERRIDE
6.84 STD. SPRING 2.41 5.50 [140mm] [207mm]
[174mm] [61mm] PORT TO PORT 7.98 DUAL SPRING OVERIDE
[203mm]
7.54 DUAL SPRING
[192mm]
6.84 STD. SPRING 2.41 5.50 [140mm]
[174mm] [61mm] PORT TO PORT
6.41
3/4" NPT [1.63mm]
CONDUIT 3/4" NPT
AA CONNECTION CONDUIT
CONNECTION
4.63
A [118mm]
B
6.12 [155mm] APPROX. 3.31

3.31 SWING RADIUS [84mm]
[84mm] 6.00
MAX PORT SIZE (NPT) A AA B C 6.00 [152mm]
[152mm]
1/2 TO 1-1/2 5.96 8.60 4.54 5.96
2 5.96 9.58 4.91 6.12
STANDARD OFFERING: Control Box X

8.44
[214mm]
6.75
[171mm]
3.06 PROXIMITY 5.50[140mm]
[77mm] DETECTOR PORT TO PORT
SWITCH
SHOWN IN
STANDARD
MOUNTING
LOCATION
9.63
[245mm] 8.44
[214mm]
6.75
PROXIMITY [171mm]
3.06
B [78mm] DETECTOR 5.50[140mm]
SWITCH PORT TO PORT
SHOWN IN
STANDARD
LOCATION MOUNTING
OF OPTIONAL LOCATION
SECONDARY
SWITCH
MAX PORT SIZE (NPT) B C

9.63
1/2 TO 1-1/2 5.90 8.27 [245mm]
2 6.27 8.54
6.26
[159mm]
LOCATION
OF OPTIONAL
SECONDARY
SWITCH
8.54 [217mm] APPROX. SWING RADIUS
STANDARD OFFERING: Control Box G

2.99 5.50 [140mm]
[56mm] C PORT TO PORT LOCATION OF
CONTROL BOX
WHEN ROTATED 90
FOR VERTICAL FLOW
(One of Four Possible
Positions)
2.99 5.50 [140mm]

[76mm] PORT TO PORT
LOCATION OF
B CONTROL BOX
WHEN ROTATED 90
FOR VERTICAL FLOW
(ONE OF FOUR
POSSIBLE POSITIONS)
TRANMITTER 3.69
PIN CONNECTOR [93.68mm]
3.34 REF.
[84.91mm]
5.04 6.82
MAX PORT SIZE (NPT) A B C [128mm] [173mm]
1/2 TO 1-1/2 6.11 4.67 7.07
2 6.82 5.04 7.31
3.69
TRANSMITTER PIN CONNECTOR [93.68mm]
7.31[186mm] APPROX. 3.34 REF.
SWING RADIUS [84.91mm]
5
DIMENSIONS
MN & MM SERIES (approximate) in inches MH SERIES
SPECIAL OFFERING: Control Box R

3.44 5.50 [140mm]
[87mm] PORT TO PORT
3/4" NPT
CONDUIT
CONNECTION.
BOX TYPE R
ONLY
A
B
C
8.74
[222mm]
1/2" NPT CONDUIT CONNECTION.
BOX TYPES RP, RT, RTV, & RTZ. 3.44 5.50 [140mm]
MAX PORT SIZE (NPT) A B C [87mm] PORT TO PORT
1/2 TO 1-1/2 8.08 6.64 9.17
2 8.80 7.02 9.44
3/4" NPT
CONDUIT
CONNECTION.
BOX TYPE R
ONLY
8.80
[224mm]
7.02
[178mm]
8.74
[222mm]
9.44 [240mm] APPROX.
SWING RADIUS 1/2" NPT CONDUIT CONNECTION.
BOX TYPES RP, RT, RTV, & RTZ.
SPECIAL OFFERING: Control Box T

8.02
[204mm]
4.15 5.50 [140mm]
[105mm] PORT TO PORT
A 8.02
[204mm]
4.15 5.50 [140mm]
B [405mm] PORT TO PORT
6.41
[163mm]
1/2" NPT CONDUIT CONNECTION

C (2) PLACES
4.63
[118mm]
MAX PORT SIZE (NPT) A B C
1/2 TO 1-1/2 5.98 4.54 8.02
2 6.69 4.91 8.20

(2) PLACES
8.20 [208mm] APPROX.

SWING RADIUS
SPECIAL OFFERING: Control Box M

2.18 5.50 [140mm]
2.18 5.50 [140mm] [55mm] PORT TO PORT
[55mm] PORT TO PORT
6.41
[163mm]
B 4.63
[118mm]
C
6.66 [169m] APPROX. PIN CONNECTOR OR
SWING RADIUS 1/2" NPT CONDUIT CONNECTION
PIN CONNECTOR OR
MAX PORT SIZE (NPT) A B C
1/2 TO 1-1/2 5.98 4.54 6.39
2 6.69 4.91 6.66
U N I V E R S A L
Universal Flow Monitors, Inc.

1755 E. Nine Mile Road P.O. Box 249 Hazel Park, MI 48030
Tel: 248-542-9635 Fax: 248-398-4274
www.universalflow.com E-mail: sales@universalflow.com
6 Catalog MN 12/26/02
U N I V E R S A L

MAX FLOW SIZES FROM MAX LIQUID PRESSURE 300 PSI (20.69 BAR) SN SERIES
0.5 TO 20 GPM (2 TO 75 LPM) MAX LIQUID PRESSURE 500 PSI (34.48 BAR) SM SERIES
MAX LIQUID PRESSURE 2000 PSI (137.93 BAR) SH SERIES
UNIVERSAL
Flow Meters
A Small Vane Style
For Liquids

CSA Certified NRTL/C
NRTL/C
CE Marked (as noted)
NIST Traceable Calibration SN Series shown with

Certificate Available A style control box
synthetic, and petroleum based

DESCRIPTION oils, paint, some corrosives,
solvents, and air and gases.
These variable-area flow meters Meter bodies are available in
have a spring-loaded vane that aluminum, anodized aluminum, F
swings open to accomindate more brass, cast-iron, or nickel-plated
flow. Mounting is in-line and in cast-iron, naval bronze, carbon C
any position. Straight pipe runs steel, or nickel-plated carbon A D
before or after the meter are not steel, and 316 stainless steel. G
required. The all-mechanical Aluminum, brass, and naval
B
sensing system responds quickly bronze are also available with
and directly drives the pointer and optional nylon orifice cover. We E
remote signaling devices. They offer internal moving parts in the
handle shocks or flow surges following materials: 300 series
beyond their rated capacities. stainless steel, 316 stainless
steel, titanium, monel, and
tantalum. Choices of materials for
Fluid enters at A, passes
CALIBRATION seals are: Buna N, EPR, Viton,
around the semi-circular
and Kalrez, and Teflon
vane B. exits at outlet C.
All flow meters are individually (Kalrez can be combined with
The vane resists the flow
calibrated for fluids with the the others). Please consult the
viscosity you specify (up to 3000 because of the spring D.
factory for compatibility of materi-
The further the vane is
SSU/650 centipoise). We also als with your application.
pushed the larger the
compensate for your fluids
specific gravity. For NIST Trace- passageway E becomes.
LINE CONNECTION This minimizes the pres-
ability please consult factory.
sure drop. The vane
Ports can be threaded or flanged. shaft turns to operate the
Threaded ports can be NPT (1/4 to 3/4") pointer F and remote
CONSTRUCTION MATERIALS
or SAE straight thread (1/4 to 5/8"). signal devices such as
The meter body, internal moving Metric threads such as BSPP, BSPT the switch G.
parts, and seals are offered in a and JIS are also available. (ANSI
variety of materials to suit a wide Flanges (1/4 to 1") are standard with
range of applications: water, DIN Flanges also available.)
1
HOW TO ORDER Select appropriate symbols and build a model code number, as in example shown:
EXAMPLE: SN - A S B 7 GM V - 6 - 320V.9 - A1 N R - ST - 2D
SERIES
Normal pressure (300 PSI) = SN
Medium pressure (500 PSI) = SM
High pressure (1500 PSI) = SH
HOUSING MATERIAL (Series SN & SM)

Aluminum =D
Aluminum, nylon bowl = A* FLUID CHARACTERISTICS
Aluminum (hard coated) =E
Brass =F Viscosity number followed by a V (for SSU), C
Brass, nylon bowl = B* (for centipoise), or CS (for centistokes) followed
Cast iron =C by the specific gravity. (32V1.0 would mean
Cast iron, nickel plated =N water.) For dual viscosity give two numbers
Carbon steel =M separated by a slash (example: 320/500V1.0)
Naval bronze =U
Naval bronze, nylon bowl = W*
Stainless steel (316) =I PORT SIZE
*Available only on Series SN NPT Flange SAE St-Thd Pipe Size Max
Symbol Symbol Symbol Inches MM GPM
2 2F 4T 1/4 6.350 8
HOUSING MATERIAL (Series SH) 3 3F 5T 3/8 9.525 8
4 4F 8T 1/2 12.70 10
Cast iron =C - - 10T 5/8 15.87 10
Cast iron, nickel plated =N 6 6F - 3/4 19.05 20
Carbon steel =M - 8F - 1 25.40 20
Stainless steel (316 carbon steel bolts Note: Metric threads such as BSPP, BSPT, JIS, etc. are
available, consult factory. Flanges available.
standard, see Special Options) =I
VALVE (FLOW CONTROL) Series SN only

INTERNAL MOVING PARTS
No Symbol = No Value
Stainless steel (300 &416 series) =S
Stainless steel (316) =I V = Valve (brass) SN bodies only on models up to 7
Titanium (N/A in SH) =T GPM (25 LPM)
Monel (N/A in SH) =L Not available on carbon steel or stainless steel housings
Tantalum (N/A in SH) =R
SCALE CALIBRATIONS
SEAL MATERIAL
GH = Calibrated in gallons per hour
Buna N =B GM = Calibrated in gallons per minute
EPR =E LH = Calibrated in liters per hour
Viton =F LM = Calibrated in liters per minute
Kalrez =J IGM = Calibrated in imperial gallons per minute
Kalrez (dynamic) and Teflon (static) CMH = Cubic meters per hour
(all metal units only) =T GLM = Dual scales (GPM and LPM) (consult factory)
Kalrez (dynamic) & Buna N (static) =A DGM = Dual viscosity on GPM scale (consult factory)
Kalrez (dynamic) and EPR (static) =H DLM = Dual viscosity on LPM scale (consult factory)
Kalrez (dynamic) and Viton (static) =K For specific calibrated increments and other scales
consult factory.
MAX FLOW RATING LIQUIDS

These may be expressed in various engineering units as shown. Here we are selecting the maximum flow that the meter will see.
The minimum reading is about 1/5th of the maximum. There are generally 5 to 7 major increments displayed on the analog scales
(traditional mechanical pointer and inscribed scale) with that number roughly doubled for the high resolution R box which allows more
accurate reading. Ultimate resolution is provided by the LCD digital display, standard with some transmitter selections. The following are
the most commonly selected options for maximum flow rates for each engineering unit. More are available if you consult with the factory.
Viscosity minimum (SSU)
Consult factory for
500 250 100 None
compatibility of
GPH: 30 60 90, 120 180, 240, 300, 200, 300, 400, 500, 600, 700, 800, 900, 1000, 1200
construction
GPM: .5 1 1.5, 2 3, 4, 5, 6, 7, 8, 9, 10, 15 & 20
materials with the
LPM: 2 4 6, 8 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 75
fluid involved.
LPH: 100 200 350, 500 600, 700, 800, 900, 1000, 1500, 2000, 2500, 3000, 3500, 4000
CMH: .1 .25 .35, .5 .75, 1, 1.25, 1.5, 2, 2.5, 3, 3.5, 4, 4.5
2
SWITCH SETTING
No symbol = Lowest possible
Or, give setting(s) in GPM or LPM. Also a symbol to indicate that accuracy
is desired during increasing flow (U) or decreasing flow (D). (2D would
mean that switch should actuate when flow rate decreases to 2 GPM.)
FLOW DIRECTION Settings are field adjustable.
R = Left to right
L = Right to left SPECIAL OPTIONS
U = Up Standard
D = Down HT = High-temp- 400F for A & R Box,
300F for transmitter options all boxes (RT, T & G)
SERVICE ST = Stainless steel ID tag for customer supplied information
PC = Pin connector (See explanation for special options.)
N = Oil and dust tight (Type 12) FL = Fault light (See explanation for special options.)
C = CSA enclosure / PVC window
W = Weatherproof (Type 4)
TG = Tempered glass window
X = Weatherproof, corrosion proof Z67SH = 316 stainless steel bolts on SH-I option. Pressure rating 1500 PSI Max.
(Type 4X) Z86 = Clearance vane for 5 GPM
STANDARD SPECIAL OFFERINGS

CONTROL BOX & READOUT (switches) R Box
High resolution pointer and scale for more accurate
A Box reading, optional switches
Simple indication with or without switches R = Scale & pointer only
A = Scale & pointer only R1 = One SPDT (3wire), CE
R2 = Two SPDT (3 wire), CE
A1 = One SPDT (3wire) , CE R3 = One SPDT (4 wire)
A1B = One high vibration SPDT (3 wire), CE R4 = Two SPDT (4 wire)
A2 = Two SPDT (3 wire), CE R53 = One SPDT (3 wire) hermetically sealed
A2B = Two SPDT (3wire) , CE R54 = Two SPDT (3 wire) hermetically sealed
A3 = One SPDT (4 wire) R61 = One SPDT (3 wire) high temperature
A4 = Two SPDT (4 wire) R62 = Two SPDT (3 wire) high temperature
R71 = One SPDT (3wire) gold contact
A61 = One SPDT (3 wire) high temperature
R72 = Two SPDT (3wire) gold contact
A62 = Two SPDT (3 wire) high temperature
A71 = One SPDT (3wire) gold contact RT Box
A72 = Two SPDT (3wire) gold contact High resolution pointer and scale for more accurate
A53 = One SPDT (3 wire) hermetically sealed reading, 4-20 mA Transmitter,
A54 = Two SPDT (3 wire) hermetically sealed optional high amp mechanical switch
A11 = Pneumatic RT = Scale & pointer only
RT1 = One SPDT (3wire) , CE
X Box RT3 = One SPDT (4 wire)
RT53 = One SPDT (3 wire) hermetically sealed
Hazardous location indication and switches RT61 = One SPDT (3 wire) high temperature
X7 = One SPDT hazardous location RT71 = One SPDT (3wire) gold contact
X7C = One SPDT, CE
X17 = One DPDT hazardous location TT BOX
X17C = One DPDT, CE 4-20 mA Transmitter with pointer & scale,
X3 = One SPST hazardous location proximity optional high amp mechanical switch, separate
X31 = Two SPST hazardous location proximity junction boxes for switch & transmitter
TT = Scale & pointer only
TT1 = One SPDT (3wire) , CE
G Box TT3 = One SPDT (4 wire)
Transmitter with digital display and 2 open TT53 = One SPDT (3 wire) hermetically sealed
collectors (standard), or remote display (optional) TT61 = One SPDT (3 wire) high temperature
GTL = internal 4-20 mA transmitter with two open collector TT71 = One SPDT (3wire) gold contact
alarms TTL Box
GTLZ = intrinsically safe 4-20 mA transmitter (no alarms) 4-20 mA Transmitter with digital display,
GP = G Box with remote transmitter. This requires a remote optional high amp mechanical switch, separate
display and transmitter to be ordered as a separate junction boxes for switch & transmitter
line item. Model UT-PM-DTLCD. TTL = Scale & pointer only
Note: G Box requires W service selection (weatherproof). G Box has a TTL1 = One SPDT (3wire) , CE
terminal strip but can be used with pin connectors ordered as Special Options TTL3 = One SPDT (4 wire)
as described above. Select PC5M for GTL and PC3M for GTLZ or GP. TTL53 = One SPDT (3 wire) hermetically sealed
TTL61 = One SPDT (3 wire) high temperature
TTL71 = One SPDT (3wire) gold contact
M Box
Metal box for minimal indication of flow,
one alarm switch and a pin connector
M1 = One SPDT (3wire) , CE
M1B = One high vibration SPDT (3 wire), CE
M3 = One SPDT (4 wire)
M61 = One SPDT (3 wire) high temperature
Note: Micro pin connectors must be selected. See special options section.
3
ENGINEERING DATA INSTALLATION
Maximum fluid temperature: Flow monitors mount in-line and are typically supported by rigid pipe. For additional
200F (95C) support when using tubing or flexible hose, order special options W (wall) or F (foot)
mounting brackets. (Foot Mounting Bracket not available on SM and SH series).
Optional max. fluid temperatures:
300 & 400F (150 & 205C) (option HT) MOUNTING BRACKETS
Maximum ambient temp: 150F (65C)
CSA listed only to 105F (40C) FOOT MOUNTING
BRACKET
Series SN max. operating pressure: WALL MOUNTING BRACKET
(3:1 safety factor): 300 PSI (20.69 BAR) 2.31
[59mm]
Series SM max. operating pressure:

4.12
(2:1 safety factor): 500 PSI (34.48 BAR) 2.77
[105mm]
[70mm]
Series SH max. operating pressure: 4.27
(3:1 safety factor) [109mm]
2000 PSI (137.93 BAR) 2.88

[73mm]
Stainless Steel with special option Z67SH, .31 THRU
(2) HOLES
1500 PSI (103.42 BAR) 1.88

.31 THRU
(2) HOLES
3.62
[92mm]
[48mm]
Readout accuracy, full scale: 5%

1.50
[38mm]
HEAVY DUTY WALL MOUNTING BRACKET

2.94
[75mm]
FLOW & PRESSURE DROP

2.77
[70mm]
These units impose a pressure drop 4.27

[109mm]
that increases over rated flow range

from 1.9 to 2.5 psi (2.2 average).
.31 [7.9mm] THRU
(2) HOLES
1.88
[48mm]
SPECIAL OPTIONS
High temperature: (option HT) Multi-pin connector: (option PC) the male Tempered-glass window:
requires all-metal construction of half of a mini or micro pin connector with (option TG) replaces the standard
housing/orifice cover with seals of enough pins to carry all signals, make all window. A tempered-glass window
Viton, EPR, Kalrez or Teflon (com- switches and to ground all AC switches. is employed where airborne solvents
patible with fluid). A thermal barrier PC3 is a mini with 3 pins, PC3M is a micro or high-ambient temperatures are
(heat-resistant cloth) is added pin. Up to 6 pins available. common.
between the housing and the control
box, which must be used with service Fault light: (option FL) a red LED in Clearance vane: (option Z86) the
option "W" (weatherproof) or "X" nameplate indicates when a flow limit has swing vane is modified to provide
(corrosion resistant). A metal scale is been reached by internal switch contact. extra clearance for liquids that
provided. Helpful with multiple meters. Add to end of contain particulate. Available for
symbol: 1 (1 light), 2 (2 lights), A (AC), maximum flow range of 5 TO 9
Identification tag: (option ST) D (DC), i.e. FL2D. Only available with GPM. This reduces the turndown.
customer-supplied information is service option W weatherproof enclosures The minimum flow is 1.5 GPM,
stamped on a stainless steel tag that or X corrosive service. Requires switch which is standard for maximum
is attached to the nameplate. option and switch setpoint. For optional flows 10 to 20 GPM.
LED colors consult factory.
Number of pins required for various combinations of current type, box type and switch option.
AC switch options 1, 1B, 61, 71 3 53
DC switch options 0 1, 1B, 61, 71 3 2, 2B, 54, 62, 72 53
A 3 4 6 5 3 4
M 3 4 5
Box R 3 4 6 5 3 4
RT 3
TT 3 3 4 3 4
TTL 3 3 4 3 4
GTL* 5
GTLZ* 3
GP* 3
*This box allows micro pin connectors only. Eg. PC3M or PC5M.
4
DIMENSIONS (approximate) in inches
STANDARD OFFERING: Control Box A

3.50[89mm]
PORT TO PORT
5.94
[151mm]
4.51
[115mm]
2.58
[66mm]
3.31
[84mm]
5.12[130mm] APPROX. 6.00
SWING RADIUS [152mm]
4.72
[120mm]
6.33 SM/SN
[161mm]
7.29 SH
[185mm]
STANDARD OFFERING: Control Box X

8.44
[214mm]
6.75
PROXIMITY DETECTOR SWITCH SHOWN [171mm]
IN STANDARD MOUNTING LOCATION 3.50[89mm]
PORT TO PORT
9.63
[245mm]
5.38
[137mm]
LOCATION OF OPTIONAL
SECONDARY SWITCH
R7.42[188mm] APPROX. SWING RADIUS
5.37
[136mm]
6.98 SM/SN
[177mm]
7.93 SH
[201mm]
STANDARD OFFERING: Control Box G

R6.12
[155.42mm]
SWING RADIUS 3.50[89mm] LOCATION OF CONTROL BOX
PORT TO PORT WHEN ROTATED 90 FOR VERTICAL FLOW
(ONE OF FOUR POSSIBLE POSITIONS)
4.16 4.91
[106mm] [124.59mm]
3.69
TRANSMITTER PIN CONNECTOR [93.68mm]
3.34 REF.
5.18 [84.91mm]
[132mm]
6.79 SM/SN
[172mm]
7.74 SH
[197mm]
5
DIMENSIONS (approximate) in inches
SPECIAL OFFERING: Control Box R

3.50[89mm]
PORT TO PORT
3/4" NPT CONDUIT CONNECTION.

BOX TYPE R ONLY
2.58
[66mm]
7.63
[194mm]
6.13 REF
[156mm]
8.74
[222mm]
8.32[211mm] APPROX.
SWING RADIUS 1/2" NPT CONDUIT CONNECTION.
5.75 BOX TYPES RP, RT, RTV, & RTZ
[146mm]
7.36 SM/SN
[187mm]
8.32 SH
[211mm]
SPECIAL OFFERING: Control Box T

8.02
[204mm]
3.50[89mm]
PORT TO PORT
4.25
3.44 [108mm]
[87mm]
7.21[183mm] APPROX.
SWING RADIUS 1/2" NPT CONDUIT CONNECTION
6.47 (2) PLACES
[164mm]
8.08 SM/SN
[205mm]
9.03 SH
[229mm]
SPECIAL OFFERING: Control Box M

3.50[89mm]
PORT TO PORT
3.39
[86mm] 4.25
2.58 [108mm]
[66mm]
5.58 [142mm] APPROX. PIN CONNECTOR OR

4.49 SWING RADIUS 1/2" NPT CONDUIT CONNECTION
[114mm]
6.10 SM/SN
[155mm]
7.05 SH
[179mm]
With 150 lb R.F. flanges

(for other flanges consult factory) U N I V E R S A L

10.25
Port (262mm)
Size A
(inches) (inches) F L O W M O N I T O R S
1/2 3.50 A
Universal Flow Monitors, Inc.
3/4 3.87
1 4.25 1755 E. Nine Mile Road P.O. Box 249
Hazel Park, MI 48030
"Flow up" or "flow down" dimensions are the same. Tel: 248-542-9635 Fax: 248-398-4274
Scale numbers are turned 90 to read correctly. www.universalflow.com
E-mail: sales@universalflow.com
6 Catalog SNSH 12/26/02

Product Data Sheet
00813-0100-2654, Rev EA
August 2004 Volume 1
Temperature Sensors and Accessories

(Volume 1)
Content
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2
Threaded Mount Sensors and Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 9
Ordering Tables
Series 68Q Sanitary Platinum RTD Sensor Assemblies . . . . . . . . . . . . . . . . . . . . . . . . page 26
Series 58C Cut-to-Fit RTD Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 28
Series 58C Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 28
Series 183 Thermocouple Sensor Assemblies WITHOUT Thermowell . . . . . . . . . . . . . page 30
Series 183 Thermocouple Sensor Assemblies WITH Thermowell . . . . . . . . . . . . . . . . page 32
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 36
Mounting Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 48
Ordering Tables
Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 50
Connection Head Model Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 49
Compression Fittings, 316 SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 51
Series 91 Thermowells. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 56
Hazardous Area Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 65
Configuration Data Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 71
www.rosemount.com
Product Data Sheet
00813-0100-2654, Rev EA
Volume 1 August 2004
Introduction
OVERVIEW Hazardous Area Approvals
Emerson Process Management offers a wide variety Includes descriptions of the FM, CSA, SAA,
of RTD and thermocouple sensors that are available and ATEX approvals for sensors and
connection heads.
alone or as complete assemblies including
connection heads, thermowells, and extension Configuration Data Sheet
fittings. In addition to complete assemblies, Emerson Provides a form used for thermowell
Process Management offers heads, coupling/nipple application calculations.
and union/nipple extensions, compression fittings,
and thermowells. Series 58C, 68, 68Q, and 78 platinum RTD
temperature sensors are primarily used when high
Using this Product Data Sheet (PDS) accuracy, durability, and long-term stability are
required. These sensors conform to international
Use this PDS to order complete temperature sensor standards: IEC-751, EN 60751, and BS EN 60751.(1)
assemblies, which include sensors, thermowells,
extensions, and connection heads. These options Series 58C platinum RTD temperature sensors:
can also be ordered separately. For example, you Combine an economical thin-film design with a
can order a thermowell, extension, or connection sheath that can be shortened to any length
head for use with an existing sensor. In each case it with tubing cutter.
is important to know and understand the sections of
Series 68Q Quick Response Sanitary RTD sensors:
this PDS when specifying the items.
Conform to 3A Sanitary Standards and
Threaded Sensors and Assemblies feature product contact surfaces designed for
Includes descriptions, specifications, and CIP cleaning.
ordering information for Series 58C, 68, 68Q, Series 68 platinum RTD temperature sensors:
and 78 RTDs, and the Series 183
thermocouples. Provide high performance in an economical
thin-film design.
Includes information for ordering sensors,
connection heads, extensions, and Series 78 platinum RTDs temperature sensors:
thermowells as complete assemblies. Use a wire-wound element which allows for a
broader measurement range.
Calibration
Includes characterization schedules and Thermocouples
information for ordering calibrated Series 68,
68Q, and 78 RTD Sensors. Series 183 thermocouple temperature sensors
conform to ASTM E-230, and are available in types
Includes information regarding the use of
J, K, E, and T.
Callendar-Van Dusen constants to match
specific Series 68, 68Q, and 78 RTDs to Series 183 thermocouple temperature sensors are
Rosemount Smart Temperature Transmitters. available:
Mounting Accessories grounded or ungrounded
Includes descriptions, specifications, and isolated or unisolated
ordering information for temperature with immersion lengths from 2 to 48 inches.
accessories such as thermowells, extensions,
connection heads, mounting adapters, lead
wire extensions, connectors, seals, and
thermowells.
(1) 100 ohms at 0 C, = 0.00385 ohms/ohm/C
-2
Product Data Sheet
00813-0100-2654, Rev EA
The Use of 2-, 3-, and 4- wire RTDs
To help you attain the highest possible temperature measurement accuracy, Rosemount provides 4-wire sensors
for all single element RTDs. You can use these RTDs in 2-, 3-, or 4-wire configurations by simply securing the
unneeded leads with tape. To properly wire the 4-wire RTD for use in a 2-, 3-, or 4-wire configuration, refer to the
following wiring diagrams:
2-wire RTDs provide one connection to each end of the sensor. In a 2-wire
configuration, lead wires add resistance to the circuit which cannot be compensated.
The 2-wire configuration is rarely used because the added lead wire resistance can
cause substantial errors in the temperature reading.
3-wire RTDs provide one connection to one end of the sensor, and two connections to
the other end. The 3-wire approach does not eliminate all lead wire effects. However,
for sensors with lead wires of the same length, lead wire effects are slight, and the
approach provides reasonable accuracy.
The most effective way to eliminate lead wire effects is with two connections at each
end of the sensor. 4-wire RTDs fully compensate for lead wire effects.
Benefits and Limitations of RTDs when compared to Thermocouples

Benefits:
Higher accuracy
Better linearity and long-term stability
Cold junction compensation not required
Special extension lead wire not required
Less susceptible to noise
Can be matched to a Rosemount transmitter with transmitter sensor matching
Limitations
Lower maximum temperature limit
Slower response time in applications without a thermowell
-3
Product Data Sheet
00813-0100-2654, Rev EA
HOW TO DECIDE WHAT TO ORDER
Start
(Select One)
Is a sensor for an Is a thermowell for an

Is a sensor with a existing thermowell existing sensor
thermowell needed? needed? needed?
Yes Yes Yes
Refer to Table 1. Do any Select a sensor without a Select a thermowell

standard lagging thermowell
length/immersion length
combinations meet the
requirements?
Yes No
Select a sensor with 1. Select a sensor

a thermowell without a thermowell
combination combination
2. Select a thermowell
Finish
-4
Product Data Sheet
00813-0100-2654, Rev EA
SPRING-LOADED SENSOR DIMENSIONS

When a spring-loaded sensor is used properly, the spring should be compressed approximately 1/2-inch. Therefore, all measurements of
spring-loaded sensors are made with the spring compressed. If you measure an existing spring-loaded sensor while it is in a relaxed state, you
must subtract 1/2-inch to arrive at the installed length (X) that must be ordered. See Figure 1.
FIGURE 1. Spring Loaded Sensors Dimensions
Compressed Spring Loaded Sensor
3.45 (88) Installed (X) Length

Max. [Spring Compressed
Sensors-0005C
0.5 (13) nominal]
Spring loaded sensor in a compressed state: The actual sensor length is measured when the spring is compressed approximately 1/2-in.
shorter than the relaxed sensor.
Relaxed Spring Loaded Sensor
2.95 (88) Max.

Installed (X) Length + 0.5 in.
Sensors-0005D
Spring loaded sensor in a relaxed state: Normally, when a spring loaded sensor is measured, it is in a relaxed state. You must subtract 1/2-in.
from your measurement to order a replacement sensor. Rosemount Inc. assumes that the sensor length you specify is that of a compressed
sensor.
Determining the Length (L) of a spring-loaded sensor

to be used with an existing non-Rosemount
Thermowell
See Figure 1, Figure 3, and Figure 4.
1. Remove the existing generic sensor from the installed thermowell. Length Code Key
2. Measure the sensor length with the spring in the relaxed state (as shown in L Thermowell length minus 0.25 in.
Figure 1). Measure from the tip of the sensor to the maximum thread engagement U Immersion length into process
point (0.53 in. into the threads). T Lagging length
3. Subtract 0.5 inches from your measurement. The resulting length is (X). E Extension fitting length
4. If the sensor is installed with an extension, measure the extension length (E), as X Sensor length
shown in Figure 4. If the sensor is not installed with an extension, let (E) = 0. Use the following equations to determine
5. Since (X) = (E) + (L), subtract (E) from (X) to find (L). all lengths
Use the resulting length (L) in the Section 2 ordering tables to choose the correct length
L = U + T + 1.5
of sensor. X=E+L
X = E + U + T + 1.5
-5
Product Data Sheet
00813-0100-2654, Rev EA
FIGURE 2. Thermowell Dimensions (use with Table 1)
Sensor with Thermowell (no extensions)
0.25-in.
L
Sensors-0007B
T U
1.75-in.
TABLE 1. Dimensions for thermowells when ordered with sensors (U), (L), and (T). Use with Figure 2.
Dimensions (in.)(1)
Code (U) (L) (T) Code (U) (L) (T) Code (U) (L) (T)
020 2.0 4.0 0.5 090 9.0 12.0 1.5 160 16.0 18.0 0.5
025 2.5 4.0 0.0 095 9.5 12.0 1.0 165 16.5 18.0 0.0
030 3.0 6.0 1.5 100 10.0 12.0 0.5 170 17.0 21.0 2.5
035 3.5 6.0 1.0 105 10.5 12.0 0.0 175 17.5 21.0 2.0
040 4.0 6.0 0.5 110 11.0 15.0 2.5 180 18.0 21.0 1.5
045 4.5 6.0 0.0 115 11.5 15.0 2.0 185 18.5 21.0 1.0
050 5.0 9.0 2.5 120 12.0 15.0 1.5 190 19.0 21.0 0.5
055 5.5 9.0 2.0 125 12.5 15.0 1.0 195 19.5 21.0 0.0
060 6.0 9.0 1.5 130 13.0 15 0.5 200 20.0 24.0 2.5
065 6.5 9.0 1.0 135 13.5 15.0 0.0 205 20.5 24.0 2.0
070 7.0 9.0 0.5 140 14.0 18.0 2.5 210 21.0 24.0 1.5
075 7.5 9.0 0.0 145 14.5 18.0 2.0 215 21.5 24.0 1.0
080 8.0 12.0 2.5 150 15.0 18.0 1.5 220 22.0 24.0 0.5
085 8.5 12.0 2.0 155 15.5 18.0 1.0 225 22.5 24.0 0.0
(1) L = U + T + 1.5
Ordering a Sensor and a Thermowell

See Figure 2 and Table 1 and Figure 3 and Figure 4. Use the following Procedure to determine if a standard lagging length can be use with the
sensor and thermowell.
1. Determine the (U), (T), and (E) lengths necessary for your installation. Length Code Key
If you do not need an extension, (E) = 0 (zero). L Thermowell length minus 0.25 in.
Note: If your existing sensor/thermowell combination is different than Figure 3, refer to U Immersion length into process
the drawings on the following pages. T Lagging length
2. Find your immersion length (U) on Table 1 above and compare the corresponding E Extension fitting length
lagging length (T) to the lagging length that you previously determined. X Sensor length
3. If your lengths match the values on the line that corresponds to your required
immersion length, order your sensor and thermowell together.
Use the following equations to determine
all lengths
If your lengths do not match the values on the line that corresponds to your measured
immersion length, order your sensor and thermowell separately. Solve for (L) using the L = U + T + 1.5
equation (L) = (U) + (T) + 1.5 (since (L) is required when ordering the sensor separately X = E + L
from the thermowell). X = E + U + T + 1.5
-6
Product Data Sheet
00813-0100-2654, Rev EA
FIGURE 3. Series 68, 78, and 183 Sensor Assembly Dimensional Drawings
Capsule Sensor Only
1.75 (44) Nominal (X) Length

Sensors-0007A
0.25 (6)
1.25 (32)
Housing Diameter (see Table 2)

General Purpose Sensor Assembly
3.2 (81) Max. Nominal (X) Length**

Weld 360 0.25 (6)
Sensors-0008A
0.25 (6)
Fixed-Position Process Mounting 0.6 (15) Max. Sensing Element*

Connection (1/214 ANPT, both sides) 0.53 (13) Max. Thread Engagement
** Actual length is 0.25 (6) less to avoid bottoming in thermowell
Spring Loaded Sensor Assembly
Installed (X) Length **

Lead Wires (see Table 2) 3.45 (88)
Max.
Sensors-0000B06A
0.25 (6)

Spring-Positioned Process Mounting 0.53 (13) Max. Thread Engagement
Connection (1/214 ANPT, both sides)
Bayonet Spring Loaded Sensor Assembly
4.75 (121) Installed (X)

Max. Length **
2.5 (64) 0.6 (15) Max. Sensing Element*
Max.
0.25 (6)
Sensors-3144-07A
Bayonet Adapter Mounting Connection 0.53 (13) Max. Thread Engagement
(1/214 ANPT, both sides)
* Spring is shown compressed 0.5 -in.(13 mm.) Do not adjust the equations in Table 2 when calculating X, L, U, and T lengths. The equation
already accounts for spring compression.
TABLE 2. Sensor Series and Dimensions

Series Housing Diameter Lead Wires Lead Wire Length Series Housing Diameter Lead Wires Lead Wire Length
in mm in mm in mm in mm
68 0.350 8.0 4 6.0 152.4 183 single 0.375 9.53 2 6.0 152.4
78 single 0.350 8.0 4 6.0 152.4 183 dual 0.375 9.53 4 12.0 304.8
78 dual 0.350 8.0 6 6.0 152.4
-7
Product Data Sheet
00813-0100-2654, Rev EA
FIGURE 4. Series 68, 78, and 183 Sensor Assembly Length Code Drawings
Sensor with Thermowell (No Extension)
X 0.25 (6)
L
Sensors-0007A
T + 1.75 (44) U
Sensor with Extension (No Thermowell)
Nipple
Coupling
1
/214 ANPT Thread
Sensors-0008A
E L
Sensor Installed in Connection Head (Flat Cover) with Union and Nipple Extensions and Thermowell
0.25 (6)
X
5.5 (140)
Extended Cover
3.5 (89) E L
Flat
Cover Union
Nipple
Sensor Mounting Thermowell

Connection
Sensors-000B06A
T + 1.75 (44) U
3/414 ANPT
Chain
-8
Product Data Sheet
00813-0100-2654, Rev EA
Threaded Sensors and Assemblies

Series 68, 68Q, and 78 RTD and Series 183 Thermocouple One assembly model number, derived from one ordering table,
Sensors may be ordered as complete assemblies. These completely defines the type of sensing element, as well as the
assemblies provide a complete, yet simple means of specifying material, length, and style of both the extension fittings and
the proper industrial hardware for most temperature thermowells. All sensor assemblies are sized and inspected by
measurements. Rosemount Inc. to ensure complete component compatibility and
performance.
FIGURE 5. Individual Components of a Complete Temperature Assembly
Standard Adapter Sensor Assembly

X
Optional Identification Tag
0.5 (13) Nominal Engagement
Extensions
Coupling-Nipple
E
L
0.5 (13) Nominal

Lead Wire Extensions and Seals Engagement
Union-Nipple
Threaded
Welded
Thermowells
Flanged
Flat or Extended Cover Aluminum Connection Heads
Threaded
Sensors-0009A04A
Welded
Flanged
Rosemount Aluminum Connection Head
-9
Product Data Sheet
00813-0100-2654, Rev EA
MOUNTING CONFIGURATIONS SERIES 68 PLATINUM RTD

Rosemount Series 68 RTD temperature sensors measure from
Capsule 50 to 400 C (58 to 752 F). Series 68 sensors are available in
Capsules are designed for direct immersion without mounting capsule, general purpose, and spring-loaded designs in sensor
fittings. Accessory compression fittings are available for adjustable lengths from 1 to 48 inches.
mounting into a thermowell. See Mounting Adapters for Series 58, Table 3 shows the interchangeability of the Series 68 RTD. As an
68, 78, and 183. option, for maximum system accuracy, Rosemount Inc. can
provide sensor calibration. See Sensor Characterization
General-Purpose Sensor Assemblies (Calibration) Schedules Option Code V. In addition, Rosemount
Designed with a welded, fixed-position 1/214 ANPT process Inc. offers optional sensor-to-transmitter matching capability
connection fitting for direct immersion or thermowell applications, obtainable through the use of Callendar-Van Dusen Constants.
this sensor design provides a moisture-proof and vapor-tight seal. See Option Code V Callendar-van Dusen Constants.
The maximum static working pressure at 20 C (68 F) with no
vibration or flow condition is 31.59 MPa (3,500 psig). The use of a TABLE 3. Series 68 Interchangeability
thermowell is recommended for process pressure containment. 0.55 C (0.99 F) at -50 C (-58 F)
Note that standard lengths are 1/4 inch less than nominal
dimension to prevent bottoming of the sensor in a thermowell. 0.30 C (0.54 F) at 0 C (32 F)
0.80 C (1.44 F) at 100 C (-212 F)
Spring-Loaded Sensor Assemblies
1.30 C (2.34 F) at 200 C (392 F)
Spring-loaded sensors have a spring-positioned,
1 1.60 C (2.88 F) at 260 C (500 F)
/214 ANPT process connection fitting that ensures good surface
contact in thermowells for faster time response and vibration 2.30 C (4.14 F) at 400 C (752 F)
resistance. Spring-loaded sensors are not intended to provide a
process seal. They must be used in conjunction with a thermowell
Construction
for this purpose.
FIGURE 7. Construction of a Platinum Thin Film RTD
NOTE
When a spring-loaded sensor is used properly, the spring should
be compressed approximately 1/2-inch. Connection Seal
Connection Leads
Bayonet Spring-Loaded Sensor Assemblies Connection Pads
Bayonet assemblies have the same advantages as the Passivation with
Sensors-3144_05A
spring-loaded sensor. However, the bayonet connector permits the Glass Layers
sensor to be easily removed from the process without tools. Photolithography
Structured Platinum
FIGURE 6. Series 68, 68Q, 78, and 58C Thin Film
Lead Wire Configurations Al2 O3 Substrate
Single Element Dual-element(1)
Red Red Design and construction of the Series 68 Platinum Sensors

provides the optimum combination of accuracy and durability
Red available for temperature measurements. The construction of the
Sensors-0002A, C
White
White sensor allows for direct immersion in non-corrosive fluids at
Black reasonable static pressures. For corrosive environments or many
industrial applications, these sensors are widely used with
White
Green standard thermowell assemblies.
White Green
(1) Dual-element sensors are only available on Series 68Q and 78

Platinum Element and Lead Wire Configurations
sensors. Single-element temperature sensors have four lead wires and may
be used in 2-, 3-, and 4-wire signal conditioning systems.
-10
Product Data Sheet
00813-0100-2654, Rev EA
Specifications Environmental
Humidity Limits
Performance Lead seal can withstanding 100% relative humidity.
Vibration Limits
Temperature Range
0.05% maximum ice-point resistance shift due to 30 minutes
50 to 400 C (58 to 752 F) of 14 g peak vibration from 5 to 350 Hz at 20 C (68 F) for
unsupported stem length of less than 6 inches.
Effect of Temperature Cycling
Quality Assurance
0.05% (0.13 C or 0.23 F) maximum ice-point resistance shift
Each sensor is subjected to a resistance accuracy test at 0 C
following 10 cycles over the specified temperature range.
and a insulation resistance test.
Stability Enclosure Ratings
0.11% maximum ice-point resistance shift following 1,000 hours When installed properly, Rosemount Series 68 sensors are
at maximum specified temperature (400 C). suitable for indoor and outdoor NEMA 4X and CSA Enclosure
Maximum Hysteresis complete installation information.
0.1% of operating temperature range.
Time Constant 500 106 ohms minimum insulation resistance when measured at
12 seconds maximum required to reach 63.2% sensor response in 500 Vdc at room temperature.
water flowing at 3 ft/s (0.91 m/s).
Self Heating
16 mW minimum power dissipation required to cause a 1 C (1.8
F) temperature measurement error in water flowing at 3 ft/s.
Sheath Material
316 SST.
Lead Wire
Teflon insulated, nickel-coated, 22-gauge stranded copper wire.
Identification Data
The model, serial numbers, and up to six lines of permanent
Weight
Capsule sensors: 5 oz
General-purpose and spring-loaded sensors: 9 oz
-11
Product Data Sheet
00813-0100-2654, Rev EA

0068 Platinum Thin-Film Temperature Sensors and Sensor Assemblies
D Rosemount Aluminum Connection head
C(1) Polypropylene Connection Head
01(2)(3) Capsule Style
11(4) General-purpose style
31(6) Bayonet spring-loaded style (available in 1-in. increments from 1 to 21 inches)
A Nipple Coupling SST
C Nipple Union SST
00 0.0 in.
60 6.0 in.
(2)(7)
010 1.0-in. 130 13.0-in. 250 25.0-in.
015 1.5-in. 135 13.5-in. 260 26.0-in.
020 2.0-in. 140 14.0-in. 270 27.0-in.
025 2.5-in. 145 14.5-in. 280 28.0-in.
030 3.0-in. 150(8) 15.0-in. 290 29.0-in.
035 3.5-in. 155 15.5-in. 300 30.0-in.
040(8) 4.0-in. 160 16.0-in. 310 31.0-in.
045 4.5-in. 165 16.5-in. 320 32.0-in.
050 5.0-in. 170 17.0-in. 330 33.0-in.
055 5.5-in. 175 17.5-in. 340 34.0-in.
060(8) 6.0-in. 180(8) 18.0-in. 350 35.0-in.
065 6.5-in. 185 18.5-in. 360 36.0-in.
070 7.0-in. 190 19.0-in. 370 37.0-in.
075 7.5-in. 195 19.5-in. 380 38.0-in.
080 8.0-in. 200 20.0-in. 390 39.0-in.
085 8.5-in. 205 20.5-in. 400 40.0-in.
090(8) 9.0-in. 210 21.0-in. 410 41.0-in.
095 9.5-in. 210 21.5-in. 420 42.0-in.
100 10.0-in. 220 22.0-in. 430 43.0-in.
105 10.5-in. 225 22.5-in. 440 44.0-in.
110 11.0-in. 230 23.0-in. 450 45.0-in.
115 11.5-in. 235 23.5-in. 460 46.0-in.
120(8) 12.0-in. 240 24.0-in. 470 47.0-in.
125 12.5-in. 245 15.5-in. 480 48.0-in.
-12
Product Data Sheet
00813-0100-2654, Rev EA
Code Options
E1(10) ATEX Flameproof approval (See Figure 29)
Calibration
F1 4-pin bayonet connector
(1) FM, CSA, SAA, and ATEX approvals are not available with the polypropylene connection head.
(2) Capsule style available in 1-in. increments only, starting at 1-in. (i.e. 1, 2, 3-inches, etc.) See Mounting Adapters for Series 58, 68, 78, and 183 on page 51.
(3) This option must be used with Sensor Lead Wire Termination code N and is not available with assembly code XA or with Approval codes E1, E5, E6, and E7.
(4) General-purpose sensors are only available in (L) lengths of 2.5-in. or greater.
(5) Spring loaded sensors must be installed in a thermowell assembly to meet the requirements of explosion-proof approvals code E6.
(6) Not available with Sensor Lead Wire Termination codes R, P, or W or with approval codes E1, E5, E6, or E7.
(7) 1-in. length without extension is only available in capsule style.
(9) SAA Flame-proof Approval is only applicable if installed with Rosemount 244E, 248, 644, 3144P, or 3244MV transmitters.
(10) ATEX Flame-proof approval is only applicable if ordered with Sensor Lead Wire Terminator code D (Rosemount connection head) or installed with
Rosemount 144, 244E, 248, 644, 3144P, or 3244MV transmitters.
(12) If ordering code XA with a transmitter, specify the same option on the transmitter model code.
Ordering Example
Number
0068 N 11 N 00 N 045 E5
-13
Product Data Sheet
00813-0100-2654, Rev EA

0068 Platinum Thin Film Temperature Sensors and Sensor Assemblies
Single Element Temperature Sensors
00 0.0 in.
60 6.0 in.
A Type 316 SST(5) J Hastelloy C (with 304 SST flange, if flange style is ordered)
B Type 304 SST L Hastelloy B (with 304 SST flange, if flange style is ordered)
U(7) L T(8) U(7) L T(8) U(7) L T(8)
090 9.0-in. 12.0 1.5-in. 205(9) 20.5-in. 24.0-in. 2.0-in. 410 41.0-in. 45.0-in. 2.5-in.
105(5) 10.5-in. 12.0-in. 0.0-in. 220(9) 22.0-in. 24.0-in. 0.5-in. 440 44.0-in. 48.0-in. 2.5-in.
-14
Product Data Sheet
00813-0100-2654, Rev EA

1
3
3
1
3
T36(10) Threaded 1-11.5 ANPT Straight
3
1
3
3
3
W48(10) Welded /4-in. pipe Straight
W50(10) Welded 1-in. pipe Straight
F62 Flanged 2-in. Class 150 Tapered
F04(10)(11) Flanged 11/2-in., Class 600 Straight
3
Code Options
-15
Product Data Sheet
00813-0100-2654, Rev EA
Calibration
Thermowell Options
(2) Not available with Sensor Lead Wire Termination codes R, P, or W.
(3) Not available with option codes E1, E5, E6, and E7.
(9) Straight or tapered stem only
(10) Straight thermowells are not recommended for (U) lengths greater than 6-in.
(11) F88 to F08 cannot be used with 0-in. (T) length. F08 cannot be used with 0- or 1/2-in. (T) length)
(12) SAA flame-proof approval is only applicable if installed with a Rosemount 248, 244E, 644, 3144P, or 3244MV transmitter.
(13) ATEX flame-proof approval is only applicable if ordered with Sensor Lead Wire Terminator code D (Rosemount connection head) or installed with a
Rosemount 144, 248, 244E, 644, 3144P, or 3244MV transmitter.

Number
0068 N 21 A 30 A 075 T22 E5
-16
Product Data Sheet
00813-0100-2654, Rev EA
SERIES 78 PLATINUM RTD FIGURE 8. Wiring Configuration of a

Dual-Element Sensor to Function as a Single
Series 78 sensors are intended for applications that require high
accuracy, dual-elements, and/or are subjected to high
Element Sensor with a Compensation Loop
temperatures. Rosemount Series 78 RTD temperature sensors
measure from 200 to 600 C (328 to 1112 F). These sensors Red
are available in capsule, general-purpose, spring-loaded, and Measurement points
Sensors-0002A, C
bayonet spring-loaded designs in sensor (X) lengths from 1 to 68 White
inches. White (extra leave disconnected)
Table 7 shows the interchangeability of the Series 78 sensors. The Black (extra leave disconnected)
performance of the standard Series 78 sensor conforms to the
standard set by IEC 751 Class B. Additionally, IEC-751 Class A Green Lead wire compensation
accuracy is available as an option. For maximum system Green
points
accuracy, Rosemount Inc. can provide sensor calibration. See
Sensor Characterization (Calibration) Schedules Option Code
Note: Isolate the two extra leads with electrical tape to ensure
V. Rosemount Inc. also offers optional sensor-to-transmitter
that they do not contact the terminals.
matching capability obtainable through the use of Callendar-Van
Dusen Constants. See Option Code V Callendar-van Dusen
Constantsand Option X8Q4: Sensor Calibrated to a Construction
Customer-Specified Temperature Range.
The wire-wound design and construction of the General-Purpose
FIGURE 9. Construction of a Platinum Wire-wound RTD
Series 78 sensor allows direct immersion in non-corrosive fluids at
reasonable static pressures. For corrosive environments and in Lead Wires
many industrial applications, these sensors are commonly used
with standard thermowell assemblies.
Seal
Sensors-3144_06A
Platinum Element and Lead Wire Configurations High Purity Insulator
Single-element high-temperature sensors have four lead wires
and may be used in 2-, 3-, and 4-wire signal conditioning systems. Platinum Resistance
Element
Dual-element sensors have redundant elements to provide
separate readout and control signals from a single measurement
point. Dual-element sensors have three lead wires for each
element and may be used with 2- or 3-wire systems. Dual-element
sensors can also be wired to be used as compensation loop
sensors (see Figure 8).
-17
Product Data Sheet
00813-0100-2654, Rev EA
Specifications Environmental
Performance Humidity Limits

Lead seal is capable of withstanding 100%
Temperature Range relative humidity.
Series 78 single- and dual-element sensors may be used in
temperatures from 200 to 500 C (328 to 932 F). Series 78 Vibration Limits
single-element high-temperature sensors are provided for Standard single- and dual-element sensors:
high-temperature service over the range of 0 to 600 C (32 to 1112 0.03% maximum ice-point resistance shift due to 30 minutes
F). of 21 g peak vibration from 5 to 350 Hz continuous sweep at
20 C (68 F) for unsupported stem length of less than 5.5
Effect of Temperature Cycling inches (140 mm).
0.04% (0.10 C or 0.18 F) maximum ice-point resistance shift Single-element high-temperature sensors:
following 10 cycles between 200 and 500 C (328 to 932 F).
Meet ASTM E 1137-95. Cycling time is 3 hours per
longitudinal axis, less the time spent at resonant dwells at the
Stability
axis, from 5 to 500 Hz. The test level is 1.27 mm (0.05 in.)
0.05% maximum ice-point resistance shift following 1,000 hours double amplitude displacement or peak g-level of 3, whichever
at 400 C (752 F). is less.
Accuracy Quality Assurance
TABLE 7. Series 78 Interchangeability Each sensor is subjected to a resistance accuracy test at 0 C and
Standard Series 78 IEC-751 Class B Temperature an insulation resistance test.
0.80 C (1.44 F) -100 C (-148 F)
Enclosure Ratings
0.30 C (0.54 F) 0 C (32 F)
0.80 C (1.44 F) 100 C (212 F) When installed properly, Rosemount Series 78 sensors are
1.80 C (3.24 F) 300 C (572 F) suitable for indoor and outdoor NEMA 4X and CSA Enclosure
2.30 C (4.14 F) 400 C (752 F) Type 4X installations. See Hazardous Area Approvals for
Series 78 with IEC-751 Class A Option Temperature complete installation information.
0.35 C (0.63 F) -100 C (-148 F)
0.15 C (0.27 F) 0 C (32 F)
0.35 C (0.63 F) 100 C (212 F)
0.75 C (1.35 F) 300 C (572 F)
Sheath Material
0.95 C (1.71 F) 400 C (752 F) 316 SST
Maximum Hysteresis Lead Wires

Single- and dual-element, standard: 0.04% of range. Teflon-insulated, nickel-coated, 22-gauge stranded copper wire.
Single-element, high temperature: 0.1% of range.
Identification Data
Time Constant The model and serial numbers and up to six lines of permanent
4 seconds maximum required to reach 63.2% sensor response in tagging information are etched on each sensor. Stainless steel
water flowing at 3 ft/s (0.91 m/s), 9.5 seconds for single-element tags are available upon request.
high-temperature sensors.
Weight
Self Heating Capsule sensors: 5 oz
18 mW minimum power dissipation required to cause a 1 C (1.8 General purpose and spring-loaded sensors: 9 oz
F) temperature measurement error in water flowing at 3 ft/s, 25
mW for single-element high temperature sensors.
500 V dc at room temperature [20 C (68 F)]. Single element
high-temperature sensors are measured at 100V dc.
-18
Product Data Sheet
00813-0100-2654, Rev EA

01(2)(3) Capsule style
03(2) Capsule style (available in (X) lengths of 3 to 24-in, increments of 1-in.)
13 General-purpose style (available in (X) lengths of 3 to 24-in, increments of 1/2-in.)
23(4) Spring-loaded style (available in (X) lengths of 3 to 24-in, increments of 1/2-in.)
33 (5) Bayonet spring-loaded style (available in (X) lengths of 3 to 21-in, increments of 1-in.)
05(2) Capsule style
00 0.0 in.
60 6.0 in.
010 1.0-in. 130 13.0-in. 250 25.0-in.
015 1.5-in. 135 13.5-in. 260 26.0-in.
020 2.0-in. 140 14.0-in. 270 27.0-in.
025 2.5-in. 145 14.5-in. 280 28.0-in.
030 3.0-in. 150 15.0-in. 290 29.0-in.
035 3.5-in. 155 15.5-in. 300 30.0-in.
040(7) 4.0-in. 160 16.0-in. 310 31.0-in.
045 4.5-in. 165 16.5-in. 320 32.0-in.
050 5.0-in. 170 17.0-in. 330 33.0-in.
055 5.5-in. 175 17.5-in. 340 34.0-in.
060(7) 6.0-in. 180 18.0-in. 350 35.0-in.
065 6.5-in. 185 18.5-in. 360 36.0-in.
070 7.0-in. 190 19.0-in. 370 37.0-in.
075 7.5-in. 195 19.5-in. 380 38.0-in.
080 8.0-in. 200 20.0-in. 390 39.0-in.
085 8.5-in. 205 20.5-in. 400 40.0-in.
090(7) 9.0-in. 210 21.0-in. 410 41.0-in.
095 9.5-in. 215 21.5-in. 420 42.0-in.
-19
Product Data Sheet
00813-0100-2654, Rev EA
100 10.0-in. 220 22.0-in. 430 43.0-in.

105 10.5-in. 225 22.5-in. 440 44.0-in.
110 11.0-in. 230 23.0-in. 450 45.0-in.
115 11.5-in. 235 23.5-in. 460 46.0-in.
120 12.0-in. 240 24.0-in. 470 47.0-in.
125 12.5-in. 245 24.5-in. 480(8) 48.0-in.
Code Options
Sensor
A(9) IEC 751 Class A Sensor
Calibration
(2) Capsule style available in 1-in. increments only. See Mounting Adapters for Series 58, 68, 78, and 183 on page -51.
(3) Must be used with Sensor Lead Wire Termination code N and is not available with assembly option XA or with approval option codes E1, E5, E6, or E7.
(4) Spring loaded sensors must be installed in a thermowell assembly to meet the requirements of explosion-proof approval option code E6.
(5) This option is not available with Sensor Lead Wire Termination codes R, P or W or approval code E1, E6, and E7.
(8) Additional lengths are available up to 68-in., increments of 1-in.
(10) SAA Flameproof approvals only applicable if installed with a Rosemount 248, 244E, 644, 3144P or 3244MV transmitter.
(11) ATEX Flameproof approvals only applicable if ordered with Sensor Lead Wire Terminator code D (Rosemount connection head) or installed with a
Rosemount 144, 248, 244E, 644, 3144P or 3244MV transmitter.

Number
0078 N 21 N 00 N 045 E5
-20
Product Data Sheet
00813-0100-2654, Rev EA
13 General-purpose style (available in (X) lengths of 3 to 24-in., increments of 1/2-in.)
23 Spring-loaded style (available in (X) lengths of 3 to 24-in., increments of 1/2-in.)
00 0.0 in.
60 6.0 in.
U(7) L T(8) U(7) L T(8) U(7) L T(8)
-21
Product Data Sheet
00813-0100-2654, Rev EA
1
3
3
1
3
3
1
3
3
3
W48 Welded /4-in. pipe Straight
3
Code Options
Sensor
A(11) IEC 751 Class A sensor
-22
Product Data Sheet
00813-0100-2654, Rev EA
Calibration
Thermowell Options
XA(3)(17) Assemble connection head or transmitter to a sensor assembly (Teflon (PTFE) paste where appropriate, fully wired.)
(2) Not available with Sensor Lead Wire Termination codes R, P or W.
(3) Not available with Approval codes E1, E6, or E7.
(6) Available only with straight stem flanged thermowells.
(9) Straight or Tapered stem only.
(10) F88 to F08 cannot be used with 0-in. (T) length. F08 cannot be used with 0- or 1/2-in. (T) length
Rosemount 144, 248, 244E, 644, 3144 or 3244MV transmitter.

Number
0078 N 21 A 30 A 075 T22 E5
-23
Product Data Sheet
00813-0100-2654, Rev EA
SERIES 68Q SANITARY PLATINUM RTD Response Time

Rosemount Series 68Q sanitary RTD temperature sensors Tri-clamp O.D. Tube Size 1-in. and greater
measure from 50 to 200 C (58 to 392 F). Series 68Q sensors Less than 3.5 seconds required to reach 63.2% sensor
are available in Tri-Clamp endcap designs in immersion lengths response in water flowing at 3 ft/s (0.91 m/s). Meets PMO
from 1.0 to 9.5 inches. Table 12 shows the interchangeability of specification
the Series 68Q sensor. Tri-clamp O.D. Tube Size 1/2 - 3/4-in.:
Less than 1.5 seconds required to reach 63.2% sensor
Accuracy response in water flowing at 3 ft/s (0.91 m/s).
TABLE 12. Series 68Q Interchangeability (IEC 751 Class B)
0.55 C (0.99 F) at 50 C (58 F)
0.30 C (0.54 F) at 0 C (32 F)
0.80 C (1.44 F) at 100 C (212 F) 100 V dc at room temperature
1.30 C (2.34 F) at 200 C (392 F)
Surface Finish
Construction 32RA standard finish on product contact surfaces. Meets 3-A
Series 68Q sensors conform to 3-A Sanitary Standards and requirements
feature product contact surfaces designed for CIP cleaning. The 15RA high mechanical polish available with option code HP.
response times of Series 68Q sensors meet the
Grade A Pasteurized Milk Ordinance (PMO) specification for
thermometric response of an indicating thermometer on a pipeline. Environmental
Series 68Q sensors are offered in a Tri-Clamp sanitary endcap
configuration. The sensor capsule is welded into the 316 SST Humidity Limits
sanitary endcap/stem assembly. The product contact of this
Lead seal is capable of withstanding 100% relative humidity
assembly is polished to a finish that exceeds No. 4 minimum finish
as required by the 3A Sanitary Council Standard #74-02. Quality Assurance
Platinum Element and Lead Wire Configurations Each sensor is subjected to a resistance accuracy test at 0 C
Single-element temperature sensors have four lead wires and may Physical Specifications
be used in 2-, 3-, and 4-wire signal conditioning systems.
Dual-element sensors have six lead wires and may be used in 2- Sheath Material
and 3-wire signal conditioning systems.
316 SST
SPECIFICATIONS Lead Wire

Teflon insulated, nickel-coated, 24-gauge stranded copper wire
Performance
Identification Data
Temperature Range The model and serial numbers and up to six lines of permanent
50 to 200 C (58 to 392 F) tagging information are etched on each sensor. Stainless steel
tags are available upon request
Maximum Hysteresis
0.09% of operating temperature range
Weight
0.6 to 2.0 lb (0.3 to 0.9 kg)
Stability
Tri-clamp O.D. Tube Size 1-in. and greater:
0.04% maximum ice-point resistance shift following 1,000
hours at maximum specified temperature 392 F (200 C).
Tri-clamp O.D. Tube Size 1/2 - 3/4-in.:
0.08% maximum ice-point resistance shift following 1,000
hours at maximum specified temperature 392 F (200 C).
-24
Product Data Sheet
00813-0100-2654, Rev EA
FIGURE 10. 68Q Sanitary Sensor and Polypropylene Connection Head Dimensional Drawings
68Q Sanitary Sensor with Tri-Clamp Endcap
STEPPED STEM STRAIGHT STEM
U
Tri-Clamp Process Connection
1 to 3 inch O.D.tube size
3.00 (76) U 1-in. (25.4) 1.5 (6.35)
1
Tri-Clamp 0.250 /2-in NPT
0.84 (21) Endcap Stem (6.35) 0.250 (6.35)
0.5 (13)
14 ANPT R 0.250 (6.35) 0.825 (20.96)

R 0.250 (6.35)
U
3.00 (76.2)
68Q Mini General Purpose Sensor with Cable and Strain Relief
Tri-Clamp Process Connection

1
0.375 /2 to 3/4 inch O.D. tube size
Vinyl Strain Relief (9.5)
0.125
(3.2)
Lead Wire Length 2.2 (55.9) 0.25 (6.4)
68Q Mini General Purpose Sensor with 1/2-in. NPT Threaded Adapter
1
/2-in. 1NPT
/2-in./ 1NPT
/2-in./ 1NPSM
/2-in. Tri-Clamp Process Connection
1/2 to 3/4 inch O.D. tube size
0.405 (10.3)
0.125 (3.2)
6 (152.4) 2.2 (55.9) 0.25 (6.4)
68Q Mini Spring Loaded Sensor with Thermowell and Replaceable Sensor
0.188
(4.8)
6 (152.4) 2.2 (55.9) 1.25 U

1.0
TABLE 13. Series 68Q Spare Parts List

Mini Spring-Loaded Sanitary Replacement Sensors and Thermowells
Immersion Length (U) Replacement Sensor Part Number Replacement Thermowell Part Number
2.0 00068-4035-0020 00068-4035-1020
2.5 00068-4035-0025 00068-4035-1025
3.0 00068-4035-0030 00068-4035-1030
-25
Product Data Sheet
00813-0100-2654, Rev EA
TABLE 14. Series 68Q Sanitary Platinum RTD Sensor Assemblies

0068Q Series 68Q Sanitary RTD Temperature Sensors
D Rosemount Aluminum Connection Head
C Polypropylene Connection Head, Six Terminals
N Sensor only, 22-gauge lead wires
11 Single Stepped Stem -50 to 200 C (-58 to 392 F)
15 Dual Stepped Stem -50 to 200 C (-58 to 392 F)
21 Single Straight Stem -50 to 200 C (-58 to 392 F)
25 Dual Straight Stem -50 to 200 C (-58 to 392 F)
30(1) (2) Mini General Purpose 6-in. lead with 1/2-in. NPT Threaded Adapter -50 to 200 C (-58 to 392 F)
31(1)(2)(3) Mini General Purpose 6-in. lead with 1/2-in. NPSM Threaded Adapter -50 to 200 C (-58 to 392 F)
32(1)(2)(3) Mini General Purpose 180-in. cable with strain relief -50 to 200 C (-58 to 392 F)
33(1)(2)(3) Mini General Purpose 300-in. cable with strain relief -50 to 200 C (-58 to 392 F)
41(4) Mini Spring Loaded with thermowell replacement sensor -50 to 200 C (-58 to 392 F)
Sensor Immersion Sensor Immersion Sensor Immersion
Code Length (L) (in.) Code Length (L) (in.) Code Length (L) (in.)
U010 1.00 U019 1.90 U060 6.00
U011 1.10 U020 2.00 U065 6.50
U012 1.20 U025 2.50 U070 7.00
U013 1.25 U030 3.00 U075 7.50
U014 1.40 U035 3.50 U080 8.00
U015 1.50 U040(5) 4.00 U085 8.50
U016 1.60 U045 4.50 U090 9.00
U017 1.70 U050(5) 5.00 U095 9.50
U018 1.80 U055 5.50
Code Endcap Type O.D. Tube Size (inches)
L050 Tri-Clamp 1/2 to 3/4
L100 Tri-Clamp 1.00

L250 Tri-Clamp 2.50
L300 Tri-Clamp 3.00
Calibration Options
V1-V7 VCallendar-van Dusen Constants. Option codes V3, V4, and V7 are not available with Series 68Q sensors.
Additional Options
R20(6) Electropolishing of wetted surfaces
HP High Mechanical Polish, 15Ra or better
Q8 Material Certification
(1) Only available in immersion lengths between 1-in. and 2-in.
(2) Only available with Tri-Clamp O.D. tube size 1/2 to 3/4-in. (Endcap type code L050).
(3) Only available with Sensor lead Wire Termination code N (sensor only).
(4) Only available in U lengths of 2.0, 2.5, or 3.0 inches.
(6) If ordering a Mini General Purpose or Mini Spring Loaded Sensor (Sensor Type codes 30, 31, 32, 33, or 41) with Electropolishing, High Mechanical Polish
(Option code HP) is also required.
Ordering Example
Typical Model Lead Wire Termination Sensor Type Immersion Length Endcap Type, Tube Size Additional Options
Model
Number 0068Q N 11 U050 L150 V2
-26
Product Data Sheet
00813-0100-2654, Rev EA
SERIES 58C PLATINUM RTD Stability

Rosemount Series 58C sensors are available in 0.035% maximum ice-point resistance shift following 1,000 hours
12-, 24-, 36-, and 48-inch (X) lengths and may be shortened to any at maximum specified temperature (200 C).
desired length with an ordinary tubing cutter. This cut-to-fit feature
eliminates the need to stock a large selection of sensors in many
specific lengths. Table 15 shows the interchangeability of the 500 106 ohms minimum insulation resistance when measured at
Series 58C Sensor. 50 V dc at room temperature.
TABLE 15. Series 58C Interchangeability (IEC 751 Class B) Environmental Specifications
0.55 C (0.99 F) at 50 C (58 F)
0.30 C (0.54 F) at 0 C (32 F) Humidity Limits
0.80 C (1.44 F) at 100 C (212 F) No permanent rear seal is installed
1.30 C (2.34 F) at 200 C (392 F)
Quality Assurance
Specifications Each sensor is subjected to a resistance accuracy test at 0 C and
an insulation resistance test
Performance Specifications
Temperature Range
50 to 200 C (58 to 392 F)
Sheath Material
316 SST
Maximum Hysteresis
0.09% of operating temperature range.
Lead Wires
Teflon-insulated, nickel-coated, 24-gauge stranded copper wire
Series 58C Sensor
Do not cut all the way through the sensor sheath when cutting the sensor to length. Damage to the sensor wires could result. To prevent damage to the sensor
wires, score the sheath considerably with a tubing cutter and gently break off the excess.
0.25 0.002 (6.35 0.13) Diameter

4 Lead Wires 6 (152) Long
X Length 0.25 (6)
Sensors-0021A
0.6 (15) Max. Sensing Element
Nylon Sleeve
Do Not Cut or Bend Sheath within 2 (51)
Option Code SNN Spring-Loaded Fitting Option Codes C01, C02, Swagelok Compression Fitting
303 SST. 1/214 ANPT 316 SST. 1/214 ANPT
for 0.25 (6)

for 0.25 (6) Diameter Sensors
Diameter Sensors
Sensors-0020A, B
2.51 1.75
(64) Max. (44) Max.
-27
Product Data Sheet
00813-0100-2654, Rev EA
TABLE 16. Series 58C Cut-to-Fit RTD Sensors

0058C Platinum Resistance Temperature Sensor (50 to 200 C (58 to 392 F))
C Polypropylene Connection Head
Code Sensor Length (X) in inches
1200 12
2400 24
3600 36
4800 48
Code Mounting Adapter
NNN None
C01(1) One-compression fitting 1/214 ANPT
C02(1) Two-compression fittings 1/214 ANPT
SNN Spring-loaded fitting 1/214 ANPT
(1) The only difference between C01 and C02 is that the C01 includes one fitting while the C02 option includes two fittings.
Ordering Example
Typical Model Lead Wire Mounting
Number Model Termination Sensor Length Adapter
0058C R 1200 SNN
TABLE 17. Series 58C Spare Parts List

(specify spare part number separately when ordering mounting
adapters)
Mounting Adapters Option Code Spare Part Number

Compression fitting 1/214 ANPT C01 and C02 C07961-0008
Spring loaded fitting 1/214 ANPT SNN 00058-0010-0001
-28
Product Data Sheet
00813-0100-2654, Rev EA
SERIES 183 THERMOCOUPLE Specifications

Rosemount Series 183 Thermocouple sensors measure from
180 to 1150 C (292 to 2102 F). Performance Specifications
The thermoelectric current relationship in a thermocouple is
Construction standardized and defined by ASTM E-230. All Series 183
The Series 183 Thermocouples are manufactured using ISA Type Thermocouples conform to these standards with special limits of
J, K, E, or T wire with special limits of error accuracy. The error accuracy. The particular characteristics of each ISA type
junction of these wires is fusion-welded to form a pure joint, to thermocouple are outlined in Table 22.
maintain the integrity of the circuit, and to ensure the highest
accuracy. Grounded junctions are available for improved response Physical
time and good thermal contact with protection from the
environment. The ungrounded and isolated junctions provide Sheath Material
electrical isolation from the sensor sheath (see Figure 11). 304 SST for types J, E, and T (used at temperatures up to 871 C).
Rosemount thermocouples are encased in a protective metal Inconel for type K (used at temperatures up to 1150 C).
sheath. The sheath material is 304 SST for types J, E, and T, used
at temperatures up to 871 C and Inconel for type K, used at Lead Wires
temperatures up to 1150 C. Metallic oxide insulation is compacted Thermocouple, internal16 AWG solid wire (max), 18 AWG solid
into the sheath to mechanically support and electrically insulate wire (min.). External lead wires20 AWG wire, Teflon insulated.
the thermocouple wire. See Table 22 for more information on the Color coded per lead wire configuration schematic shown in Figure
different types of thermocouples. 12.
FIGURE 11. Series 183 Junction Configurations Identification Data

Single, Grounded Dual, Grounded, Unisolated tagging information are etched on each sensor. Stainless steel
+ +
+ Weight
Capsule sensors: 5 ounces. General-purpose and spring-loaded
sensors: 9 ounces.

Single, Ungrounded Dual, Ungrounded, Unisolated

+ 100 V dc at room temperature.
+
+
Enclosure Ratings
suitable for indoor and outdoor
Dual, Ungrounded, Isolated
NEMA 4X and CSA Enclosure Type 4X installations. See
Hazardous Area Approvals for complete installation information.
+
+
FIGURE 12. Series 183 Lead Wire Configurations
Type J Type E
+ White + Purple
Red Red
Type K Type T
+ Yellow + Blue
Red Red
-29
Product Data Sheet
00813-0100-2654, Rev EA
TABLE 18. Series 183 Thermocouple Sensor Assemblies WITHOUT Thermowell

N Sensor only with 6-in. Teflon -insulated, 22-gauge lead wires (12-in. lead wires for dual thermocouples)
Capsule Sensor(2)(3)
01(2) Single Grounded
02 Dual Grounded
General Purpose Sensors
11 Single Grounded
12 Dual Grounded
Spring-Loaded Sensors(4)
21 Single Grounded
22 Dual Grounded
31 Single Grounded
32 Dual Grounded
J2 J 0 to 760 C (32 to 1400 F)
K2 K 0 to 1150 C (32 to 2102 F)
E2 E 0 to 871 C (32 to 1600F)
T2 T 180 to 371 C (292 to 700 F)
J2 J 0 to 760 C (32 to 1400 F)
00 0.0 in.
60 6.0 in.
-30
Product Data Sheet
00813-0100-2654, Rev EA
020 2.0-in. 140 14.0-in. 260 26.0-in.
025 2.5-in. 145 14.5-in. 270 27.0-in.
030 3.0-in. 150(8) 15.0-in. 280 28.0-in.
035 3.5-in. 155 15.5-in. 290 29.0-in.
040(8) 4.0-in. 160 16.0-in. 300 30.0-in.
045 4.5-in. 165 16.5-in. 310 31.0-in.
050 5.0-in. 170 17.0-in. 320 32.0-in.
055 5.5-in. 175 17.5-in. 330 33.0-in.
060(8) 6.0-in. 180(8) 18.0-in. 340 34.0-in.
065 6.5-in. 185 18.5-in. 350 35.0-in.
070 7.0-in. 190 19.0-in. 360 36.0-in.
075 7.5-in. 195 19.5-in. 370 37.0-in.
080 8.0-in. 200 20.0-in. 380 38.0-in.
085 8.5-in. 205 20.5-in. 390 39.0-in.
090(8) 9.0-in. 210 21.0-in. 400 40.0-in.
095 9.5-in. 215 21.5-in. 410 41.0-in.
100 10.0-in. 220 22.0-in. 420 42.0-in.
105 10.5-in. 225 22.5-in. 430 43.0-in.
110 11.0-in. 230 23.0-in. 440 44.0-in.
115 11.5-in. 235 23.5-in. 450 45.0-in.
120(8) 12.0-in. 240 24.0-in. 460 46.0-in.
125 12.5-in. 245 15.5-in. 470 47.0-in.
130 13.0-in. 250 25.0-in. 480 48.0-in.
135 13.5-in.
Code Options
Assembly Options
XA(11) Assemble connection head or transmitter to a sensor assembly (hand tight, Teflon (PTFE) paste where appropriate, fully wired.)
(2) This option must be used with Sensor Lead Wire Termination code N and is not available with assembly options XA.
(3) Cannot be used with approval option codes E1, E5, E6, or E7. See Mounting Adapters for Series 58, 68, 78, and 183 on page -51.
(4) Spring-loaded sensors must be installed in a thermowell assembly to meet the requirement option code E6.
(5) This option is not available with explosion-proof approval option code E6.
(6) Bayonet spring-loaded style is available to 45-inches but is not available with Sensor Lead Wire Termination codes R, P, or W.

Model Model Termination Sensor Type ISA Type Type Length Code Length Options
Number
0183 N 11 J2 N 00 N 045 E5
-31
Product Data Sheet
00813-0100-2654, Rev EA
TABLE 20. Series 183 Thermocouple Sensor Assemblies WITH Thermowell

General-Purpose Sensors
11 Single Grounded
12 Dual Grounded
15 Dual, Isolated
Spring-Loaded Sensors
21 Single Grounded
22 Dual Grounded
31 Single Grounded
32 Dual Grounded
J2 J 0 to 760 C (32 to 1400 F)
K2 K 0 to 1150 C (32 to 2102 F)
E2 E 0 to 871 C (32 to 1600F)
T2 T 180 to 371 C (292 to 700 F)
00 0.0 in.
30 3.0 in.
60 6.0 in.
-32
Product Data Sheet
00813-0100-2654, Rev EA

U(7) L T(8) U(7) L T(8) U(7) L T(8)
085 8.5-in. 12.0-in. 2.0-in.
T20(5) Threaded 1/2-14 ANPT Stepped
3/4-14 ANPT
T22(5) Threaded Stepped
3/4-14 ANPT
T34 Threaded Straight
1/2-14 ANPT
T44 Threaded Tapered
3
3/4-in. pipe
W42 Welded Tapered
3/4-in. pipe
W48 Welded Straight
-33
Product Data Sheet
00813-0100-2654, Rev EA

3
Code Options
Thermowell Options
R01 Full penetration weld
Assembly Options
(2) This option is not available with explosion-proof approval option codes E1, E5, E6, or E7.
(3) Bayonet spring-loaded style available to 45 inches. Codes 31 - 35 are not available with Sensor Lead Wire Termination codes R or P.
(9) Straight or Tapered stem thermowells only.
(10) Cannot be used with 0-in. (T) length. F08 cannot be used with 0- or 1/2-in. (T) length

Typical Lead Wire Sensor Extension Extension Material Immersion Mounting Additional
Model Model Termination Type ISA Type Type Length Code Length Style Options
Number
0183 N 21 J2 A 30 A 075 T22 E5
-34
Product Data Sheet
00813-0100-2654, Rev EA
Comparison of Thermocouples
80
Type E
60
Type K
Millivolts (approx.)
Type J
40
Type T
20
SENSORS_VOL1_01A
0
32 1000 2000
Degrees Farenheit
Thermocouple Conditions for Use

Type J Maximum operating temperature of 760 C (1400 F). Used with or without protective tubing where deficiency of free oxygen
Iron / Constantan exists. Protective tube not essential, but desirable for cleanliness and longer service.
Type K Suitable for extended use in temperature reaching 1150 C (2102 F). Use of metal or ceramic protective tube desirable,
Chromel / Alumel especially in reducing atmospheres. in oxidizing atmospheres, protective tubing necessary only to promote cleanliness and
longer service.
Type E Suitable for use at temperature p to 900 C (1652 F) in vacuum r inert, mildly oxidizing or reducing atmosphere. Not subject to
Chromel / Constantan corrosion at cryogenic temperatures. Has highest EMF output per degree of all commonly used thermocouples.
Type T Operating temperature range of 180 to 371 C (292 to 700 F). Use in either oxidizing or reducing atmospheres. Protective
Copper /Constantan tubing necessary only to promote cleanliness and longer service. Stable at lower temperature. Superior for a wide variety of uses
in cryogenic temperatures.
TABLE 22. Characteristics of Series 183 Thermocouple Types

ISA Temperature Range
Thermocouple Thermocouple Wire
Types Alloys C F Limits of Error (Interchangeability)
J Iron/Constantan 0 to 760 32 to 1400 1.1 C or 0.4% of measured temperature, whichever is greater
K Chromel/Alumel 0 to 1150 32 to 2102 1.1 C or 0.4% of measured temperature, whichever is greater
E Chromel/Constantan 0 to 871 32 to 1600 1.0 C or 0.4% of measured temperature, whichever is greater
T Copper/Constantan 180 to 0 292 to 32 1.0 C or 1.5% of measured temperature, whichever is greater
0 to 371 32 to 700 0.5 C or 0.4% of measured temperature, whichever is greater
-35
Product Data Sheet
00813-0100-2654, Rev EA
Calibration
CALIBRATION OPTIONS Note that this is a modification of the fourth-order CVD equation
where = 0 for temperatures greater than 0 C. Since this
Sensor calibration may be required for input to quality systems, or modified equation is a second-order degree equation, at least
for control system enhancement. More frequently, it is used to
three distinct temperature values are needed in order to curve fit
improve the overall temperature measurement performance by
the behavior of the RTD. For the temperature range from 0 to 100
matching the sensor to a temperature transmitter. C only these two end points are used, and an approximation is
Transmitter-Sensor matching is available for RTD sensors used
made to render the constants.
with Rosemount 644, 3144P, and 3244MV temperature
Once the sensor-specific constants are entered, the transmitter
transmitters where the inherent stability and repeatability of the
RTD technology is well established. uses them to generate a custom curve to best describe the
relationship between resistance and temperature for the particular
sensor and transmitter system. Matching a Series 68 or 78 RTD
Transmitter-Sensor Matching sensor to a 644, 3144P, and 3244MV transmitter typically results in
Using Callendar-Van Dusen Constants a 3- or 4-fold improvement in temperature measurement accuracy
for the total system. This substantial system accuracy
Significant temperature measurement accuracy improvement can
be attained using a temperature sensor that is matched to a improvement is realized as a result of the transmitters ability to
use the sensors actual resistance-vs.-temperature curve instead
temperature transmitter. This matching process entails teaching
of an ideal curve.
the temperature transmitter the relationship between resistance
and temperature for a specific RTD sensor. This relationship, An example of the benefits of using the sensor matching capability
approximated by the Callendar-Van Dusen equation, described as: of a Rosemount 3144P Temperature transmitter along with a
matched Series 68 RTD sensor are shown in Typical
Rt = Ro + Ro[t (0.01t 1)(0.01t) (0.01t 1)(0.01t)3], Transmitter-Sensor Matching Uncertainty Improvements.
where:
Calibration Uncertainty
Rt = Resistance (ohms) at Temperature t (C)
Calibration uncertainties of the lab are equal to or better than 1/10
Ro = Sensor-Specific Constant (Resistance at t = 0 C) IEC 751 Class B interchangeability:
=Sensor-Specific Constant
=Sensor-Specific Constant Uncertainty = 0.03 + 0.0005 t
=Sensor-Specific Constant (0 at t > 0 C, 0.11 at t < 0C)
t = absolute value of temperature in C
The exact values for R0, , , , known as Callendar-Van Dusen
(CVD) constants are specific to each RTD sensor, and are
established by testing each individual sensor at various
temperatures.
The calibration temperature values using the CVD equation are
divided into two major temperature areas: above 0 C and below 0
C. The calibration for the temperature range between 0 and 660
C is obtained from the following formula:
t t
R t = R 0 1 + t --------- --------- 1
100 100

-36
Product Data Sheet
00813-0100-2654, Rev EA
TYPICAL TRANSMITTER-SENSOR MATCHING UNCERTAINTY IMPROVEMENTS

Transmitter: 3144 (has built-in sensor matching Sensor Interchangeability Total Calibrated Sensor
capabilities), span of 1 to 200 C, accuracy = 0.1 C) Temperature Error Uncertainty(1)
Sensor: Series 68 RTD C F C F C F
Callendar van Dusen Option: V2 0 32 0.30 0.54 0.10 0.18
Process Temperature: 150 C 50 122 0.55 0.99 0.17 0.31
100 212 0.80 1.44 0.22 0.40
150 302 1.05 1.89 0.18 0.32
200 392 1.30 2.34 0.16 0.29
(1) Includes calibration uncertainties of the lab, hysteresis, and repeatability.
System Uncertainty Comparison at 150 C:

Standard 68 Sensor
1.0 C Standard Series 68 RTD: 1.05 C
1.05 C
0.75 C
68 Sensor with V2 Option
0.5 C
Standard Series 68 RTD: 0.18 C
0.22 C
Standard With Sensor
Matching
(1) Calculated using RSS statistical method:
SystemAccuracy = ( TransmitterAccuracy )2 + ( SensorAccuracy ) 2
Sensor Characterization
(Calibration) Schedules Option Code V
Series 68, 68Q, and 78 RTD sensors can be ordered with an For applications requiring the increased accuracy obtainable
option (V1, V2,...V7, see Option Code V Callendar-van Dusen through a matched sensor and transmitter, order the appropriate
Constants), that provides Callendar-Van Dusen constants that are V option (seeOption Code V Callendar-van Dusen Constants).
shipped with the sensor. When you order this option, the values of To ensure optimal performance, select a V option such that the
all four sensor-specific constants are physically attached to each sensors range of actual operation is between the minimum and
sensor with a wire-on tag. Rosemount 644, 3144P, and 3244MV maximum calibration points.
have a unique, built-in sensor matching capability. To use this The accuracy (uncertainty) of different calibration points varies
capability, the four sensor-specific constants are programmed into because each calibration schedule has specific hysteresis and
the 644, 3144P, and 3244MV at the factory by ordering a C2 repeatability characteristics. For example, the accuracy of
option on the transmitter, or easily entered and changed in the calibration points at 100 C for options V1 and V2 differs because
field using a HART Communicator or AMS. When these values are of the two different temperature ranges.
entered into a Rosemount 644, 3144P, and 3244MV, the sensor
and transmitter become matched.
NOTE
Each V option is specific to a particular temperature range for a
An RTD ordered with the V option is shipped with CVD constants
given sensor type (see Option Code V Callendar-van Dusen
only; it does not include calibration tables.
Constants). As with option code X8Q4, the accuracies associated
with each option code represent worst-case conditions when the
sensor is used over the entire temperature range.
-37
Product Data Sheet
00813-0100-2654, Rev EA
OPTION CODE V CALLENDAR-VAN DUSEN CONSTANTS
Total Uncertainty(2) of Calibrated Sensor
Option Calibration Uncertainty(1) of Series 78 Series 78 High

Code Temperature Range Points Calibration Lab Series 68 Standard Temperature
C F C F C F C F C F C F
V1(3) 0 to 100 32 to 212 0 32 0.03 0.05 0.06 0.11 0.06 0.11 0.06 0.11
100 212 0.08 0.14 0.10 0.18 0.10 0.18 0.10 0.18
V2(3) 0 to 200 32 to 392 0 32 0.03 0.05 0.10 0.18 0.09 0.16 0.10 0.18
100 212 0.08 0.14 0.22 0.40 0.15 0.27 0.23 0.41
200 392 0.13 0.23 0.16 0.29 0.15 0.27 0.16 0.29
V3(3) 0 to 400 32 to 752 0 32 0.03 0.05 0.20 0.29 0.16 0.29 0.20 0.29
200 392 0.13 0.23 0.42 0.76 0.29 0.52 0.44 0.79
400 752 0.23 0.41 0.30 0.54 0.28 0.50 0.30 0.54
V4(3)(4) 0 to 600 32 to 1112 0 32 0.03 0.05 NA NA NA NA NA NA
200 392 0.13 0.23 NA NA NA NA NA NA
400 752 0.23 0.41 NA NA NA NA NA NA
V5(3) 50 to 100 58 to 212 0 32 0.03 0.05 0.08 0.14 0.06 0.11 0.09 0.16
100 212 0.08 0.14 0.10 0.18 0.10 0.18 0.10 0.18
V6(3) 50 to 100 58 to 392 50 58 0.06 0.10 0.14 0.25 0.11 0.20 0.14 0.25
0 32 0.03 0.05 0.20 0.36 0.14 v0.25 0.21 0.38
100 212 0.08 0.14 0.26 0.47 0.18 0.32 0.27 0.49
200 392 0.13 0.23 0.18 0.32 0.16 0.29 0.17 0.3
V7(3) 50 to 400 58 to 752 50 58 0.06 0.10 0.23 0.41 0.19 0.34 0.23 0.41
0 32 0.03 0.05 0.31 0.56 0.22 0.40 0.32 0.58
200 392 0.13 0.23 0.46 0.83 0.31 0.56 0.48 0.86
400 752 0.23 0.41 0.32 0.58 0.29 0.52 0.32 0.58
(1) Includes only the uncertainly of the lab.
(2) Includes the uncertainty of the lab, hysteresis, and repeatability.
(3) Uncertainties are valid for option code X8Q4 when ordered with the corresponding temperature range. The largest error shown in each temperature range
is the worst case error for all points not shown in that range.
(4) Only available with Series 78 High Temperature Sensors 10-in. or longer.
Specify Sensor Model Number with V Option Example
Sensor Model 0068 N 11 N 00 N 120 V2
FIGURE 13. Typical Sensor Ordered with Option Code V
Sensors-0004B
-38
Product Data Sheet
00813-0100-2654, Rev EA
Option Code X8Q4

The X8Q4 option calibrates the sensor to a customer-specified FIGURE 14. Graph of a Typical Two-point Trim
temperature range. The X8Q4 report includes the Callendar-Van
Dusen (CVD) constants (Ro, , , ), a resistance-versus- A two-point trim
temperature table in one-degree increments, and a graph which shifts the ideal curve
Resistance ()
includes the maximum errors due to the uncertainty of the up or down, and
calibration equipment, hysteresis, and repeatability. The values in changes the slop
the tables are calculated using Callendar-Van Dusen based on the two
methodology. Two of the values on this table could be used to characterized
perform a two-point trim. The X8Q4 option also provides the CVD points.
constants on a stainless steel tag attached to the sensor. Temperature (C)
See Figure 16.
Option X8Q4: Sensor Calibrated to a Customer-Specified Temperature Range

When you order an RTD with the X8Q4 option, you must specify a temperature range over which the sensor is to be calibrated. Before
specifying the range, take careful note of the sensor temperature limits.
Ordering Example:

Number
0068 N 11 N 00 N 045 X8Q4
X8X9Q4
If X8Q4 and X9Q4 are both required, do not repeat the Q4 code in the model string. Include the following instead:
Calibrate from 10 to 120 C
Option Code X9Q4

The X9Q4 option calibrates the sensor at a single FIGURE 15. Graph of a Typical One-point Trim
customer-specified point. A calibration certificate with the
resistance value at this point is supplied. This value could be used
to perform a one-point trim on the transmitter.All characterizations
are traceable to the National Institute of Standards and Technology
(NIST). The calibration table is dated and marked with the sensor
Resistance ()
series and serial number.
Sensors-0000_04A
See Figure 17.
NOTE
The X9Q4 option can be ordered and used in conjunction with the Temperature (C)
X8Q4 option.
A one-point trim shifts the ideal curve up or down based on the
single characterized point.
Option X9Q4: Sensor Calibrated to a Customer-Specified Single Point

When you order an RTD with theX9Q4 option, you must specify a single temperature point at which the sensor is to be calibrated. Before
specifying the point, take careful note of the sensor temperature limits.
Ordering Example:

Number
0068 N 11 N 00 N 045 X9Q4
If X8Q4 and X9Q4 are both required, do not repeat the Q4 code in the model string. Include the following instead: X8X9Q4
Calibrate at 50 C
-39
Product Data Sheet
00813-0100-2654, Rev EA
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00813-0100-2654, Rev EA
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Product Data Sheet
00813-0100-2654, Rev EA
TABLE 23. Option Code X9Q4 Calibration Uncertainties for the Series 68 and 78 Standard and High Temperature
Temperature Uncertainty of Calibration Lab(1) Total Uncertainty of Calibrated Sensor(2)
C F C F C F
50 58 0.06 0.10 0.07 0.13
0 32 0.03 0.05 0.06 0.11
100 212 0.08 0.14 0.09 0.16
200 392 0.13 0.23 0.14 0.25
400 752 0.23 0.41 0.24 0.43
(1) Includes only the uncertainty of the lab.
(2) Includes uncertainty of the lab and repeatability.
TABLE 24. Resistance vs. Temperature

IEC 751
Platinum 100, = 0.00385 RTD
F Ohms F Ohms F Ohms C Ohms C Ohms C Ohms
330 18.04 210 138.08 690 235.15 200 18.52 90 134.71 380 240.18
320 20.44 220 140.19 700 237.09 190 22.83 100 138.51 390 243.64
310 22.83 230 142.29 710 239.02 180 27.10 110 142.29 400 247.09
300 25.20 240 144.39 720 240.95 170 31.34 120 146.07 410 250.53
290 27.57 250 146.49 730 242.87 160 35.54 130 149.83 420 253.96
280 29.93 260 148.58 740 244.79 150 39.72 140 153.58 430 257.38
270 32.27 270 150.67 750 246.71 140 43.88 150 157.33 440 260.78
260 34.61 280 152.75 760 248.62 130 48.00 160 161.05 450 264.18
250 36.94 290 154.83 770 250.53 120 52.11 170 164.77 460 267.56
240 39.26 300 156.91 780 252.44 110 56.19 180 168.48 470 270.93
230 41.57 310 158.98 790 254.34 100 60.26 190 172.17 480 274.29
220 43.88 320 161.05 800 256.24 90 64.30 200 175.86 490 277.64
210 46.17 330 163.12 810 258.14 80 68.33 210 179.53 500 280.98
200 48.46 340 165.18 820 260.03 70 72.33 220 183.17 510 284.30
190 50.74 350 167.24 840 263.80 60 76.33 230 186.84 520 287.62
180 53.02 360 169.30 850 265.68 50 80.31 240 190.47 530 290.92
170 55.29 370 171.35 860 267.56 40 84.27 250 194.10 540 294.21
160 57.55 380 173.40 870 269.44 30 88.22 260 197.71 550 297.49
150 59.81 390 175.45 880 271.31 20 92.16 270 201.31 560 300.74
140 62.06 400 177.49 890 273.17 10 96.09 280 204.90 570 304.01
130 64.30 410 179.53 900 275.04 0 100.00 290 208.48 580 307.25
120 66.54 420 181.56 910 276.90 10 103.90 300 212.05 590 310.49
110 68.77 430 183.59 920 278.75 20 107.79 310 215.61 600 313.71
100 71.00 380 173.40 930 280.61 30 111.67 320 219.15 610 316.92
90 73.22 390 175.45 940 282.46 40 115.54 330 222.68 620 320.12
80 75.44 400 177.49 950 284.30 50 119.40 340 226.21 630 323.30
70 77.66 410 179.53 960 286.14 60 123.24 350 229.72 640 326.48
60 79.86 420 181.56 970 287.98 70 127.08 360 233.21 650 329.64
50 82.07 430 183.59 980 289.82 80 130.90 370 236.70 660 332.79
40 84.27 450 187.65 990 291.65
30 86.47 460 189.67 1000 293.48
20 88.66 470 191.68 1010 295.30
10 90.85 480 193.70 1020 297.12
10 93.03 490 195.71 1030 298.94
20 95.21 500 197.71 1040 300.75
30 97.39 510 199.71 1050 302.56 Note
40 99.57 520 201.71 1060 304.37
50 101.74 530 203.71 1070 306.17 To covert from C to F: {1.8 X (C)] + 32 = F
60 106.07 540 205.70 1080 307.97 Example: (1.8 X 100) + 32 = 212 F
70 108.23 550 207.69 1090 309.77
80 110.38 560 209.67 1100 311.56
90 112.53 570 211.66 1110 313.35 To convert from F to C: 0.556 [(F) 32] = 100 F
100 114.68 580 213.63 1120 315.14 Example: 0.556 (212 32) = 100 C
110 116.83 590 215.61 1130 316.92
120 118.97 600 217.58 1140 318.70
130 121.11 610 219.55 1150 320.47
140 123.24 620 221.51 1160 322.24
150 125.37 630 223.47 1170 324.01
160 127.50 640 225.42 1180 325.77
170 129.62 650 227.38 1190 327.53
180 131.74 660 229.33 1200 329.29
190 133.86 670 231.27 1210 331.04
200 135.97 680 233.21
-47
Product Data Sheet
00813-0100-2654, Rev EA
Mounting Accessories
ROSEMOUNT CONNECTION HEAD EXTENDED COVER CONNECTION HEAD
The Rosemount Connection head is for general-purpose and The Extended Cover Connection Head (P/N 00079-0324-xxxx)
spring-loaded sensors. The terminal block has six terminals for provides the additional space required by sensors that have
either single or dual element sensors. If the sensor assembly is bayonet connectors. This model can also be used with
ordered assembled to a Rosemount 248 or 644H head mount general-purpose and spring-loaded sensors. The terminal block
transmitter then the terminal block is replaced by the transmitters. has six terminals for either single- or dual-element sensors.
Specifications Specifications
Sensor Connection Sensor Connection
1/214 NPT mounting thread. Screw terminals for lead wire 1/214 ANPT mounting thread. Screw terminals for lead wire
connections. connections
Electrical Connection Electrical Connection
1/214 NPT conduit 3/414 ANPT conduit
Materials of Construction Materials of Construction
Housing: Low copper aluminum Housing: Low-copper aluminum alloy
Paint: Polyurethane O-Ring Seal: Silicone rubber
Cover O-ring: Buna-N Terminals: Nickel-plated brass
Weight Temperature Limits
18.5 oz (524 g) Head Type Unapproved With E5 option With E6 option
Enclosure Rating Painted 100 to 100 C 50 to 85 C 50 to 85 C
148 to 212 F 58 to 185 F 58 to 185 F
NEMA 4X, IP66, and IP68 Unpainted 100 to 200 C 50 to 85 C 50 to 200 C
148 to 392 F 58 to 185 F 58 to 392
POLYPROPYLENE CONNECTION HEAD Weight

The polypropylene connection head (part number 2 lb 8 oz
00644-4198-0011) is designed for use with sanitary sensors. It is Enclosure Ratings
FDA-compliant, and is resistant to attack by acids, alkalies, and When installed properly, painted connection heads are
organic solvents. suitable for indoor and outdoor NEMA 4X and CSA Enclosure
Type 4X installations. When installed properly, unpainted
Specifications
connection heads are suitable for NEMA 4 and CSA
Sensor Connection Enclosure Type 4 installations. See Hazardous Area
1/214 NPT mounting thread. Screw terminals for lead wire Approvals for complete installation information
connections
Electrical Connection
1/214 NPT conduit
FLAT COVER CONNECTION HEAD
The Flat Cover Connection Head (P/N 00079-0325-xxxx) is for
Housing: White polyporpylene polymer
O-Ring Seal: Silicone rubber has six terminals for either single- or dual-element sensors.
Terminals: Nickel-plated brass
Temperature Limits Specifications
73 to 104 C (100 to 220 F) Weight
Weight 1 lb 9 oz
0.5 lb
-48
Product Data Sheet
00813-0100-2654, Rev EA
Connection Head Model Numbers Connection Head Dimensional Drawing

Model Description Rosemount Connection Head
00644-4410-0011 Rosemount Connection Head, painted aluminum
007903242003 Six Terminals with Extended Cover, 104
Approved, Unpainted
007903240002 Six Terminals with Extended Cover,
FM Approved, Unpainted 78
007903250003 Six Terminals with Flat Cover, CSA
Approved, Unpainted
CSA Approved, Unpainted
100
Unapproved, Painted
Unapproved, Painted
Polypropylene
Approved, Painted
007903240004 Six Terminals with Extended Cover, 118 (4.65)
FM Approved, Painted
007903250005 Six Terminals with Flat Cover, CSA
Approved, Painted
248/248_08a
CSA Approved, Painted
00644-4198-0011 Six Terminals, No Approval Options,
White Polypropylene 84 (3.331)
Flat Cover Extended Cover Terminal View
3.5 5.5 1
(89) (140) /214 ANPT
4.9
(124)
Sensors-0035A
3/414 ANPT
Chain Terminal Block (6 terminals)

-49
Product Data Sheet
00813-0100-2654, Rev EA
EXTENSION FITTING ASSEMBLIES Choosing an Extension and a

Extension fitting assemblies are available in Thermowell
a coupling and nipple assembly Aside from ambient temperature variations, the heat from the
a union and nipple assembly process is transferred from the thermowell to the transmitter
housing. If the process temperature is near or beyond specification
FIGURE 18. Extension Fitting
limits, consider the use of additional thermowell lagging, an
extension nipple, or a remote mounting configuration to isolate the
Length (E) (Nominal) Coupling and Nipple transmitter from the excessive temperatures. Use Figure 20 and
Assembly
the example below to determine an adequate thermowell
extension length.
Sensors-0036A
0.53 (13) Max. Thread Engagement (14 ANPT Ref.) FIGURE 19. 3144 Transmitter Housing Temperature Rise
versus Extension Length for a Test Installation
Union and Nipple
Assembly
60
50
TABLE 25. Extension
Coupling and Nipple, SST Union and Nipple, SST
40
Model Number Length (E) Model Number Length (E) HOUSING
007903540250 2.5-in. 007903550250 2.5-in. RISE ABOVE 30
AMBIENT (C) 815 C Oven Temperature
007903540300 3.0-in.(1) 007903550300 3.0-in.(1)
007903540350 3.5-in. 007903550350 3.5-in. 20
3044-0123A
007903540400 4.0-in. 007903550400 4.0-in. 540 C Oven
007903540450 4.5-in. 007903550450 4.5-in. Temperature
10
0079035-0500 5.0-in. 007903550500 5.0-in.
250 C Oven Temperature
007903540550 5.5-in. 007903550550 5.5-in. 0
007903540600 6.0-in.(1) 007903550600 6.0-in.(1) 3 4 5 6 7 8 9
007903540650 6.5-in. 007903550650 6.5-in. N LENGTH (in.)
007903540700 7.0-in. 007903550700 7.0-in.
007903540750 7.5-in. 007903550750 7.5-in. Example
007903540800 8.0-in. 007903550800 8.0-in.
The rated ambient temperature specification is 85 C. If the
007903540850 8.5-in. 007903550850 8.5-in.
maximum ambient temperature is 40 C and the process
007903540900 9.0-in. 007903550900 9.0-in.
temperature to be measured is 540 C, the maximum allowable
(1) Standard configuration with best delivery. Also available for housing temperature rise is the rated temperature specification
emergency requirements. Consult factory for information.
limit minus the existing ambient temperature (85 40), or 45 C.
As shown in Figure 20, an extension (E) dimension of 3.0-in (76
mm) will result in a housing temperature rise of 30 C. An E
dimension of 3-in. would therefore be the minimum recommended
length, and would provide a safety factor of about 15 C. A longer
E dimension, such as 6-in. (152 mm), would be desirable in order
to reduce errors caused by transmitter temperature effect,
although in that case the transmitter would probably require extra
support. If a thermowell with lagging is used, the E dimension
may be reduced by the length of the lagging.
-50
Product Data Sheet
00813-0100-2654, Rev EA
MOUNTING ADAPTERS FOR SERIES 58, 68, 78, AND 183

M5M7, Sensor Compression Fittings, 316 SST
For adjustable sensor length.
Fitting Diameter
For low pressure applications
(100 psig maximum).
Fits -inch diameter sensors.
Available with 1/827 (M5), 18 (M6), and 14 (M7) ANPT
process threads.
Not available on spring-loaded sensors.
Sensors-0025A
Sensor Process Thread
Length
TABLE 26. Compression Fittings, 316 SST

(for attachment to the stem of the capsule)
Model Number Option Code Sensor Process Thread Fitting Diameter Length
in. mm in. mm
1/827 ANPT
C07961-0005 M5 0.25 6.35 1.31 33.27
1/418 ANPT
C07961-0006 M6 0.25 6.35 1.5 38.1
1/214 ANPT
C07961-0008 M7 0.25 6.35 1.75 44.45
-51
Product Data Sheet
00813-0100-2654, Rev EA
LEAD WIRE EXTENSIONS, CONNECTORS, AND SEALS

The following options are available on most Series 68 and 78 sensors. They are not available for use on Series 58C, 68Q, and 183 sensors or
with SAA or ATEX/ISSeP Flameproof approval (Option Codes E7 or E1).
(Capsule Sensor Only)

Twisted Lead WIre Extension
(Option Codes A1 A8)
(Capsule Sensor with Standard Adapter)
Shielded Cable Lead Wire Extension

(Option Codes B1 B8)
Armored Cable Lead Wire Extension

(Option Codes C1 C8)
Armored Cable
Mating Plug with Lead
Wire Extension
(Option Codes L1 L8) Armored Cable Lead Wire Extension with
Electrical Plug
(Option Codes D1 D8)
4-Pin Connector
(Option Codes H1 H8) Bayonet Connector
(Option Code F1)
Moisture-Proof Seal Assembly for
Armored Cable (Option Code J1)
Sensors-0009A05A
3244MV Transmitter Armored Cable Lead Wire Extension (Option Codes C1 C8)
A1A8, Twisted Lead Wire Extension

Lead wire connections are silver brazed and Option Code Y Length (ft) Option Code Y Length (ft)
individually insulated by shrinkable Teflon tubes A1 11/2 A5 24
A2 3 A6 50
Withstands 95 percent relative humidity
A3 6 A7 75
200 C (392 F) maximum temperature A4 12 A8 100
22-Gauge Teflon (PTFE) Lead Wire

Teflon Sensor
Sensors-0027A
6 (152) [Ref.]
Y
Not available for use with Series 68Q Sanitary RTDs and 183 thermocouples or with SAA or ATEX/ISSeP flameproof approval (option codes
E7 or E1)
-52
Product Data Sheet
00813-0100-2654, Rev EA
B1B8, Shielded Cable Lead Wire Extension
Copper shielded cable prevents electrical noise distortions to Option Code Y Length (ft) Option Code Y Length (ft)
sensor signal output B1 11/2 B5 24
B2 3 B6 50
B3 6 B7 75
200 C (392 F) maximum temperature B4 12 B8 100
Shielded Cable Teflon Jacket Rubber Seal

0.375 (10) Diameter
22-Gauge Teflon-Insulated Wires 0.25 (6) [Approx.] Sensor
Sensors-0028A
Y 2.75 (70) [max.]
Not available for 58C, 68Q, and 183 sensors or with SAA or ATEX/ISSeP flameproof approval (option codes E7 or E1)
C1C8, Armored Cable Lead Wire Extension

Provides lead wire protection Option Code Y Length (ft) Option Code Y Length (ft)
in heavy duty environments. C1 11/2 C5 24
C2 3 C6 50
C3 6 C7 75
200 C (392 F) maximum temperature C4 12 C8 100
22-Gauge Teflon-Insulated Wire

Armor Cable 0.34 (8.64) I.D. 0.375 (10) Diameter 0.445 (11)
Sensor
Sensors-0030A
6.0
Y 2.75 (70) [Max.]
(152)
D1D8, ARMORED CABLE LEAD WIRE EXTENSION

WITH ELECTRICAL PLUG Option Code Y Length (ft) Option Code Y Length (ft)
Provides lead wire protection in D1 11/2 D5 24
heavy-duty environments D2 3 D6 50
D3 6 D7 75
D4 12 D8 100
Mates with Option Codes L1L8

Armor Cable 0.25 (6) 0.375 (10) Diameter
Sensor Sensors-0029A
Y 2.75 (70) [Max.]

-53
Product Data Sheet
00813-0100-2654, Rev EA
L1L8, ARMORED CABLE MATING PLUG WITH LEAD Option Code Y Length (ft) Option Code Y Length (ft)
WIRE EXTENSION L1 11/2 L5 24
Completes quick-disconnect capability for armored cable L2 3 L6 50
Withstands 95 percent relative humidity L3 6 L7 75
L4 12 L8 100
Twisted lead wire extension for lowest cost installation
22-Gauge Teflon Lead Wire Mates with Option Codes D1D8
Sensors-0031A
Y
F1, 4-PIN BAYONET CONNECTOR

Withstands 100 percent relative humidity with connector mate
Available for capsule and general purpose with 4-wire lead
wire configuration only
Receptance Shell and Pin 0.652 (17) Mates with Option Codes H1H8
Finish Are Nickel Plate Dia. Max. 0.375 (10) Diameter
Sensors-0032A
Wiring Schematic Sensor
A 2.0 (51)
B
4-Wire 3.0 (76)
C
D 150 C Max. for Series 68 and 78
Not available for 58C, 68Q, and 183 sensors, or with FM or CSA explosion-proof, or with SAA or ATEX/ISSeP flameproof approval (option
codes E5, E6, E7, or E1)
H1H8, 4-PIN CONNECTOR MATING PLUG WITH LEAD Option Code Y Length (ft) Option Code Y Length (ft)
WIRE EXTENSION H1 11/2 H5 24
Completes the quick-disconnect capability of connector H2 3 H6 50
Provides twisted lead wire extension for H3 6 H7 75
remote installations H4 12 H8 100
with connector mate
F1 connector is required if H1H8 lead wire extension is used
22-Gauge Teflon
4-Pin Connector (Mates with Option Code F1)
Lead Wire
Sensors-0033A
Y
codes E5, E6, E7, or E1)
-54
Product Data Sheet
00813-0100-2654, Rev EA
J1, MOISTURE-PROOF SEAL ASSEMBLY FOR
ARMORED CABLE
Prevents moisture migration through armored cable
For use in humid environments but not for direct liquid
immersion
Non-disconnectable type assembly with armored cable
and sensor
Nipple, 304 SST, 1/214 ANPT 1.12 (28.45) Long
Moisture-Proof Seal (J1)

Compression Fitting Sensor
ensors-0034A
Armored Cable Lead Wire
(Specify Option Codes C1C8)
J1
codes E5, E6, E7, or E1).
Moisture-proof seal assembly must be ordered with armored cable lead wire extension (option codes C1 C8)
THERMOWELLS
To simplify ordering, the previous Series 79, 80, and 81 thermowell Construction
offerings are all included in the new Series 91 thermowell option. All thermowell bodies with an overall length less than 42-in. are
machined from solid bar stock to ensure water-tightness. Flange
Materials mounts are welded to the thermowell body. Standard construction
Rosemount Thermowells are supplied in most materials required provides immersion lengths (U) from 2 to 48 inches with overall
for industrial applications. Standard materials are 316 SST, 304 lengths (L) from 4 to 59 inches respectively. Thermowells with
SST, and C1018 carbon steel. For corrosive environments, special overall lengths larger than 42-in. will be a 3-piece welded
materials such as Monel, Hastelloy, and Inconel 600 are construction. Consult the factory for more information on welded
available. Consult factory for other material availability. 3-piece construction thermowells.
Strength (Pressure and Flow Vibration) Identification Data

The strength of a thermowell depends on several parameters that The part number is etched on each thermowell. Additional tagging
relate thermowell construction to the installation environment. For for specific customer requirements is available.
most industrial applications, standard Rosemount thermowells
provide the necessary strength if the material, style, and length are Installation
correct for the application. The proper selection of a thermowell For dimensional drawings of Thread Mounted, Weld Mounted, and
depends on fluid type, temperature, pressure, and fluid velocity. It Flange Mounted Thermowells, refer to Figure 20, 22, and 24.
is important to note that most thermowell failures are caused by
vibration that is induced by fluid flow. If static pressure strength is a
major consideration, refer to Table 27 for standard material ratings
for a 1/2-inch tip. Tapered thermowells are offered for additional
strength.
Strength Calculation
Rosemount Inc. has the ability to perform thermowell frequency
calculations to verify that the thermowell dimensions you provide
are appropriate for your specific application. To take advantage of
this calculation, fill out and return the Configuration Data Sheet
on page -71.
TABLE 27. Thermowell Material Rating

Process Rating(1) (psi) at Temperature (F)
Material Recommended Usage 0 F 300 F 500 F 700 F 900 F 1100 F 1300 F
304 SST Good resistance to oxidation 5600 4800 4700 4600 3400 2400 780
316 SST Good resistance to corrosion. Better resistance to 5600 5400 5300 5200 4400 3200 1250
chemical attack than 304 SST
Carbon Steel For non-corrosive service 3700 3700 3700 3650 2000
(1) In case of an explosion, the integrity of the thermowell is maintained to the specified pressures.
-55
Product Data Sheet
00813-0100-2654, Rev EA
TABLE 28. Series 91 Thermowells
Model Description
0091 Series 0091 Thermowells
Code Thermowell Material Code Thermowell Material Code Thermowell Material
A Type 316 SST G Monel R Nickel 200
B Type 304 SST H Inconel 600 T Titanium
C Carbon Steel J Hastelloy C (304 SST Flange, if U(2) 316 SST with tantalum sheath
D 316L SST L Hastelloy B (304 SST Flange, if V 310 SST
E 304L SST M 304 SST with Teflon coating W 321 SST
F Alloy 20 P Chrome Molybdenum F22 Z Chrome Molybdenum F11
Code Length (U) in inches(1) Code Length (U) in inches(1) Code Length (U) in inches(1)
(2)
015 1.5 130 13.0 260 26.0
020 2.0 135 13.5 270 27.0
025 2.5 140 14.0 280 28.0
030 3.0 145 14.5 290 29.0
035 3.5 150 15.0 300 30.0
040 4.0 155 15.5 310 31.0
045 4.5 160 16.0 320 32.0
050 5.0 165 16.5 330 33.0
055 5.5 170 17.0 340 34.0
060 6.0 175 17.5 350 35.0
065 6.5 180 18.0 360 36.0
070 7.0 185 18.5 370 37.0
075 7.5 190 19.0 380 38.0
080 8.0 195 19.5 390 39.0
085 8.5 200 20.0 400 40.0
090 9.0 205 20.5 410 41.0
095 9.5 210 21.0 420 42.0
100 10.0 215 21.5 430 43.0
105 10.5 220 22.0 440 44.0
110 11.0 225 22.5 450 45.0
115 11.5 230 23.0 460 46.0
120 12.0 240 24.0 470 47.0
125 12.5 250 25.0 480 48.0
Code Thermowell Mounting Style Stem Style Tip A (in.) Root B (in.)
T24 Thread, 111.5 ANPT Stepped 0.50 0.88
T28 Thread, 111.5 ANPT Tapered 0.63 1.06
T30 Thread, 11/211.5 ANPT Tapered 0.75 1.50
T36 Thread, 111.5 ANPT Straight 0.75 0.75
W38 Weld, 3/4-in. pipe Stepped 0.50 0.75
W40 Weld, 1-in. pipe Stepped 0.50 0.88
W42 Weld, 3/4-in. pipe Tapered 0.63 0.88
W44 Weld, 1-inch Pipe, Tapered 0.75 1.00
W46 Weld, 11/4-inch Pipe Tapered 0.75 1.25
W48 Weld, 3/4-inch Pipe Straight 0.75 0.75
W50 Weld, 1-inch Pipe Straight 0.75 0.75
-56
Product Data Sheet
00813-0100-2654, Rev EA
Q04 Sanitary, 11/2-in., Tri-Clamp Stepped 0.50 0.75
Q06 Sanitary, 2-in., Tri-Clamp Stepped 0.50 0.75
Q26 Sanitary, 2-in., Tri-Clamp Straight 0.50 0.50
Thermowell Lagging Thermowell Lagging Thermowell Lagging
Code Length (T) in. Code Length (T) in. Code Length (T) in.
T000 0.0 T035 3.5 T070 7.0
T005 0.5 T040 4.0 T075 7.5
T010 1.0 T045 4.5 T080 8.0
T015 1.5 T050 5.0 T085 8.5
T020 2.0 T055 5.5 T090 9.0
T025 2.5 T060 6.0 T095 9.5
T030 3.0 T065 6.5
Code Instrument Connection Thread
P 1/214 NPSM
D 1/214 ANPT for CSA
-57
Product Data Sheet
00813-0100-2654, Rev EA

Thermowell Options
R01(5) Thermowell special external pressure testing
R14(8) Thermowell special surface finish (12 Ra Max) (Maximum (U) length = 22.5 in.)
R16(3)(6)(7) Ring joint flange (Not available with 0-in. (T) length)
(1) Thermowells with an overall lengths (U + T + 1.75-in.) of 42-in. or less are machined from solid bar stock. Thermowells with an overall length larger
than 42-in. will be constructed using a welded 3-piece design and are available only with a stepped stem style.
(2) Available in straight stem only
(3) Not available with 0-in. (T) length.
(4) Not available with 0- or 1/2-in. (T) length.
(5) Maximum (U) length = 42.0-in.
(8) Maximum (U) length = 22.5 inches.
Ordering Example
Typical Model Immersion Lagging
Number Model Material Length Mounting Style Length Connection Thread Additional Options
0091 A 030 F52 T040 P R01
R05
R07
-58
Product Data Sheet
00813-0100-2654, Rev EA
FIGURE 20. Thread Mounted Thermowells
Straight
Wrench and
Lagging Extension, Nom. Thread U
T
Allowance
1.75 (44)
Sensors-0010A
P Process
H 0.875 Mounting Thread
(22) Max.
L 0.25 (6)
Nominal

0.5 0.75 ANPT 1.125
111.5 ANPT 1.375
Tapered
Wrench and
Lagging Extension, Nom. T Thread
Allowance U
14 NPSM* 1.75 (44) Root Diameter B
A Tip Diameter
Sensors-0012A
P Process Inside Diameter 0.26 (7)
H 0.875
(22) Max. Mounting Thread
L 0.25 (6)
Nominal

0.5 0.75 ANPT 1.125
111.5 ANPT 1.375
-59
Product Data Sheet
00813-0100-2654, Rev EA
FIGURE 21. Thread Mounted Thermowells (continued)
Stepped
Wrench and
Thread
Lagging Extension, Nom. T Allowance U
1.75 (44)
14 NPSM* 2.5 (64)
B Root A Tip Diameter
Diameter
Sensors-0011A
H 0.875 P Process Mounting
(22) Max. Thread
L
0.25 (6)
Nominal
T 1.75 (44) U
14 NPSM*
2.5 (64)
Pipe
0.26 (7) Nominal
Sensors-0051A
H
Welds 0.25 (6)

0.5 0.75 ANPT 1.125
111.5 ANPT 1.375
-60
Product Data Sheet
00813-0100-2654, Rev EA
FIGURE 22. Weld Mounted Thermowells
Straight
1.75
T U
(44)
Sensors-0015A
0.875 (22) Max.

L 0.25 (6) Nominal

0.75-in. 1.050 0.010
1-in. 1.315 0.010
Tapered
T 1.75 U
(44)
Root Diameter B
Sensors-0017A
0.875 (22)
L 0.25 (6) Nominal

0.75-in. 1.050 0.010
1-in. 1.315 0.010
-61
Product Data Sheet
00813-0100-2654, Rev EA
FIGURE 23. Weld Mounted Thermowells (continued)
Stepped
1.75
T (44) U
14 A Tip Diameter
NPSM* 2.5 (64)
Sensors-0016B
0.875 (22) Max. B Root Diameter Inside Diameter 0.26 (7)
0.25 (6)
L Nominal
14 U
T 1.75 (44) 2.5 (64)

Pipe
0.26 (7) Nominal
Sensors-0052A
0.25 (6)
Welds
L

0.75-in. 1.050 0.010
1-in. 1.315 0.010
-62
Product Data Sheet
00813-0100-2654, Rev EA
FIGURE 24. Flange Mounted Thermowells
Straight
G 1.7
T U
5 Flange Mount
1.25 (32) Diameter
14 A Tip Diameter
NPSM*
Sensors-0013A
0.875
(22)
Max. H
E
Tapered
G
1.75
1.25 (32) Diameter T (44) U
14 Flange
NPSM* Mount A Tip Diameter

R Root Diameter
(22) Max.
Sensors-0047A
H
E
Class 150 Class 600

1.0 4.25 3.12 four-0.625 0.5625 1.0 4.88 3.5 four-0.75 0.94
1.5 5.0 3.88 four-0.625 0.6875 1.5 6.12 4.5 four-0.88 1.13
2.0 6.0 4.75 four-0.75 0.75 2.0 6.5 5.0 eight-0.75 1.25
3.0 7.5 6.00 four-0.75 0.94 Class 900 and 1500
Class 300 1.5 7.0 4.88 four-1.12 1.5
1.0 4.88 3.5 four-0.75 0.69 Class 2500
1.5 6.12 4.5 four-0.88 0.81 1.5 8.0 5.75 four-1.25 2.0
2.0 6.5 5.0 eight-0.75 0.88

-63
Product Data Sheet
00813-0100-2654, Rev EA
FIGURE 25. Flange Mounted Thermowells (continued)
Stepped
G 1.75
T (44) U
Flange
1.25 (32) Diameter 14 A Tip
Mount
NPSM* 2.5 Diameter
Sensors-0014A
R Root
(22) Max.
Diameter
H
F 0.25 (6) Nominal
L
E
1.75
T (44.5)
G
1.25 (32) Diameter
U
Flange
Weld Weld
14 Pipe 2.5 (64)
NPSM*
0.26 (7) Nominal

F 0.25 (7) Nominal
Welds
Sensors-0053A
E
Class 150 Class 600

1.0 4.25 3.12 four-0.625 0.5625 1.0 4.88 3.5 four-0.75 0.94
1.5 5.0 3.88 four-0.625 0.6875 1.5 6.12 4.5 four-0.88 1.13
2.0 6.0 4.75 four-0.75 0.75 2.0 6.5 5.0 eight-0.75 1.25
3.0 7.5 6.00 four-0.75 0.94 Class 900 and 1500
Class 300 1.5 7.0 4.88 four-1.12 1.5
1.0 4.88 3.5 four-0.75 0.69 Class 2500
1.5 6.12 4.5 four-0.88 0.81 1.5 8.0 5.75 four-1.25 2.0
2.0 6.5 5.0 eight-0.75 0.88

-64
Product Data Sheet
00813-0100-2654, Rev EA
Hazardous Area Approvals

SENSORS SENSOR AND TRANSMITTER
Factory Mutual (FM) Approval ASSEMBLIES
E5 Explosion Proof for Class I, Division 1, Groups B, C, and D. ATEX Approval
Dust-Ignition Proof for Class II/III, Division 1, Groups E, F, E1 ATEX Explosion- proof
and G. Suitable for indoor and outdoor (NEMA 4X)
Certificate Number: KEMA99ATEX8715
ATEX Marking: II 2 G
drawing 00068-0013. EEx d IIC T6 ( 40C Tamb +65C)
Rosemount Series 68 and 78 RTD and Series 183
Canadian Standards Association (CSA) Approval
thermocouple temperature sensors with spring-loaded or
E6 Explosion Proof for Class I, Division 1, Groups B, C, and D. general purpose style sensors are approved only for direct
Dust-Ignition Proof for Class II/III, Division 1, Groups E, F, mount to the Rosemount 3144P, 3244MV, 644, 244E, 144H,
and G. Suitable for Class I, Division 2, Groups A, B, C, and and 248 or mounted to the Rosemount Connection Head.
D. Suitable for indoor and outdoor (CSA Enclosure Type 4X)
To ensure approval compliance, specify the E1 option on
both the sensor and the transmitter at the time of ordering.
drawing 00068-0033.
To ensure approval compliance install sensors in exact
accordance with the specified installation drawings (see NOTE
Figure 27). Rosemount series 68 and 78 RTD and Series 183 Thermocouple
Temperature Sensors can be supplied as a replacement part with
the E1 option for installation in an existing temperature
CONNECTION HEADS measurement assembly.
Factory Mutual (FM) Approval
E5 Explosion Proof for Class I, Division 1, Groups B, C, and D.
Dust-Ignition Proof for Class II/III, Division 1, Groups E, F, Standard Association of Australia (SAA)
and G. Painted models are suitable for indoor and outdoor Flameproof Approval
(NEMA 4X) hazardous locations. Unpainted models are E7 Ex d IIC T6 (Tamb = 20 to 60 C)
suitable for indoor and outdoor (NEMA 4) hazardous Rosemount Series 68 and 78 RTD and Series 183
locations. When used with temperature sensors, connection thermocouple temperature sensors with spring-loaded or
heads must be installed in accordance with Rosemount general purpose style sensor adapters are approved for
drawing 00068-0013. direct mount to the Rosemount 144, 244E, 644, 3144 and
3244MV Smart Temperature Transmitters or mounted to the
Canadian Standards Association (CSA) Approval Rosemount Connection Head.
E6 Explosion Proof for Class I, Division 1, Groups C, and D. To ensure approval compliance, specify the E7 option on
Dust-Ignition Proof for Class both the sensor and the transmitter at the time of ordering,
II/III, Division 1, Groups E, F, and G. Suitable for Class I, and install in exact accordance with Rosemount drawing
Division 2, Groups A, B, C, and D. 03144-0225 (see Figure 30).
Painted models are suitable for indoor and outdoor (CSA
Enclosure Type 4X) hazardous locations. Unpainted models
are suitable for indoor and outdoor (CSA Enclosure Type 4)
hazardous locations. When used with temperature sensors,
connection heads must be installed in accordance with
Rosemount drawing 00068-0033.
To ensure approval compliance, install connection heads in
exact accordance with the specified installation drawings
(see Figure 27).
-65
Product Data Sheet
00813-0100-2654, Rev EA
Factory Mutual (FM) Explosion-Proof

FIGURE 26. Installation Drawing 00068-0013, Rev. AD
NOTE
drawing 00068-0013.
-66
Product Data Sheet
00813-0100-2654, Rev EA
Canadian Standards Association (CSA) Explosion-Proof

FIGURE 27. Installation Drawing 00068-0033, Rev. AB Page 1 of 2
NOTE
drawing 00068-0033.
-67
Product Data Sheet
00813-0100-2654, Rev EA
FIGURE 28. Installation Drawing 00068-0033, Rev. AB Page 2 of 2
-68
Product Data Sheet
00813-0100-2654, Rev EA
ATEX Flameproof
FIGURE 29. Installation Drawing 03144-0324, Rev. AB
-69
Product Data Sheet
00813-0100-2654, Rev EA
Standard Association of Australia (SAA) Flameproof

FIGURE 30. Drawing 03144-0225, Rev. A
-70
Product Data Sheet
00813-0100-2654, Rev EA
Configuration Data Sheet

Calculations conducted per ASME/ANSI PTC 19.3 but with Strouhal number varying with Reynolds number.
Company Information
Requesting Company: Phone: Fax:

Contact Tag Number
End Customer Date of Request:
Thermowell Information (Information for either (a), (b), or (c) required)
a) Rosemount Thermowell Part Number (example 0091A030FS2T040PR01):

b) Rosemount Sensor Model Number (example 0078R21C30A120F54):
c) Generic Thermowell Information:
Thermowell Material: Mounting Stem
Style Style
Stem Style: Straight U A
Stepped
Threaded Straight
Tapered
D
Mounting Threaded
Style: T
Welded
U
Flanged Z A
If flanged, ANSI/ASME Welded
SENSORS_0010B, 0016B, 0047B

Stepped
specify:
DIN D
B T
Size: Class:
Thermowell Bore Diameter (D):
U
Tip Diameter (A):
A
Tip Thickness (T):
Length from Tip to Support (U): Flanged Tapered

Root Diameter (B): D
B
(same as (A) for straight thermometers)
T
Length of Tip Diameter (Z):
(stepped thermowells only)
Service: Liquid Gas Steam Fluid Description:

Operating Fluid Flow Rate; Maximum:
Operating Fluid Flow Rate Units:
gal/s gal/min gal/hr l/s l/min l/hr ft/s
ft3/min ft3/hr bbl/hr impgal/s impgal/min impgal/hr m/s
m3/min m3/hr shton/hr lb/hr kg/s kg/hr other:
Operating Max. Fluid Pressure: Gauge
Absolute
Viscosity: kg/ms (Pas)
Centipoise
Operating Fluid Specific F Operating Fluid Density: m3/kg
Temperature: C ft3/lbm
Specific Volume: at process conditions
at standard conditions (STP)
Process Pipe Size:

Pipe Schedule:
For Rosemount Internal Use Only
Rosemount Order/Quotation # Line Item # Ship Set # ID #

Customer Order/Item # Salesperson:
Cont. Admin. Tech. Specialist:
-71
Product Data Sheet
00813-0100-2654, Rev EA
Teflon is a registered trademark of E.I. du Pont de Nemours & Co.
Hastelloy is a registered trademark of Haynes International.
Monel and Inconel is a registered trademark of International Nickel Co.
All other marks are the property of their respective owners.
Emerson Process Management
Rosemount Inc. Emerson Process Management Emerson Process Management Asia

8200 Market Boulevard Temperature GmbH Pacific Private Limited
Chanhassen, MN 55317 USA Frankenstrasse 21 1 Pandan Crescent
T (U.S.) 1-800-999-9307 63791 Karlstein Singapore 128461
T (International) (952) 906-8888 Germany T (65) 6777 8211
F (952) 949-7001 T 49 (6188) 992 0 F (65) 6777 0947
F 49 (6188) 992 112 AP.RMT-Specialist@emersonprocess.com
www.rosemount.com
00813-0100-2654}
2004 Rosemount Inc. All rights reserved.
Double & Single Engagement Gear Couplings Installation and Maintenance
a good name in industry Sizes 1010 thru 1070G & GP & Sizes 1 thru 7GF (Page 1 of 8)
How To Use This Manual Type G/GP/GF20 Type G/GF32 Type G/GP/GF52
This manual provides detailed instructions on installation,
maintenance, and parts identification for Falk Lifelign gear
couplings, Types G & GF10, 20, 31, 32, 51, 52, & GP20 & GP52.
Use the table of contents below to locate required information.
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
1000G Series Pictured
Lube Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
Limited End Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1 highly recommended.
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 1-2 Gear couplings initially lubricated with Falk Long Term Grease
Balanced Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3 (LTG) will not require re-lubrication for up to three years.
Bi-Annual & Annual Maintenance . . . . . . . . . . . . . . . . Page 3 The use of general purpose grease requires re-lubrication of the
Installation & Alignment Instructions . . . . . . . . . Pages 3-6 & 7 coupling at least once every six months. If coupling leaks
Installation & Alignment Data . . . . . . . . . . . . . . . . . . . Page 6 grease, is exposed to extreme temperatures, excessive moisture,
Parts Identification & Parts Interchangeability. . . . . . . Page 7-8 experiences frequent reversals or axial movements; more
frequent lubrication may be required.
CAREFULLY FOLLOW THE INSTRUCTIONS IN THIS
MANUAL FOR OPTIMUM PERFORMANCE AND USDA Approval
TROUBLE FREE SERVICE. LTG has the United States Department of Agriculture Food
Safety & Inspection Service approval for applications where
INTRODUCTION there is no possibility of contact with edible products.
This manual applies to standard coupling Types G & GF10, 31 (H-2 ratings.)
and 51 with shrouded bolts, and G & GF20, 32, 52, and GP20 &
GP52 with exposed bolts. For couplings furnished with special Long Term Grease (LTG)
features, refer to assembly drawing furnished with coupling for The high centrifugal forces encountered in couplings separate
proper assembly arrangement and any additional installation or the base oil and thickener of general purpose greases. Heavy
maintenance requirements. Refer to the specific manuals for GV thickener, which has no lubrication qualities, accumulates in the
vertical gear couplings installation and maintenance. tooth mesh area of gear couplings resulting in premature mesh
IMPORTANT: Use G/GF51 & 52 couplings for floating shaft failure unless periodic lubrication cycles are maintained.
assemblies or as the fourth bearing in three bearing systems. Falk Long Term Grease (LTG) was developed specifically for
When gear couplings are mounted on a horizontal floating couplings. It resists separation of the oil and thickener. The
shaft, use a gap disc in each coupling. Where limited end float consistency of Falk LTG changes with operating conditions. As
is required or where sleeve bearing motors are used, consult manufactured, it is an NLGI #1/2 grade. Working of the
Falk. Type GP52 couplings are recommended for horizontal lubricant under actual service conditions causes it to become
application only. Refer Type GP52 floating shaft applications to semifluid, while the grease near the seals will set to a heavier
Falk. grade, helping to prevent leakage.
CAUTION: Consult applicable local and national safety codes LTG is highly resistant to separation, easily out performing all
for proper guarding of rotating members. Observe all safety other lubricants tested. The resistance to separation allows the
rules when installing or servicing couplings. lubricant to be used for relatively long periods of time.
WARNING: Lockout starting switch of prime mover and remove all Although LTG grease is compatible with most other coupling
external loads from drive before installing or servicing couplings. greases, the mixing of greases may dilute the benefits of LTG.
CAUTION: Do not use LTG in bearings. Do not use LTG for low
LUBE FITTINGS speed applications. Refer to Table 4, Page 6 for coupling speed
Sleeves have 18 NPT lube holes for sizes 1010G20 - 1035G20, range of LTG grease.
1GF20 - 7GF20, 1025G10 - 1035G10, and 2 12 GF10 - 5 12
GF10. (Sizes 1010G10 - 1020G10 and 1GF10 - 2GF10 use Packaging
1 -28 SAE LT automotive plugs and fittings.) Sizes 1040G thru
4
14 oz. (0,4 Kg) CARTRIDGES Individual or case lots of 10
1070G have 14 NPT holes. Use a standard grease gun and or 60.
lube fittings.
35 lb. (16 Kg) PAILS, 120 lb. (54 Kg) KEG & 400 lb. DRUMS.
LIMITED END FLOAT Specifications Falk LTG (Long Term Grease)
Where limited end float is required or where sleeve bearing
motors are used, consult Falk. TEMPERATURE RANGE 20F (29C) to 250F (121C).
Minimum pump = 20F (7C).
LUBRICATION MINIMUM BASE OIL VISCOSITY 3300SSU (715cSt) @
Adequate lubrication is essential for satisfactory operation. 100F (38C).
Because of its superior lubricating characteristics and low THICKENER Lithium soap/polymer.
centrifuge properties, Falk Long Term Grease (LTG) is
The Falk Corporation, P.O. Box 492, Zip 53201-0492 458-110

3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131 June 2002
Fax: 414-937-4359 e-mail: falkinfo@falkcorp.com web: www.falkcorp.com Supersedes 4-00
Installation and Maintenance Double & Single Engagement Gear Couplings
(Page 2 of 8) Sizes 1010 thru 1070G & GP & Sizes 1 thru 7GF a good name in industry
CENTRIFUGE SEPARATION CHARACTERISTICS ASTM For temperatures beyond this range, consult Falk. The minimum
#D442584 (Centrifuge Test) K36 = 2/24 max., very high operating temperature must not be lower than the pour point of
resistance to centrifuging. the oil. The specified amount of grease listed in Table 4, Page
NLGI GRADE (ASTM D-217) 1/2 6, is in pounds and also applies to the volume of oil in pints.
CONSISTENCY (ASTM D-217) 60 stroke worked Specifications
penetration value in the range of 315 to 360 measured @
Type: Mild EP gear oil that meets AGMA
77F (25C). Specifications 250.04.
DROPPING POINT 350F (177C) minimum. Grade: AGMA #8EP (ISO VG 680).
MINIMUM TIMKEN EP O.K. LOAD 40 lb. (18 kg). Viscosity: 612-748 cSt @ 104F (40C).
ADDITIVES Rust and oxidation inhibitors that do not corrode Pour Point: 20F (7C) Maximum.
steel or swell or deteriorate synthetic seals. Must not corrode steel or swell or deteriorate synthetic seals.
General Purpose Grease TABLE 1 NLGI #1 Grease

Bi-annual Lubrication The following specifications and Manufacturer Lubricant H
lubricants for general purpose grease apply to Falk gear couplings
Amoco Oil Co. Rykon Grease #1 EP
that are lubricated bi-annually and operate within ambient BP Oil Co. Energrease LS-EP1
temperatures of 30F (34C) to 200F (93C). For temperatures Chevron U.S.A., Inc. Dura-Lith EP1
beyond this range, consult Falk. For normal service, use a NLGI Citgo Petroleum Corp Premium Lithium Grease EP1
Conoco Inc. EP Conolith Grease #1
#1 extreme pressure (EP) grease EXCEPT when the coupling speed
Exxon Company, U.S.A.. Lidok EP1
is less than the minimum specified in Table 4, Page 6. At these Imperial Oil Ltd. Ronex EP1
lower speeds, use a NLGI #0 extreme pressure (EP) grease. When Kendall Refining Co. Lithium Grease L-416
one or more gear couplings in an application require NLGI #0 Keystone Div., Pennwalt Corp. Zeniplex-1
Lyondell Lubricants Litholine Complex EP1
grease, the same grease may be used in all of the couplings. DO
Mobil Oil Corp.. Mobilux EP1
NOT use cup grease. Petro-Canada Products Multipurpose EP1
If coupling leaks grease, is exposed to extreme temperatures, Phillips 66 Co. Philube Blue EP
Shell Oil Co. Alvania EP Grease 1
excessive moisture or experiences frequent reversals or axial Shell Canada Ltd. Alvania Grease EP1
movements; more frequent lubrication may be required. Sun Oil Co. Sun Prestige 741 EP
Texaco Lubricants Multifak EP1
Lubricants listed in Tables 1, 2 & 3 are typical products only and Unocal 76 (East & West) Unoba EP1
should not be construed as exclusive recommendations.
Specifications General Purpose

Coupling Lubricants TABLE 2 NLGI #0 EP Grease
COUPLING SPEED RANGE See Table 4, Page 6. Manufacturer Lubricant H
TEMPERATURE RANGE 30F to +200F(34C to +93C) Amoco Oil Co. Rykon Premium Grease 0 EP
BP Oil Co. Energrease LS-EP 0
WORKED PENETRATION AT 77F(25C) Chevron U.S.A., Inc. Dura-Lith EP 0
NLGI #1 . . . . . . . . 310-340 (See Table 1) Citgo Petroleum Corp Premium Lithium Grease EP 0
Conoco Inc. EP Conolith Grease #0
NLGI #0 . . . . . . . . 355-385 (See Table 2)
Imperial Oil Ltd. Unirex EP0
DROPPING POINT 300F(149C) or higher Exxon Company, U.S.A.. Lidok EP 0
Kendall Refining Co. Lithium Grease L-406
TEXTURE Smooth or fibrous Keystone Div., Pennwalt Corp. Zeniplex-0
Mobil Oil Corp.. Mobilux EP 0
MINIMUM TIMKEN O.K. LOAD 30 lb.
Petro-Canada Products Multipurpose Lotemp EP Grease
SEPARATION AND RESISTANCE Low oil separation rate and Phillips 66 Co. Philube Blue EP
high resistance to separation from centrifuging. Shell Oil Co. Alvania EP Grease RO
Shell Canada Ltd. Alvania Grease EPW
LIQUID CONSTITUENT Possess good lubricating Sun Oil Co. Sun Prestige 740 EP
properties . . . equivalent to a high quality, well refined Texaco Lubricants Multifak EP 0
petroleum oil with EP additives. Unocal 76 (East & West) Unoba EP 0
INACTIVE Must not corrode steel or cause swelling or

TABLE 3 Oil Lubricants
deterioration of synthetic seals.
Manufacturer Lubricant H
Oil Lubrication Amoco Permagear EP 160
EP oils may be a more effective lubricant than grease when the Chevron, U.S.A. NL Gear Compound 680
Exxon Co., U.S.A. Spartan EP680
required coupling speed is one half of the minimum speed Gulf Oil Co. EP Lubricant HD 680
range of NLGI #1 grease listed in Table 4, Page 6 (Minimum Mobil Oil Co. Mobilgear 636
rpm 2). Oil lubricated couplings must be sealed to prevent Shell Oil Co. Omala Oil 680
leakage, i.e. keyways, etc. Couplings must be drained and Texaco Inc. Meropa 680
Union Oil Co. of Calif. Extra Duty NL Gear Lube 8EP
refilled with new oil every six months for operating temperatures
H Lubricants listed may not be suitable for use in the food processing industry;
up to 160F (71C) and every three months for couplings check with lube manufacturer for approved lubricants.
operating at temperatures of 160F (71C) up to 200F (93C).
458-110 The Falk Corporation, P.O. Box 492, Zip 53201-0492

June 2002 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131
Supersedes 4-00 Fax: 414-937-4359 e-mail: falkinfo@falkcorp.com web: www.falkcorp.com
HORIZONTAL COUPLING INSTALLATION, ANNUAL MAINTENANCE

ALL TYPES For extreme or unusual operating conditions, check coupling
Only standard mechanics tools, torque wrenches, inside more frequently.
micrometer, dial indicator, straight edge, spacer bar, and feeler 1. Check alignment per Step 7, Page 7. If the maximum
gauges are required to install Falk gear couplings. Clean all operating misalignment values are exceeded, realign the
parts using a non-flammable solvent. Check hubs, shafts, and coupling to the recommended installation values. See Table
keyways for burrs. DO NOT heat clearance fit hubs. Use a 4, for installation and maximum operating misalignment
lubricant that meets the specifications on Page 2. Pack sleeve values.
teeth with grease and lightly coat seals with grease BEFORE 2. Check tightening torques of all fasteners.
assembly. The required amount of grease is listed in Table 4. 3. Inspect seal ring and gasket to determine if replacement
Make certain flange fasteners are tightened to the required is required.
torque listed in Table 4. 4. Re-lubricate coupling if using general purpose grease.
Interference Fit Hubs Unless otherwise specified, Falk gear
couplings are furnished for an interference fit without setscrews. NOTE: Longer
Heat hubs to 275F(135C) using an oven, torch, induction shank toward
gap end.
heater, or an oil bath.
CAUTION: To prevent seal damage DO NOT heat hubs
beyond a maximum temperature of 400F (205C) for Type G
and 500F (260C) for Type GF.
When an oxy-acetylene or blow torch is used, use an excess
acetylene mixture. Mark hubs near the center of their length in NOTE:
FLEX HUB Flush here. RIGID HUB
several places on hub body with a temperature sensitive crayon,
275F (135C) melt temperature. Direct flame towards hub
bore using constant motion to avoid overheating an area. ALL TYPES G/GF/GP HORIZONTAL
WARNING: If an oil bath is used, the oil must have a flash COUPLING INSTALLATION
point of 350F (177C) or higher. Do not rest hubs on the 1 Mount Flanged Sleeves, Seals & Hubs
bottom of the container. Do not use an open flame in a
Place the flanged sleeves WITH seal rings on shafts BEFORE
combustible atmosphere or near combustible materials.
mounting flex hubs. Mount flex or rigid hubs on their respective
shafts, as shown above, so that each face is flush with the end
Maximize Performance & Life of its shaft. Allow hubs to cool before proceeding. Seal keyways
The performance and life of couplings depend largely upon to prevent leakage. Insert setscrews (if required) and tighten.
how you install and maintain them. Before installing couplings, Position equipment in approximate alignment with approximate
make certain that foundations of equipment to be connected hub gap.
meet manufacturers requirements. Check for soft foot. The use
of stainless steel shims is recommended. Measuring For Type G/GF10 & 20 and GP20, position equipment in
misalignment and positioning equipment within alignment approximate alignment with gap equal to that given in Table 4.
tolerances is simplified with an alignment computer. These For Type G/GF31 & 32 spacer and G/GF/GP51 & 52 floating
calculations can also be done graphically or mathematically, shaft, with rigid hubs on floating shaft, position equipment in
and allow the incorporation of cold offsets, which will approximate alignment with approximate distance between
compensate for shaft position changes due to thermal growth. shafts per Step 4A, Figure 2 on Page 5.
For G/GF/GP51 & 52 with flex hubs on the floating shaft, refer
Balanced Couplings to Step 4A, Figure 1 on Page 5, to determine distance
The fasteners provided are matched sets and must not be mixed between shafts.
or substituted. Assembly balanced
couplings are match marked and
must be assembled with mating
match marks aligned. In some sizes,
the flanges are not match marked. A1 A1 A1 A1 B1 B1
Coupling flanges must be assembled

with O.D.s aligned to within .002"
(0,05 mm). Component parts of
assembly balanced couplings must
not be replaced without re-balancing the complete assembly.
BI-ANNUAL MAINTENANCE
Re-lubricate coupling if using general purpose grease. If
coupling leaks grease, is exposed to extreme temperatures,
excessive moisture or frequent reversals; more frequent
lubrication may be required.

2 Gap & Angular Alignment for Close 3 Offset Alignment for Close Coupled,
Coupled, Spacer, Short Floating Shaft, and Spacer, Short Floating Shaft, and Insulated
Insulated Couplings Couplings
ALWAYS MEASURE
TO SAME DEPTH
GAP
2A Type G/GF10 & 20 & GP20 3A Type G/GF10 & 20 & GP20
Use a spacer bar equal in thickness to gap specified in Table 4. Align so that a straight edge rests squarely on both hubs as
Insert bar, as shown above, to same depth at 90 intervals and shown above and also at 90 intervals. Check with feelers. The
measure clearance between bar and hub face with feelers. The clearance should not exceed the INSTALLATION OFFSET limit
difference in minimum and maximum measurements must not specified in Table 4. Tighten foundation bolts and repeat Steps
exceed the INSTALLATION ANGULAR limit specified in Table 4. 2A and 3A. Realign coupling if necessary. Use a dial indicator if
hub extension is too short for accurate use of a straight edge.
2B G/GF31 & 32 (Spacer), and Type G/GF51

& 52 (Short Floating Shaft, See Step 4 for Long
Floating Shaft) 3B Type G/GF31 & 32 (Spacer), and Type
Use an inside micrometer as shown above and at 90 intervals
G/GF51 & 52 (Short Floating Shaft, See Step 4
to measure the distance between hubs. The difference in for Long Floating Shaft)
minimum and maximum measurements should not exceed the Align so that a straight edge rests squarely (or within the limits
INSTALLATION ANGULAR limit specified in Table 4. specified in Table 4) on both hubs as shown above and also at
90 intervals. Check with feelers. The clearance should not
exceed the INSTALLATION OFFSET limit specified. Tighten all
foundation bolts and repeat Steps 2B and 3B. Realign coupling
if necessary.
GAP
RIGID HUB
2C G/GF51 & 52 & GP52 (As Fourth Bearing RIGID HUB

in Three Bearing System)
Use a spacer bar equal in thickness to the X dimension
3C Type G/GF51 & 52 & GP52 (As Fourth
specified in Table 4. Insert bar, as shown above to same depth Bearing in Three Bearing System)
at 90 intervals and measure clearance between bar and hub Clamp a dial indicator to the rigid hub as shown and rotate the
face with feelers. The difference in minimum and maximum rigid hub one complete turn. The total indicator reading DIVIDED
measurements must not exceed the INSTALLATION ANGULAR by two must not exceed the INSTALLATION OFFSET limit
limit specified in Table 4. specified in Table 4. Tighten all foundation bolts and repeat

specified in Table 4. Tighten all foundation bolts and repeat ANGULAR limit specified in Table 4.
Steps 2C and 3C. Realign coupling if necessary.
4B2 Refer to Figure 3
GAP DISCS
Align coupling & floating shaft so that, with the square head (or
(BOTH ENDS) depth micrometer) resting squarely on the flange, equal
clearance measurements are obtained between flange and the
hub O.D. in four places 90 apart. The difference between
GAP GAP minimum and maximum feeler readings should not exceed the
X X
INSTALLATION OFFSET limit in Table 4 divided by 2. The above
measurement is TIR.
4C Position Second Drive

RIGID DISTANCE BETWEEN RIGID HUB FLANGE RIGID
HUB FACES EQUALS SHAFT LENGTH PLUS 2 "X" HUB Position second drive for the correct X dimension and align
per Steps 4B1 & 4B2. DO NOT move the floating shaft. Bolt
Figure 1 drive in place and recheck alignment and gap. Realign if
4 Type G/GF/GP51 & 52 With Long Floating Shaft necessary. For greater accuracy, check alignment with a depth
micrometer or dial indicator.
4A Determine Distance Between Shafts
For Figure 1 above, measure the length of the floating shaft
GAP DISCS
RIGID HUBS OR SPACER (BOTH ENDS)
GAP GAP
X X
DISTANCE BETWEEN SHAFTS EQUALS

Figure 2 DISTANCE BETWEEN FLANGE FACES PLUS 2 "X"
5 Assemble Coupling G and GF Only
Insert gasket between flanges and gap disc into counterbore of
and add 2 times the gap dimension from Table 4 to get the each rigid hub for floating shaft assemblies and bolt flanges
distance between the shafts to be coupled. together. Use only the fasteners furnished with the coupling.
For Figure 2 above, measure the overall floating shaft or spacer IMPORTANT: Tighten fasteners to torque specified in Table 4.
assembly length from flange to flange and add 2 times the X
5A Assemble Coupling Insert Insulator
dimension from Table 4 to get the distance between the shafts
to be coupled. Parts and Join Flanged Sleeves (GP20 & GP52)
Clean flange faces and coat with Permatex #2 or equivalent.
4B Position First Drive & Floating Shaft DO NOT install gaskets. Insert insulator bushings into flanged
Set the drive most difficult to move to true level and bolt it in holes. Draw one sleeve onto hub and position insulator center
place. Set the floating shaft on V-blocks. Then align coupling on plate on flange face. Draw other sleeve onto hub and assemble
fasteners with insulator washers. Use only fasteners furnished
USE
FEELERS FLEX HUB with coupling. IMPORTANT: Tighten fasteners to torque
(ANGULAR) GASKET specified in Table 4.
RIGID HUB
SLEEVE
X
GAP
USE
FEELERS
(OFFSET)
Figure 3
fixed drive as follows: 6 Lubricate

Remove all grease plugs and fill with recommended grease until
4B1 Refer to Figure 3 an excess appears at an open hole; then insert plug. Continue
Use a spacer bar equal in thickness to the X dimension procedure until all plugs have been inserted. CAUTION:
specified in Table 4. Insert the bar to the same depth at 90 Remove grease fitting and make certain all plugs are inserted
intervals and measure the clearance between the bar and hub after lubricating.
face with feelers as shown. The difference in minimum and
maximum measurements should not exceed the INSTALLATION

TABLE 4 Installation & Alignment Data For Types G/GF10, 20, 31, 32, 51, 52 & GP20 & GP52
H Dimensions Inches (Metric mm)
1010G 1015G 1020G 1025G 1030G 1035G 1040G 1045G 1050G 1055G 1060G 1070G
COUPLING SIZE
1GF 1-GF 2GF 2-GF 3GF 3-GF 4GF 4-GF 5GF 5-GF 6GF 7GF
G/GF10 & 20 .125 .125 .125 .188 .188 .250 .250 .312 .312 .312 .312 .375
(3) (3) (3) (5) (5) (6) (6) (8) (8) (8) (8) (10)
GP20 .325 .325 .385 .385 .450 .450 .450 .450 .510
... ... ...
(8) (8) (10) (10) (11) (11) (11) (11) (13)
Gap
G/GF51 & 52 .156 .156 .156 .188 .188 .218 .281 .312 .344 .344 .406 .500
(4) (4) (4) (5) (5) (6) (7) (8) (9) (9) (10) (13)
GP52 .325 .325 .350 .420 .450 .480 .480 .540 .635
... ... ...
(8) (8) (9) (11) (11) (12) (12) (14) (16)
G/GF51 & 52 .056 .056 .056 .088 .088 .118 .121 .152 .144 .144 .146 .170
(1) (1) (1) (2) (2) (3) (3) (4) (4) (4) (4) (4)
X Dimension
GP52 .215 .215 .245 .246 .280 .270 .270 .270 .295
... ... ...
(5) (5) (6) (6) (7) (7) (7) (7) (8)
G/GF10, 20, 31, 32, 51 & 52 .006 .007 .009 .011 .013 .015 .018 .020 .022 .024 .026 .031
Angular
& GP20 & GP52 (0,15) (0,19) (0,23) (0,28) (0,33) (0,39) (0,46) (0,51) (0,55) (0,61) (0,66) (0,78)
G/GF10 & 20 & GP20 Offset .002 .003 .003 .004 .005 .006 .007 .008 .009 .010 .011 .013
Installation (0,05) (0,07) (0,8) (0,10) (0,13) (0,15) (0,18) (0,20) (0,23) (0,26) (0,28) (0,33)
Limits .001 .001 .001 .002 .002 .002 .003 .003 .003 .003 .004 .005
G/GF51 & 52 & GP52 Offset
(0,03) (0,03) (0,03) (0,04) (0,05) (0,05) (0,06) (0,08) (0,08) (0,08) (0,10) (0,11)
G/GF31 & 32 Offset .006 .006 .007 .008 .009 .011 .012 .013 .015 .016 .017 .017
(0,14) (0,16) (0,17) (0,20) (0,23) (0,28) (0,30) (0,32) (0,38) (0,41) (0,43) (0,44)
Installation Check All Types .006 .007 .009 .011 .013 .015 .018 .020 .022 .024 .026 .031
(0,15) (0,19) (0,23) (0,28) (0,33) (0,39) (0,46) (0,51) (0,55) (0,61) (0,66) (0,78)
W
Operating Limit Check All Types .035 .045 .054 .067 .079 .092 .108 .121 .131 .144 .157 .183
(0,90) (1,13) (1,38) (1,71) (2,00) (2,33) (2,74) (3,08) (3,33) (3,66) (3,99) (4,66)
G10, 20, NLGI #0 Grease-Max. 7000 6000 5000 4750 4400 3900 3600 3200 2900 2650 2450 2150
51, 52 &
GP20 & Falk LTG or Min. 1030 700 550 460 380 330 290 250 230 210 190 160
Coupling NLGl #1 Grease
Speed GP52 Allow. 8000 6500 5600 5000 4400 3900 3600 3200 2900 2650 2450 2150
Range NLGI #0 Grease-Max. 7000 5500 4600 4000 3600 3100 2800 2600 2400 2200 2100 1800
(rpm)
G31 & 32 Falk LTG or Min. 1030 700 550 460 380 330 290 250 230 210 190 160
NLGl #1 Grease Allow. 7000 5500 4600 4000 3600 3100 2800 2600 2400 2200 2100 1800
G10 & 20 .09 .16 .25 .50 .80 1.20 2.00 2.30 3.90 4.90 7.00 9.60
(0,041) (0,073) (0,11) (0,23) (0,36) (0,54) (0,91) (1,0) (1,8) (2,2) (3,2) (4,4)
G51 & 52 .05 .09 .15 .26 .40 .60 1.03 1.25 2.00 2.50 3.75 5.00
(0,023) (0,041) (0,068) (0,12) (0,18) (0,27) (0,47) (0,57) (0,91) (1,1) (1,7) (2,3)
G31 & 32 per in. Spacer Length .03 .06 .06 .12 .20 .20 .20 .20 .20 .20
.... ....
(0,014) (0,027) (0,027) (0,054) (0,091) (0,091) (0,091) (0,091) (0,091) (0,091)
G31 & 32 Less Spacer .09 .16 .25 .50 .80 1.20 2.00 2.30 3.90 4.90 7.00 9.60
(0,041) (0,073) (0,11) (0,23) (0,36) (0,54) (0,91) (1,0) (1,8) (2,2) (3,2) (4,4)
GF10 & 20 .09 .15 .27 .47 .74 .88 1.48 2.62 2.87 4.44 4.95 6.79
Grease - (0,039) (0,068) (0,12) (0,21) (0,33) (0,40) (0,67) (1,2) (1,3) (2,0) (2,2) (3,1)
pounds
(kg) GP20 .50 .80 1.20 2.00 2.30 3.90 4.90 7.00 9.60
... ... ...
(0,227) (0,363) (0,544) (0,907) (1,04) (1,77) (2.22) (3,18) (4,35)
GF51 & 52 .06 .09 .15 .27 .41 .50 .87 1.46 1.66 2.47 2.93 4.27
(0,025) (0,042) (0,070) (0,12) (0,19) (0,23) (0,40) (0,66) (0,75) (1,1) (1,3) (1,9)
GP52 .26 .40 .60 1.03 1.25 2.00 2.50 3.75 5.00
... ... ...
(0,118) (0,181) (0,272) (0,467) (0,567) (0,907) (1,13) (1,70) (2,27)
GF31 & 32 per in. Spacer Length .06 .07 .07 .08 .02 .16 .21 .12 .13 .14 .71 .91
(0,027) (0,032 (0,032 (0,037) (0,009) (0,072) (0,095) (0,053) (0,059) (0,065) (0,322) (0,413)
GF31 & 32 Less Spacer .09 .15 .27 .47 .74 .88 1.48 2.62 2.87 4.44 4.95 6.97
(0,039) (0,068) (0,12) (0,21) (0,33) (0,40) (0,67) (10,2) (1,3) (2,0) (2,2) (3,2)
G/GF10, 31 & 51 108 372 372 900 900 1800 1800 1800 3000 3000
.... ....
(12) (42) (42) (102) (102) (203) (203) (203) (339) (339)
Flange Bolt Torque - 108 372 900 1800 1800 3000 3000 3000 3000 3000 3000 3000
G/GF20, 32 & 52
lb-in. (Nm) (12) (42) (102) (203) (203) (339) (339) (339) (339) (339) (339) (339)
GP20 & GP52 420 420 840 840 840 1440 1440 1440 1800
... ... ...
(47,5) 47.5) (94,9) (94,9) (94,9) (162,7) (162,7) (162,7) (203,4)
H Refer to Selection Guide for maximum bores and Manual 427-108 for reboring instructions.
Flexible couplings are designed to accommodate changes in operating conditions. Coupling life expectancy between initial alignment and maximum operating limits is a
function of load, speed and lubrication. Application requirements in excess of 3/4 misalignment per flex half coupling should be referred to Falk for review.
Couplings with NLGI #0 grease may be operated at any speed between zero and the maximum shown.

"W" = Wmax. Wmin. 7 Assembled Coupling Alignment Check

Wmax. All Styles
The alignment can be checked without disassembling the
coupling as shown at left. Determine W by measuring
distances Wmax. and Wmin. between flex hub and sleeve
using a depth micrometer or feeler gauges. The difference
between Wmax. and Wmin. must not exceed the W
Wmin. value given in Table 4. Check W at each coupling end.
Check "W" at each flexible hub.
PARTS IDENTIFICATION AND PART EXAMPLE:

NUMBER LOCATION Complete 1050G20 Gear Coupling
Coupling parts have identifying size and part numbers as Consisting of:
2 1050G20 Sleeves
illustrated below. When ordering parts, always SPECIFY SIZE,
(Includes: Gasket & Seal)
TYPE, HUB BORE, KEYWAY, and PART NUMBER found on
2 1050G Flex Hubs
each item. Bore: 6.750 Keyway: 1.750 x .750
Contact your Falk Distributor or Falk for price Bore: 7.375 Keyway: 1.750 x .750
and availability. 1 Fastener Set
TYPE G/GF10 & 20 1015 G 20

1-1/2 GF 20
COUPLING TYPE
LUBE SIZE PRODUCT
PLUG CLASSIFICATION
SLEEVE FLEX HUB SLEEVE
FLEX HUB
(SPECIFY BORE (SPECIFY BORE
& KEYWAY) & KEYWAY)
LUB E
L UB E FAL K 1015G 20
F AL K 1015G 20
F AL
K 10
5G 23730 744671
15G 2.370744671
101
LK
FA
SEAL RING
LUBE
SIZE, BORE & PLUG
SEAL RING PART NUMBER
GASKET (EITHER LOCATION)
FASTENERS
TYPE G/GF31 & 32

1015 G 32
1-1/2 G 32
COUPLING TYPE
LUBE SIZE PRODUCT
PLUG CLASSIFICATION
FLEX HUB
& KEYWAY) & KEYWAY)
L UB E F
F AL
AL K 1015G 20
K 10
5G 23730 744671
15G 2.370744671
101
LK
FA
SEAL RING
LUBE
SEAL RING SIZE, BORE & PLUG
SPACER GASKET PART NUMBER
GASKET (EITHER LOCATION)
(SPECIFY
LENGTH)
FASTENERS
FASTENERS

TYPE G/GF51 & 52

1015 G 52
1-1/2 G 52
COUPLING TYPE
LUBE SIZE PRODUCT
PLUG CLASSIFICATION
SLEEVE FLOATING SHAFT SLEEVE
FLEX HUB GAP (SPECIFY DIAMETER FLEX HUB
(SPECIFY BORE DISC & LENGTH) GAP (SPECIFY BORE
& KEYWAY) DISC & KEYWAY)
L UB E
F AL K 1015G20
F AL
K 10
5G 23730 744671
15G 2.370744671
101
LK
FA
SEAL
SIZE, BORE & LUBE RING
SEAL RIGID HUB PLUG
RING GASKET RIGID HUB GASKET PART NUMBER
(SPECIFY BORE (SPECIFY BORE (EITHER LOCATION)
& KEYWAY) & KEYWAY)
FASTENERS
FASTENERS
TYPE GP20
1015 GP 20
COUPLING TYPE
LUBE SIZE PRODUCT
PLUG CLASSIFICATION
FLEX HUB
& KEYWAY) & KEYWAY)
LUB E
F AL K 1015G 20
F AL
K 10
5G 23730 744671
15G 2.370744671
101
LK
FA
SEAL RING
LUBE
INSULATOR SIZE, BORE & PLUG
SEAL RING WASHERS PART NUMBER
INSULATOR (EITHER LOCATION)
CENTER PLATE
FASTENERS
INSULATOR
BUSHINGS
TYPE GP52
1015 GP 52
COUPLING TYPE
LUBE SIZE
PLUG PRODUCT
CLASSIFICATION
SLEEVE FLEX HUB GAP
(SPECIFY BORE DISC
& KEYWAY)
L UB E
F AL K 1015GL 20
FALK
5G 23730 744671
1015G GA P E ND
101
LK
FA
SEAL INSULATOR
RING INSULATOR RIGID HUB
WASHERS CENTER PLATE (SPECIFY BORE
& KEYWAY)
FASTENERS
INSULATOR
BUSHINGS

Acoplamientos de engranaje de engrane doble y simple Instalacin y mantenimiento
a good name in industry Tamaos 1010 al 1070G y tamaos 1 al 7GF (Pgina 1 de 7)
Cmo usar este manual

Este manual proporciona las instrucciones en detalle para la Tipo G/GF20 Tipo G/GF32 Tipo G/GF52
instalacin, mantenimiento e identificacin de piezas de los
acoplamientos de engranaje Lifelign de Falk, tipos G y GF10, 20,
31, 32, 51 y 52. Para ubicar la informacin requerida, usar la tabla de
materias siguiente.
Tabla de materias
Introduccin Pgina 1
Graseras Pgina 1
Lubricacin Pginas 1-2 Serie 1000G
Acoplamientos equilibrados Pgina 3
Instrucciones de instalacin y alineacin Pginas 3-6
Mantenimiento anual Pgina 3
Datos de instalacin y alineacin Pgina 6 Aprobacin del USDA
Identificacin e intercambiabilidad de piezas Pgina 7 La LTG tiene la aprobacin del Servicio de Seguridad e Inspeccin de
Alimentos del Departamento de Agricultura de EE.UU. para las
PARA OBTENER OPTIMO RENDIMIENTO Y UN SERVICIO SIN aplicaciones donde no existe ninguna posibilidad de contacto con
PROBLEMAS, SEGUIR CUIDADOSAMENTE LAS INSTRUCCIONES productos comestibles (clasificacin H-2).Long Term Grease (LTG)
DADAS EN ESTE MANUAL.
Grasa de larga duracin (LTG)
INTRODUCCION Las grandes fuerzas centrfugas encontradas en los acoplamientos
Este manual se refiere a los acoplamientos estndar tipos G y GF10, separan el aceite base y el espesador de las grasas universales. El
31 y 51 con pernos cubiertos y G y GF20, 32 y 52 con pernos espesador viscoso, que no tiene ninguna cualidad lubricante, se
expuestos. Para los acoplamientos que incorporan caractersticas acumula en el rea de los dientes de los acoplamientos de engranaje,
especiales, consultar el dibujo de montaje suministrado con el dando por resultado la falla prematura del engrane si no se mantienen
acoplamiento para la disposicin correcta de montaje y cualquier ciclos peridicos de lubricacin..
requerimiento adicional para la instalacin o el mantenimiento.
Consultar los manuales especficos para la instalacin y mantenimiento La grasa de larga duracin (LTG) de Falk fue desarrollada
de acoplamientos de engranaje verticales GV. especficamente para los acoplamientos. Es resistente a la separacin
del aceite y el espesador, adems de ser una grasa para presiones
IMPORTANTE: Usar los acoplamientos G/GF51 y 52 con conjuntos de extremas.
eje flotante, o como un cuarto cojinete en sistemas con tres cojinetes.
Cuando los acoplamientos de engranaje se montan en un eje flotante Aunque la LTG es compatible con la mayora de las grasas para
horizontal, instalar un disco separador en cada acoplamiento. Cuando acoplamientos, la mezcla de grasas puede reducir los beneficios de la
se requiere limitar la flotacin del extremo, o si se usan motores con LTG.
manguito de soporte, consultar con la fbrica. PRECAUCION: No usar LTG en cojinetes. No usar LTG en aplicaciones
de baja velocidad. Consultar la tabla 4, pgina 6 para el intervalo de
PRECAUCION: Consultar los cdigos de seguridad locales y
velocidad de grasa LTG.
nacionales correspondientes para la proteccin adecuada de
los componentes giratorios. Respetar todas las reglas de Presentacin
seguridad durante la instalacin o revisin de los CARTUCHOS DE 0,4 kg (14 oz.) Individuales o en cajas de 10 de
acoplamientos. 60 unidades.
ADVERTENCIA: Bloquear el interruptor de arranque de la CUBOS de 16 kg (35 lb.) CUETES de 54 kg (120 lb.) y TAMBORES
mquina motriz y quitar toda carga externa del mando antes de de 181 kg (400 lb).
instalar o revisar los acoplamientos.
Especificaciones Grasa LTG (de larga
GRASERAS duracin) Falk
Los manguitos tienen agujeros de lubricacin de 1/8 NPT en los GAMA DE TEMPERATURA -29C (-20F) a 121C (250F).
tamaos 1010G a 1035G y 1GF a 7GF, y agujeros de tamao 1/4 Temperatura mnima para bombeo: -7C (20F).
NPT para los tamaos 1040G a 1070G. Usar una pistola engrasadora VISCOSIDAD MINIMA DEL ACEITE BASE 715 cSt (3300SSU) a
y graseras normales. 38C (100F).
ESPESADOR Jabn/polmero de litio.
LUBRICACION CARACTERISTICAS DE SEPARACION POR CENTRIFUGACION
La lubricacin adecuada es esencial para el funcionamiento
ASTM N D4425-84 (Prueba de centrifugacin) K36 = 2/24 mx.,
satisfactorio. Se recomienda el uso de la grasa de larga duracin (LTG)
resistencia muy alta a la centrifugacin.
de Falk, debido a sus excelentes caractersticas de lubricacin y a las
propiedades de baja separacin por centrifugacin. GRADO NLGI (ASTM D-217) 1/2
Los acoplamientos de engranaje lubricados inicialmente con grasa de CONSISTENCIA (ASTM D-217) Valor de penetracin forzada de 60
larga duracin (LTG) de Falk no requieren lubricacin por lapsos de carreras en la gama de 315 a 360 medida a 25C (77F).
hasta tres aos. TEMPERATURA DE LICUEFACCION 177C (350F) mnimo.
El uso de grasa universal requiere la relubricacin del acoplamiento CARGA MINIMA TIMKEN A PRESION EXTREMA 18 kg (40 lbs.).
por lo menos una vez cada seis meses. Si el acoplamiento pierde ADITIVOS Inhibidores de herrumbre y oxidacin que no corroen el
grasa, es expuesto a temperaturas extremas o humedad excesiva, acero ni hinchan o deterioran los sellos sintticos.
experimenta inversiones de movimiento o movimientos axiales
frecuentes, puede ser necesario lubricar ms frecuentemente.
The Falk Corp., subsidiaria de Sundstrand Corp. 458-110S

P.O. Box 492, Milwaukee, WI 53201 EE.UU. febrero 1997
Telfono: 414-342-3131, Fax: 414-937-4359 sustituye a 3-91
Instalacin y mantenimiento Acoplamientos de engranaje de engrane doble y simple
(Pgina 2 de 7) Tamaos 1010 al 1070G y tamaos 1 al 7GF a good name in industry
Grasa universal TABLA 1 Grasa NLGI N 1

Lubricacin semestral Las especificaciones siguientes y los Fabricante Lubricante H
lubricantes para uso como grasa universal corresponden a los
acoplamientos de engranaje que se lubrican semestralmente y que Amoco Oil Co. Rykon Grease #1 EP
BP Oil Co. Energrease LS-EP1
funcionan a temperaturas de -34C a 93C. Para temperaturas fuera Chevron U.S.A., Inc. Dura-Lith EP1
de este intervalo, consultar con la fbrica. Para el servicio normal, usar Citgo Petroleum Corp Premium Lithium Grease EP1
una grasa para presin extrema (EP) NLGI N 1 EXCEPTO cuando la Conoco Inc. EP Conolith Grease #1
velocidad de funcionamiento del acoplamiento es menor que el valor Exxon Company, U.S.A.. Lidok EP1
mnimo especificado en la Tabla 4, pgina 6 y en la Tabla 5, pgina 7. Imperial Oil Ltd. Ronek EP1
A velocidades menores, usar grasa para presin extrema (EP) NLGI N Kendall Refining Co. Lithium Grease L-416
0. Si uno o ms acoplamientos de engranaje en una aplicacin Keystone Div., Pennwalt Corp. Zeniplex-1
Lyondell Lubricants Litholine Complex EP1
particular requiere grasa NLGI N 0, se puede usar la misma grasa en
todos los acoplamientos. Mobil Oil Corp.. Mobilux EP1
Petro-Canada Products Multipurpose EP1
Si el acoplamiento pierde grasa, es expuesto a temperaturas extremas Phillips 66 Co. Philube Blue EP
o humedad excesiva, experimenta inversiones de movimiento o Shell Oil Co. Alvania EP Grease 1
movimientos axiales frecuentes, puede ser necesario lubricar ms Shell Canada Ltd. Alvania Grease EP1
frecuentemente. Sun Oil Co. Sun Prestige 741 EP
Texaco Lubricants Multifak EP1
Los lubricantes indicados en las Tablas 1, 2 y 3 son solamente Unocal 76 (East & West) Unoba EP1
productos tpicos y no se los deber considerar como recomendaciones
exclusivas.
Especificaciones Lubricantes universales

para acoplamientos TABLA 2 Grasa EP NLGI N 0
GAMA DE VELOCIDAD DEL ACOPLAMIENTO Ver la Tabla 4, Fabricante Lubricante H
pgina 6. Amoco Oil Co. Rykon Premium Grease 0 EP
GAMA DE TEMPERATURA -34c a +93C (-30F a +200F) BP Oil Co. Energrease LS-EP 0
Chevron U.S.A., Inc. Dura-Lith EP 0
PENETRACION A 25C (77F) Citgo Petroleum Corp Premium Lithium Grease EP 0
NLGI N 1 . . . . . . . . . 310-340 (Ver la Tabla 1) Conoco Inc. EP Conolith Grease #0
NLGI N 0 . . . . . . . . . 355-385 (Ver la Tabla 2) Exxon Company, U.S.A.. Lidok EP 0
TEMPERATURA DE LICUEFACCION 149C (300F) o mayor Kendall Refining Co. Lithium Grease L-406
Keystone Div., Pennwalt Corp. Zeniplex-0
TEXTURA Lisa o fibrosa Mobil Oil Corp.. Mobilux EP 0
CARGA MINIMA TIMKEN 13,6 kg (30 lb) Petro-Canada Products Multipurpose Lotemp EP Grease
Phillips 66 Co. Philube Blue EP
SEPARACION Y RESISTENCIA Bajo porcentaje de separacin del Shell Oil Co. Alvania EP Grease RO
aceite y alta resistencia a separacin por centrifugacin. Shell Canada Ltd. Alvania Grease EPW
CONSTITUYENTE LIQUIDO Posee buenas propiedades lubricantes Sun Oil Co. Sun Prestige 740 EP
equivalentes a un aceite de petrleo bien refinado de buena calidad Texaco Lubricants Multifak EP 0
Unocal 76 (East & West) Unoba EP 0
con aditivos para presin extrema.
INACTIVO No debe corroer el acero ni causar hinchazn o
deterioro de los sellos sintticos.
Lubricacin con aceite TABLE 3 Aceites lubricantes

Los aceites para presin extrema (EP) pueden ser lubricantes ms
Fabricante Lubricante H
eficaces que la grasa cuando la velocidad de funcionamiento del
acoplamiento es la mitad de la velocidad mnima indicada para el uso Amoco Permagear EP 160
de grasa NLGI N 1 en la Tabla 4, pgina 6 (velocidad mnima 2). Chevron, U.S.A. NL Gear Compound 680
Exxon Co., U.S.A. Spartan EP680
Los acoplamientos lubricados con aceite deben estar sellados para Gulf Oil Co. EP Lubricant HD 680
evitar las fugas, por ejemplo, a travs de chaveteros, etc. Se debe
Mobil Oil Co. Mobilgear 636
cambiar el aceite de los acoplamientos cada seis meses si funcionan a Shell Oil Co. Omala Oil 680
temperaturas de hasta 71C (160F) y cada tres meses para Texaco Inc. Meropa 680
acoplamientos que funcionan a temperaturas de 71C (160F) hasta Union Oil Co. of Calif. Extra Duty NL Gear Lube 8EP
93C (200F). Para temperaturas fuera de este intervalo, consultar con H Los lubricantes indicados pueden no ser apropiados para uso en la industria
la fbrica. La temperatura mnima de funcionamiento no debe ser de proceso de alimentos; consultar al fabricante para los lubricantes
menor que el punto de fluidez del aceite. La cantidad de grasa aprobados para tal uso.
especificada en la Tabla 4, pgina 6, se da en libras y corresponde al
volumen de aceite dado en pintas.
Especificaciones
Tipo: Aceite para engranajes EP suave que cumple con las
especificaciones 250.04 de AGMA.
Grado: AGMA N 8EP (ISO VG 680).
Viscosidad: 612-748 cSt a 40C (104).
Punto de fluidez: -7C (20F) mximo.
No debe corroer el acero ni causar hinchazn o deterioro
de los sellos sintticos.
458-110S The Falk Corp., subsidiaria de Sundstrand Corp.

febrero 1997 P.O. Box 492, Milwaukee, WI 53201 EE.UU.
sustituye a 3-91 Telfono: 414-342-3131, Fax: 414-937-4359
INSTALACION DE ACOPLAMIENTOS MANTENIMIENTO SEMESTRAL

HORIZONTALES, TODOS LOS Volver a lubricar el acoplamiento si se utilizan grasas universales. Si el
MODELOS acoplamiento pierde grasa, es expuesto a temperaturas extremas o
humedad excesiva, experimenta inversiones de movimiento o
Para instalar acoplamientos de engranaje Falk slo se necesitan movimientos axiales frecuentes, puede ser necesario lubricar ms
herramientas normales de taller, llaves torsiomtricas, micrmetros de frecuentemente.
separaciones interiores, un indicador de cuadrante, una regla, una
barra espaciadora y calibradores de separaciones. Limpiar todos los
componentes usando un solvente no inflamable. Revisar los cubos, ejes
MANTENIMIENTO ANUAL
y chaveteros en busca de rebabas. NO calentar los cubos de ajuste Para condiciones de funcionamiento extremas o poco comunes, revisar
con huelgo. Usar un lubricante que cumpla con las especificaciones el acoplamiento ms frecuentemente.
dadas en la pgina 2. Engrasar los dientes de los manguitos y cubrir 1. Comprobar la alineacin segn el paso 7 en la pgina 6. Si
los sellos con una capa liviana de grasa ANTES de armar los se exceden los lmites mximos de desalineacin de
componentes. La cantidad necesaria de grasa se indica en la Tabla 4. funcionamiento, volver a alinear el acoplamiento segn los
Asegurarse que las fijaciones de brida estn apretadas a los valores lmites de instalacin recomendados. Para los lmites de
indicados en la Tabla 4. instalacin y alineacin de funcionamiento, ver la Tabla 4.
Cubos de ajuste con apriete Salvo indicacin contraria, los 2. Revisar el apriete de todas las fijaciones.
acoplamientos de engranaje Falk se proveen para instalacin de ajuste
con apriete sin tornillos de fijacin. Calentar los cubos a 135C 3. Inspeccionar el anillo de sellado y la empaquetadura para
(275F) usando un horno, soplete, calentador por induccin o bao de determinar si es necesario cambiarlos.
aceite. 4. Volver a lubricar el acoplamiento si se utiliza grasa
PRECAUCION: Para evitar daar los sellos, NO calentar los universal.
cubos a ms de 205C (400F) para los modelos tipo G y a
NOTA: El cuerpo ms largo
ms de 260C (500F) para los modelos tipo GF. se orienta hacia la separacin.
Cuando se utiliza un soplete oxiacetilnico o soplete de aire, usar una
mezcla con exceso de acetileno. Marcar los cubos cerca del centro de
su longitud en varios lugares en el cuerpo del cubo con un lpiz
termosensible, de una temperatura de fusin de 135C (275F). Dirigir
la llama hacia la cavidad usando un movimiento constante para evitar
sobrecalentar el rea.
ADVERTENCIA: Si se utiliza un bao de aceite, el aceite debe NOTA:
tener una temperatura de inflamacin de 177C (350F) o A ras en
CUBO CUBO
este punto.
mayor. No apoyar los cubos en el fondo del recipiente. No usar FLEXIBLE RIGIDO
llama expuesta en una atmsfera combustible ni cerca de
materiales combustibles.
Maximizacin del rendimiento y la INSTALACION DE ACOPLAMIENTOS

duracin HORIZONTALES G/GF, TODOS LOS
El rendimiento y la duracin de los acoplamientos dependen en gran
MODELOS
parte de la manera en que se los instala y mantiene. Antes de instalar 1 Montaje de manguitos embridados, sellos
los acoplamientos, cerciorarse que las bases del equipo a ser
conectado satisfacen los requisitos del fabricante. Revisar si hay una y cubos
base blanda. Es recomendable el uso de suplementos de acero Colocar los manguitos embridados CON anillos de sellado en los ejes
inoxidable. La medicin de la desalineacin y el posicionamiento del ANTES de montar los cubos flexibles. Montar los cubos flexibles o
equipo dentro de las tolerancias de alineacin se simplifican utilizando rgidos en sus ejes respectivos, como se muestra en la ilustracin
una computadora de alineacin. Estos clculos tambin pueden anterior, de modo que sus caras queden a ras con los extremos de sus
hacerse grfica o matemticamente, y pueden tomar en cuenta el ejes. Dejar que los cubos se enfren antes de continuar. Sellar los
descentramiento en fro, compensando el cambio de posicin que chaveteros para evitar las fugas. Insertar los tornillos de fijacin (en su
sufre el eje debido a expansin trmica. caso) y apretarlos. Colocar el equipo aproximadamente alineado,
separando los cubos una distancia aproximadamente igual a la
Acoplamientos especificada.
equilibrados Modelos tipo G/GF10 y 20: Colocar el equipo aproximadamente

alineado, con una separacin igual a la dada en la Tabla 4.
Las fijaciones se suministran como
conjuntos apareados y no deben A1 A1 A1 A1 B1 B1 Modelos tipo G/GF31 y 32 de espaciador y G/GF51 y 52 de eje
combinarse entre s ni sustituirse. Los flotante, con cubos rgidos en eje flotante: Colocar el equipo
acoplamientos equilibrados tienen marcas aproximadamente alineado, separando los ejes una distancia
de alineacin y deben armarse con sus aproximadamente igual a la dada en el paso 4A, Figura 2 en la pgina
marcas correspondientes alineadas entre 5.
s. En algunos casos, las bridas no tienen marcas de alineacin. Las Modelos G/GF51 y 52 con cubos flexibles en eje flotante: Ver el paso
bridas de acoplamiento deben armarse con sus dimetros interiores 4A, Figura 1 en la pgina 5, para determinar la distancia de
alineados, con un margen de tolerancia de 0,05mm (0,002"). Los separacin entre los ejes.
componentes de un acoplamiento equilibrado no deben sustituirse sin
equilibrar el conjunto despus de haberlo armado.

2 Ajuste de separacin y alineacin angular 3 Alineacin de acoplamientos cerrados,

para acoplamientos cerrados, con espaciador y con espaciador y con eje flotante corto
con eje flotante corto
SIEMPRE MEDIR HASTA
UNA MISMA PROFUNDIDAD
SEPARACION
3A Tipo G/GF10 y 20
2A Tipo G/GF10 y 20 Alinear los cubos de modo que se pueda colocar una regla a escuadra
Usar una barra espaciadora cuyo espesor sea igual al indicado en la sobre ambos en puntos separados 90 entre s, como se muestra en la
Tabla 4. Insertar la barra, como se ilustra en la figura anterior, hasta ilustracin anterior. Comprobar usando un calibrador de separaciones.
una misma profundidad en puntos separados 90 entre s y medir la La separacin no debe exceder el LIMITE DE DESCENTRAMIENTO de
separacin entre la barra y la cara del cubo usando un calibrador de INSTALACION indicado en la Tabla 4. Apretar los pernos de la base y
separaciones. La diferencia entre la separacin mxima y mnima repetir los pasos 2A y 3A. Volver a alinear el acoplamiento, de ser
medida no debe exceder el LIMITE ANGULAR de INSTALACION necesario. Usar un indicador de cuadrante si la extensin del cubo es
indicado en la Tabla 4. demasiado corta para poder usar una regla con precisin.
3B Tipo G/GF31, 32 (espaciador), y tipo

2B Tipo G/GF31, 32 (espaciador) y tipo
G/GF51, 52 (eje flotante corto, ver el paso 4 si
G/GF51, 52 (eje flotante corto, ver paso 4 si
tiene eje flotante largo)
tiene eje flotante largo)
Alinear los cubos de modo que se pueda colocar una regla a escuadra
Usar un micrmetro de separaciones interiores como se muestra arriba (o dentro de los lmites indicados en la Tabla 4) sobre ambos en puntos
y medir la distancia entre los cubos en puntos separados 90 entre s. separados 90 entre s, como se muestra en la ilustracin anterior.
La diferencia entre la separacin mxima y mnima medida no debe Comprobar usando un calibrador de separaciones. La separacin no
exceder el LIMITE ANGULAR de INSTALACION indicado en la Tabla 4. debe exceder el LIMITE DE DESCENTRAMIENTO de INSTALACION
indicado. Apretar los pernos de la base y repetir los pasos 2C y 3C.
Volver a alinear el acoplamiento, de ser necesario.
SEPARACION
CUBO RIGIDO
CUBO RIGIDO
2C Tipo G/GF51 y 52 (funcionando como
cuarto cojinete en un sistema de tres cojinetes) 3C Tipo G/GF51 y 52 (como cuarto cojinete
Usar una barra espaciadora cuyo espesor sea igual a la dimensin X en un sistema de tres cojinetes)
indicada en la Tabla 4. Insertar la barra, como se muestra arriba, a Fijar un indicador de cuadrante al cubo rgido como se muestra en la
una misma profundidad y en puntos separados 90 entre s; luego ilustracin y girar el cubo rgido una vuelta completa. La distancia total
medir la separacin entre la barra y la cara del cubo con un calibrador registrada por el indicador DIVIDIDA entre dos no debe exceder el
de separaciones. La diferencia entre la separacin mxima y mnima LIMITE DE DESCENTRAMIENTO de INSTALACION indicado en la
medida no debe exceder el LIMITE ANGULAR de INSTALACION Tabla 4. Apretar los pernos de la base y repetir los pasos 2B y 3B.
indicado en la Tabla 4. Volver a alinear el acoplamiento, de ser necesario.

4 Tipo G/GF51 y 52 con eje flotante largo medida no debe exceder el LIMITE ANGULAR de INSTALACION
indicado en la Tabla 4.
4A Determinacin de la distancia entre ejes
4B2 Consultar la Figura 3
DISCOS SEPARADORES
(AMBOS EXTREMOS) Alinear el acoplamiento y el eje flotante de modo que al colocar una
regla escuadra (o micrmetro de profundidades) reposando a escuadra
con la brida, se obtengan medidas iguales de separacin en el
dimetro exterior del cubo en cuatro puntos separados 90 entre s. La
SEPARACION SEPARACION
X X diferencia entre la separacin mxima y mnima medida no debe
exceder el LIMITE DE DESCENTRAMIENTO de INSTALACION indicado
en la Tabla 4 dividido entre dos. La medida anterior es el
descentramiento total indicado (TIR).
CUBO LA DISTANCIA ENTRE LAS CARAS DE BRIDAS CUBO 4C Posicionamiento del segundo mando
RIGIDO DE LOS CUBOS RIGIDO Colocar el segundo mando hasta obtener la dimensin X correcta y
RIGIDOS ES IGUAL AL LARGO DEL EJE MAS DOS VECES "X". alinearlo segn las instrucciones dadas en los pasos 4B1 y 4B2. NO
Figura 1 mover el eje flotante. Empernar el mando en su lugar y volver a
Refirindose a la Figura 1 anterior, medir el largo del eje flotante y comprobar la alineacin y la separacin. Volver a alinear de ser
sumar a esta medida dos veces la distancia X dada en la Tabla 4 necesario. Para mayor precisin, comprobar la alineacin usando un
para calcular la distancia requerida entre las caras de las bridas de los micrmetro de profundidades o un indicador de cuadrante.
cubos rgidos.
DISCOS SEPARADORES
CUBOS RIGIDOS O ESPACIADOR (AMBOS EXTREMOS)
SEPARACION SEPARACION
X X
LA DISTANCIA ENTRE LOS EJES

ES IGUAL A LA DISTANCIA
Figura 2 ENTRE LAS CARAS DE BRIDAS DE LOS
CUBOS RIGIDOS MAS DOS VECES "X".
Refirindose a la Figura 2 anterior, medir el largo total del eje flotante o
del conjunto del espaciador, de brida a brida, y sumarle a esta medida 5 Armado de acoplamientos Todos los
dos veces la distancia X dada en la Tabla 4 para calcular la distancia modelos
requerida entre los ejes a ser acoplados.
IInsertar una empaquetadura entre las bridas y el disco separador en el
4B Posicionamiento del primer mando y del agujero contrataladrado de cada uno de los cubos rgidos para
conjuntos con eje flotante y empernar las bridas entre s. Usar
eje flotante nicamente las fijaciones provistas con el acoplamiento.
Nivelar el mando ms difcil de mover y apretar sus pernos de fijacin. IMPORTANTE: Apretar las fijaciones a los valores de apriete dados en
Colocar el eje flotante sobre bloques con muescas en V. Despus la Tabla 4.
alinear el acoplamiento del mando fijo de la manera siguiente:
USAR CALIBRADOR
(ANGULAR)
CUBO FLEXIBLE
CUBO RIGIDO EMPAQUETADURA
MANGUITO
X
SEPARACION
USAR CALIBRADOR
(DESCENTRAMIENTO)
6 Lubricacin
Figura 3
Sacar todos los tapones de engrase y llenar con la grasa recomendada
hasta que se observe el exceso de grasa por uno de los agujeros
abiertos; despus insertar su tapn en el mismo. Repetir este
4B1 Consultar la Figura 3 procedimiento hasta haber insertado todos los tapones.
Usar una barra espaciadora cuyo espesor sea igual a la dimensin X PRECAUCION: Quitar la grasera y asegurarse de haber insertado
indicada en la Tabla 4. Insertar la barra a una misma profundidad en todos los tapones despus de haber concluido la lubricacin..
puntos separados 90 entre s y medir la separacin entre la barra y la
cara del cubo con un calibrador de separaciones, como se muestra en
la ilustracin. La diferencia entre la separacin mxima y mnima

"W" = Wmx. - Wmn.

7 Revisin de alineacin de acoplamiento
Wmx. armado Todos los modelos
La alineacin puede revisarse sin necesidad de desarmar el
acoplamiento, de la forma ilustrada a la izquierda. Determinar la
distancia W midiendo las distancias Wmx. y Wmn. entre el cubo
flexible y el manguito usando un micrmetro de profundidad o un
calibrador de separaciones. La diferencia entre Wmx. y Wmn. no
debe exceder el valor W dado en la Tabla 4. Revisar la distancia W
Wmn.
en cada extremo de acoplamiento.
Revisar la distancia "W" en cada cubo flexible.
TABLA 4 Datos de instalacin y alineacin para los acoplamientos tipo G/GF210, 20, 31, 32,
51 y 52 H Dimensiones - pulg (mm)
1010G 1015G 1020G 1025G 1030G 1035G 1040G 1045G 1050G 1055G 1060G 1070G
TAMAO DEL ACOPLAMIENTO
1GF 1-GF 2GF 2-GF 3GF 3-GF 4GF 4-GF 5GF 5-GF 6GF 7GF
G/GF10 y 20 .125 .125 .125 .188 .188 .250 .250 .312 .312 .312 .312 .375
(3) (3) (3) (5) (5) (6) (6) (8) (8) (8) (8) (10)
Separacin
G/GF51 y 52 .156 .156 .156 .188 .188 .218 .281 .312 .344 .344 .406 .500
(4) (4) (4) (5) (5) (6) (7) (8) (9) (9) (10) (13)
X Dimensin G/GF51 y 52 .056 .056 .056 .088 .088 .118 .121 .152 .144 .144 .146 .170
(1) (1) (1) (2) (2) (3) (3) (4) (4) (4) (4) (4)
G/GF10, 20, 31, 32, 51 y 52 Angular .006 .007 .009 .011 .013 .015 .018 .020 .022 .024 .026 .031
(0,15) (0,19) (0,23) (0,28) (0,33) (0,39) (0,46) (0,51) (0,55) (0,61) (0,66) (0,78)
G/GF10 y 20 Paralelo .002 .003 .003 .004 .005 .006 .007 .008 .009 .010 .011 .013
Lmites de (0,05) (0,07) (0,08) (0,10) (0,13) (0,15) (0,18) (0,20) (0,23) (0,26) (0,28) (0,33)
instalacin .001 .001 .001 .002 .002 .002 .003 .003 .003 .003 .004 .005
G/GF51 y 52 Paralelo
(0,03) (0,03) (0,03) (0,04) (0,05) (0,05) (0,06) (0,08) (0,08) (0,08) (.10) (.11)
G/GF31 y 32 Paralelo .006 .006 .007 .008 .009 .011 .012 .013 .015 .016 .017 .017
(0,14) (0,16) (0,17) (0,20) (0,23) (0,28) (.0,30) (0,32) (0,38) (0,41) (.43) (.44)
Todos los .006 .007 .009 .011 .013 .015 .018 .020 .022 .024 .026 .031
W Revisin de instalacin
modelos (0,15) (0,19) (0,23) (0,28) (0,33) (0,39) (0,46) (0,51) (0,55) (0,61) (0,66) (0,78)
Todos los .035 .045 .054 .067 .079 .092 .108 .121 .131 .144 .157 .183
W Lmite de funcionamiento
modelos (0,90) (1,13) (1,38) (1,71) (2,00) (2,33) (2,74) (3,08) (3,33) (3,66) (3.,99) (4,66)
Grasa NLGI N 0 - Mx. 7000 6000 5000 4750 4400 3900 3600 3200 2900 2650 2450 2150
G10, 20,
Gama de Grasa LTG Falk o Mn. 1030 700 550 460 380 330 290 250 230 210 190 160
51 y 52
velocidad NLGI N 1 Admisible 8000 6500 5600 5000 4400 3900 3600 3200 2900 2650 2450 2150
de
acoplamient Grasa NLGI N 0 - Mx 7000 5500 4600 4000 3600 3100 2800 2600 2400 2200 2100 1800
o (rpm) G31 y 32 Mn. 1030 700 550 460 380 330 290 250 230 210 190 160
Grasa LTG Falk o
NLGI N 1 Admisibl 7000 5500 4600 4000 3600 3100 2800 2600 2400 2200 2100 1800
G10 y 20 .09 .16 .25 .50 .80 1.20 2.00 2.30 3.90 4.90 7.00 9.60
(0,041) (0,073) (0,11) (0,23) (0,36) (0,54) (0,91) (1,0) (1,8) (2,2) (3.,2) (4,4)
G51 y 52 .05 .09 .15 .26 .40 .60 1.03 1.25 2.00 2.50 3.75 5.00
(0,023) (0,041) (0,068) (0,12) (0,18) (0,27) (0,47) (0,57) (0,91) (1,1) (1,7) (2,3)
G31 y 32, long. espaciador por pulg .03 .06 .06 .12 .20 .20 .20 .20 .20 .20
.... ....
(0,014) (0,027) (0,027) (0,054) (0,091) (0,091) (0,091) (0,091) (0,091) (0,091)
G31 y 32 sin espaciador .09 .16 .25 .50 .80 1.20 2.00 2.30 3.90 4.90 7.00 9.60
Grasa - lb (0,041) (0,073) (0,11) (0,23) (0,36) (0,54) (0,91) (1,0) (1,8) (2,2) (3,2) (4,4)
(kg) .09 .15 .27 .47 .74 .88 1.48 2.62 2.87 4.44 4.95 6.79
GF10 y 20
(0,039) (0,068) (0,12) (0,21) (0,33) (0,40) (0,67) (1,2) (1,3) (2,0) (2,2) (3,1)
GF51 y 52 .06 .09 .15 .27 .41 .50 .87 1.46 1.66 2.47 2.93 4.27
(0,025) (0,042) (0,070) (0,12) (0,19) (0,23) (0,40) (0,66) (0,75) (1,1) (1,3) (1,9)
GF31 y 32, long. espaciador por pulg .06 .08 .02 .16 .21 .12 .13 .14
.... .... .... ....
(0,027) (0,037) (0,009) (0,072) (0,095) (0,053) (0,059) (0,065)
GF31 y 32 sin espaciador .09 .15 .27 .47 .74 .88 1.48 2.62 2.87 4.44 4.95 6.97
(0,039) (0,068) (0,12) (0,21) (0,33) (0,40) (0,67) (10,2) (1,3) (2,0) (2,2) (3,2)
G/GF10, 31 y 51 108 372 372 900 900 1800 1800 1800 3000 3000
.... ....
Apriete de pernos de (12) (42) (42) (102) (102) (203) (203) (203) (339) (339)
brida - lb-pulg (Nm)) 108 372 900 1800 1800 3000 3000 3000 3000 3000 3000 3000
G/GF20, 32 y 52
(12) (42) (102) (203) (203) (339) (339) (339) (339) (339) (339) (339)
H Consultar la gua de seleccin para las cavidades mximas y el manual 427-108 para las instrucciones de retaladrado de cavidades.
Los acoplamientos con grasa NLGI N 0 pueden usarse a cualquier velocidad entre cero y el lmite mximo indicado.

IDENTIFICACION DE PIEZAS Y EJEMPLO:

Acoplamiento de engranaje 1050G20 completo
UBICACION DE NUMEROS DE PIEZA Consistente en:
Las piezas de los acoplamientos tienen nmeros que identifican la 2 anguitos 1050G20
pieza y su tamao, como se muestra a continuacin. Al pedir piezas de
(Incluye empaquetadura y sello)
repuesto, siempre ESPECIFICAR el TAMAO, TIPO, CAVIDAD DE
CUBO, CHAVETERO y NUMERO DE PIEZA hallados en cada pieza.. 2 Cubos flexibles 1050G
Cavidad: 6,750 Chavetero: 1,750 x 0,750
Comunicarse con el distribuidor Falk para una cotizacin y
Cavidad: 7,375 Chavetero: 1,750 x 0,750
disponibilidad..
1 Juego de fijaciones
1015 G 20
TIPO G/GF10 Y 20 1-1/2 GF 20
TAMAO DE ACOPLAMIENTO TIPO
TAPON CLASIFICACION DEL PRODUCTO
DE ENGRASE
MANGUITO CUBO FLEXIBLE CUBO FLEXIBLE MANGUITO
(ESPECIFICAR CAVIDAD (ESPECIFICAR CAVIDAD
Y CHAVETERO)
Y CHAVETERO)
LUB E
F A L K 1015G 20
FA
LK 1
F AL K
015G 2.370744671
23730 744671
1015G GA P E ND
G
1015
LK
FA
ANILLO DE SELLADO
TAPON
ANILLO DE SELLADO EMPAQUETADURA TAMAO, DIAMETRO DE CAVIDAD DE ENGRASE
Y NUMERO DE PIEZA (EN UNO DE
ESTOS PUNTOS)
FIJACIONES
TIPO G/GF31 Y 32 1015 G 32

1-1/2 G 32
TAMAO DE TIPO
TAPON DE ACOPLAMIENTO CLASIFICACION DEL PRODUCTO
ENGRASE
MANGUITO MANGUITO
CUBO FLEXIBLE CUBO FLEXIBLE
(ESPECIFICAR CAVIDAD (ESPECIFICAR CAVIDAD
Y CHAVETERO) Y CHAVETERO)
L UB E F
L UB E FAL K 1015GL 20
FA
A L K 1015GL 20
LK 1
F AL K
015G 2.370744671
23730 744671
1015G GA P E ND
G
1015
LK
FA
ANILLO DE SELLADO
ANILLO DE SELLADO TAPON DE
EMPAQUETADURA ESPACIADOR EMPAQUETADURA ENGRASE
(ESPECIFICAR LARGO) TAMAO, DIAMETRO DE CAVIDAD
Y NUMERO DE PIEZA
FIJACIONES (EN UNO DE ESTOS PUNTOS)
FIJACIONES
TIPO G/GF51 Y 52 1015 G 52

1-1/2 G 52
TAMAO DE TIPO
TAPON DE ACOPLAMIENTO CLASIFICACION
ENGRASE DEL PRODUCTO
MANGUITO EJE FLOTANTE MANGUITO
CUBO FLEXIBLE DISCO (ESPECIFICAR DIAMETRO CUBO FLEXIBLE
DISCO
(ESPECIFICAR CAVIDAD SEPARADOR Y LARGO) (ESPECIFICAR CAVIDAD
Y CHAVETERO) SEPARADOR
Y CHAVETERO)
L UB E
L UB E FAL K 1015GL 20
F A L K 1015GL 20
FA
F AL K
LK 1
23730 744671
015G 2.370744671
1015G GA P E ND
G
1015
ANILLO
LK
FA
DE SELLADO
TAPON DE
ANILLO EMPAQUETADURA CUBO RIGIDO EMPAQUETADURA ENGRASE
DE SELLADO (ESPECIFICAR CAVIDAD Y CHAVETERO)
TAMAO, DIAMETRO DE CAVIDAD
Y NUMERO DE PIEZA
FIJACIONES (EN UNO DE ESTOS PUNTOS)
FIJACIONES

HYDRAULIC & MECHANICAL POWER
PE 20 & 70 SERIES
PRO
20 - MAG
& 70 SERIES
ELECTRIC POWER PUMPS
USTRY W Operating & Maintenance Instructions
IND IT
G
For 1/2 and 11/2 H.P. Electric Pumps
H
RVIN
PRIDE
SINCE - 1899 Does Not Include "PED" Dump Pump.

SE
Tem .
pl eton ., I nc
Ke nly & Co
Q U A L IT Y
E R VI C E A S S
E NT S OC
PM I
AT
I
EQ U
ION
REB
U IL D T
ER S O F T MEN
O OLS & EQ UIP
US
A
AD
A
Part Sheet #: 54393 MEMBER CA

N
Revised: 10-1-99
The world's most complete line of industrial, hydraulic and

mechanical lifting and positioning equipment.
SIMPLEX DIVISION OF TEMPLETON, KENLY & CO., INC.
2525 Gardner Road Broadview, Illinois 60155 (708) 865-1500 / Fax (708) 865-0894
www.tksimplex.com
OPERATING INSTRUCTIONS AT A GLANCE
Before Operating Pump:
1. Be sure the electrical connection is grounded. Check that your power supply agrees
with the motor nameplate.
2. Use only cylinders, hoses and equipment rated at 10,000 PSI.
3. Make sure all hose and fitting connections are tight and secure. Hoses cannot be
kinked or twisted.
4. Oil level should be 1 to 2" from the top of the reservoir plate, with cylinders retracted
and motor off.
5. Never operate the pump with the directional control valve in advance or retract at
10,000 PSI without ram movement for more than 1 minute. Leaving the valve in the
advance or retract position without the rams piston rod moving will overheat the oil.
After Completing the Job:
1. Before disconnecting hoses, fittings, etc., first be sure the ram is retracted & unloaded,
then unplug the power cord and shift the hydraulic controls several times to release
system
pressure.
2. Store the pump in a clean, dry area.
Periodic Maintenance:
1. Completely change the hydraulic oil and clean the oil filter screen and magnet (located
in the reservoir) twice a year. (Use Simplex oil only, Model # AO1, 1 gallon). Change
the oil more frequently when used in extremely dusty areas or when the oil has been
overheated. Using oil other than Simplex Brand voids the pumps warranty.
-1-
SECTION I
SAFETY
1-1. Working Pressure
The pump's maximum working pressure is 10,000 PSI (700 kg/cm2). Make sure that all hy-
draulic equipment such as rams, hoses, etc. used with this pump are rated at 10,000 PSI
operating pressure.
1-2. Hydraulic Connections
Never disconnect or connect any hydraulic hoses or fittings without first unloading the ram,
then unplug the electrical cord of the pump and shift, or open all hydraulic controls several
times to assure that the system has been depressurized. If the system includes a gauge,
double check the gauge to assure pressure has been released.
When making connections with quick disconnect couplings, make sure the couplings are fully
engaged. Threaded connections such as fittings, gauges, etc. must be securely tightened
and leak free.
! CAUTION: Loose or improperly threaded fittings can be potentially dangerous if pressurized,

however, severe over tightening can cause premature thread failure. Fittings need to be
tightened secure & leak free. Never hold or stand directly in line with any hydraulic connec-
tions while pressurizing. Never grab, touch or in any way come in contact with a hydraulic
pressure leak. Escaping oil can penetrate the skin and a serious injury can result.
*Do not subject the hose to potential hazard such as sharp surfaces, extreme heat or heavy
impact. Do not allow the hose to kink & twist. Inspect each hose for wear before it is used.
1-3. Electrical Power
1. CHECK FOR PROPER ELECTRICAL SUPPLY BEFORE CONNECTING.
2. THIS MOTOR MAY SPARK. DO NOT OPERATE IN AN EXPLOSIVE

ATMOSPHERE OR IN THE PRESENCE OF CONDUCTIVE LIQUIDS.
a. Do not use a power or extension cord that is damaged or has exposed wiring.
b. All single phase motors come equipped with a three prong grounding type plug
to fit the proper grounded type electrical outlet. Do not use a two prong
ungrounded extension cord as the pump's motor must be grounded.
1-4. Jacking Safely
You must know the weight of what you intend to lift and choose a ram with at least 10% more
capacity.
The ram should be placed on a solid foundation so that the base of the ram is fully supported.
The load must be centered on the ram, or equally distributed on multiple rams. Off center
loading can result in the ram slipping out and loss of the load.
Never crawl or place any part of your body under any load at any time. Insert blocking or
cribbing under the load as you lift. Hydraulic rams are meant for lifting only and should not be
used to support the load for any period of time.
You should obtain and be familiar with the American National Standards Institute rules that
apply to hydraulic rams and jacks (ANSI B30.1).
-2-
SECTION II
INSTRUCTIONS BEFORE USE
Read carefully. Most malfunctions in new equipment are the result of improper operation
and/or improper set-up assembly.
Preparation: Remove pump from shipping container -- but do not remove any plugs or
valves until the unit is ready to be fully assembled to prevent dirt or foreign matter from
contaminating system.
Inspection: Visually inspect all components for shipping damage. If any damage is found,
notify carrier immediately.
2-1. Electrical Connections:
Compare motor nameplate against power availability to prevent motor burnout or dangerous
electrical overloading.
Minimize the length of extension cords and be sure they are of adequate wire size, with
grounded connections.
0.5 H.P., 115V

up to 50' 12-3 gage
2-2. Hydraulic Connections:
Check hydraulic oil level to prevent possible pump burnout. Open the red plastic fill plug
located on reservoir plate. Oil level should be approximately 2" from top of reservoir plate --
with cylinders retracted and motor off. Add Simplex oil as necessary. Do not mix different
grades of oil.
Make sure all desired gauge, valve, hose and quick coupler connections are tight and secure
before operating (See Section 1.2). The pumps pressure ports are 3/8 NPTF and are located
just below the control valve. (See Section 3-1).
The use of a pressure gauge is strongly recommended for normal operation of these pumps
and required when the external adjustable relief valve pressures are changed. Mounted on a
gauge adapter between the pump and cylinder, the gauge permits the operator to monitor
loads on cylinders.
Do not exceed rated capacity of equipment connected to pump. Where shock loading or
unsteady loads may cause overloading of cylinders, the operator must use larger capacity
cylinders to provide additional operating margin.
-3-
SECTION III
OPERATION
3-1. Control Valves:

* Useable 3/8 NPTF port
a. 2-Way Valve for Single Acting Rams
To Advance.........turn lever to the right *

& start motor.
To Hold................turn motor off.
To Retract............turn lever to the left.
b. 3-Way Valve for Single Acting Rams Return ports

only. *A
To Advance..........push lever to right. (Marked T)
For Neutral/Hold...place lever in middle.
To Retract.............push lever to left. *A
c. 4-Way Valve for Double Acting Rams
Pushing lever to right directs pump output

to right-hand port.
B* *A
Pushing lever to left directs pump output to
left-hand port.
Center position is neutral/hold. Pump
B* *A
output is directed back to tank.
3-2.. Before starting pump, place valve in Neutral/Hold position (as described above) to prevent
accidental lifting or moving of load. Start the pump and let the pump idle for a few minutes.
3-3. Bleeding the Hydraulic System--air can be removed from the system by fully advancing and
retracting the hydraulic cylinder several times with the pump elevated so its reservoir is higher
than the cylinder. Single-acting cylinder should be inverted, and double-acting on their side
with the coupling fitting up. When the trapped air is removed from the hydraulic circuit, the
cylinder will advance and retract smoothly. Sluggish cylinder action is usually the first sign of
air in the system.
3-4. Move lever to Advance position (as described above) to activate ram or cylinder. To hold
load, place lever into Neutral/Hold. Move lever to Retract position (as described above) to
release load.
3-5. Never operate the pump at 10,000 PSI without ram movement for more than 1 minute without
shifting the control valve to neutral. Leaving the valve in the advance or retract position
without the piston rod moving will overheat the oil.
-4-
SECTION IV
MAINTENANCE
WARNING: THE ELECTRICAL POWER CORD MUST BE DISCONNECTED FROM ELEC-

TRICAL OUTLETS BEFORE PERFORMING MAINTENANCE OR REPAIR
PROCEDURES.
4-1. Maintain Oil Level -- check hydraulic oil level every 30 hours of operation. Add Simplex oil
(Model # AO1 -- 1 gallon) when necessary. Oil level should be no more than 2" from top of
reservoir plate -- with cylinders retracted and motor off.
Completely change oil at least twice a year. The following conditions require more frequent
oil changes:
a. Rigorous duty, where oil temperature may reach 140 F.
b. High humidity environment and extreme changes in temperature that can result in con-
densation inside the reservoir.
c. Dirty or dusty environments that may contaminate the oil.
4-2. Clean Oil Filter Screen Once a Year
a. Loosen and remove reservoir plate bolts. Lift pump unit off the reservoir, being careful not
to damage the gasket.
b. Unscrew screen from bottom of pump unit and clean with nonflammable solvent.
c. Blow dry and reassemble.
4-3. Keep areas around pump unobstructed to provide good air flow around the motor and pump.
Keep the motor and pump as clean as possible.
4-4. Adjusting the External Relief Valve:
a. Install gauge and gauge adapter between pump and cylinder.

b. Remove cover to expose adjusting screw. Place valve lever in Neutral/Hold position and
start motor. Move lever to direct pump output to pressure port (Advance).
c. Insert allen wrench into adjusting screw in the hole on the lower left side of valve.
d. Turn adjusting screw clockwise to increase, or counter clockwise to decrease pressure .
(Do not exceed 10,000 PSI.)
e. Check valve setting by shifting the valve to advance and retract cylinder several times.
Maximum gauge reading should remain constant.
4-5. Flushing the Pump. If you suspect your pump has been contaminated or discover sludge or
other deposits on internal components, you should thoroughly flush the pump.
a. Remove the old oil from the reservoir, then thoroughly clean the reservoir and refill with a
clean, nonflammable flushing oil.
b. Reassemble the pump and motor to the reservoir.
c. Now run the pump in no load condition for 1 or 2 minutes maximum.
d. Unplug the pump and remove the motor and pump assembly again. Now drain the flush-
ing oil and reclean the inside of the reservoir. (Make sure flushing fluid is also drained
from pump assembly). Refill the reservoir with Simplex hydraulic oil and reassemble
the pump.
-5-
SECTION V
TROUBLESHOOTING
If the procedures listed below do not remedy the problem -- the pump will require
service and should be taken to an authorized Simplex service center for repair
Problem Cause -- Solution
Sporadic Cylinder Action 1. Air in the hydraulic system. See Sec. 3-3 for
correct bleeding procedure.
2. Check reservoir oil level.
Motor Will Not Start Be sure power cord is not damaged. Check for
tripped circuit breaker--be sure breaker is of ad-
equate size. Have qualified electrician inspect for
loose or faulty wiring. Have motor checked for
defective motor capacitor. Be sure electrical supply
and extension cords are adequate.
Noisy Operation 1. Air in system. (See Sec. 3-3 for bleeding

procedure).
2. Be sure the oil reservoir is filled to normal level.
3. Check all points where air might leak into
system.
Pump Oil is Over Heating 1. Oil viscosity too high. Replace with Simplex #9.
2. Check for high pressure leakage on upper
pressure plate. (Leaking at plug).
3. Oil level is low. Fill reservoir to normal level, or
refit the pump with larger reservoir.
4. (See Section 3-5)
Pump Runs but Will Not Pump Oil 1. Pump is not primed. Run pump a few minutes
tipping from side to side.
2. Check to make sure that externally adjustable
relief valve set properly.
Check internal relief valve.
3. Damaged O-Rings. Take to nearest Simplex
service center for repair.
4. Defective control valve. (Troubleshoot
separately).
-6-
20 & 70 SERIES POWER PUMPS
33
K1 K2
15
15 2
43
1 2 3 4 5 6 7 8 9 10
White
25 24
Green
Black
30 40
White
43
Green Black
-
E.M
+
35 51 4 12
28 19
3
30
39 39
13 41
34 42 40
21
44 24 36 38
16
14 20 37
22
5
9 23
ROY REYNOLDS
32
45
7
6
11 10 27
26
8 17
46
18
47
29
PEM 20 & 70 SERIES ELECTRIC POWER PUMPS
PEM2021
PEM2022
PEM2031
PEM2032
PEM2035
PEM2041
PEM2042
PEM2045
PEM2052
PEM2062
PEM7022
PEM7025
PEM7032
PEM7035
PEM7042
PEM7045
PEM7052
PEM7062
Item Part Description
Number
1 18135 18135 1 2 1 2 6 1 2 6 2 2 2 6 2 6 2 6 2 2
2 69159 Switch On/Off 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
3 65887 Spade Terminal 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
4 68000 Breather Vent 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
5 66012 Gasket Motor 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
6 68231 Gasket Pump 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
7 68608 Gasket Reservoir 1 1 1
66014 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
8 69242 Gasket Valve 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
69078 1 1
9 68258 Plug SAE #4 1 1 1 1 1 1 1 1 1 1 1 1 1 1
10 68551 Gasket Pump 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
68511 1 1 1
11 69090 Reservoir 1 1 1 1 1 1 1 1 1 1
18388 1 1 1 1 1
12 87492 Pipe Plug 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
13 69074 Shroud 1 1 1 1 1 1 1 1 1 1 1 1 1
69076 1 1 1 1 1
69570 1 1 1 1 1 1
14 69621 Manifold Assembly 1 1
69100 1 1 1 1 1
68581 1 1
15 68571 Filler Plug 1 2 1 2 2 1 2 2 2 2 2 2 2 2 2 2 2 2
16 68595 Cord & Plug 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
17 68963 Adapter Assembly 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
18 18718 Pump Assembly 1 1 1 1 1 1 1 1 1 1
18852 1 1 1 1 1 1 1 1
19 86095 Screw Cover 8 8 12 12 8 12 12 12 12 12 12 12 12
65891 12 12 12 12 12
20 87145 Plug-Shipping 1 1 1 1 1 2 2 2 1 2 1 1 1 1 2 2 1 2
21 68957 Motor Electric 1 1 1 1 1 1 1 1 1 1
68376 1 1 1 1 1 1 1 1
68094 1 1 1 1
22 68349 Valve Assembly 1 1 1 1 1 1 1
18379 1 1 1 1 1 1 1
23 93599 Screw Manifold 3 3 3 3 3 3 3 3 3 3 3 3 3 3
99921 3 3 3 3
24 85510 Locknut 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
25 68375 Fitting-Cord 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2
26 69026 Pin-Dowel 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
27 93596 Screw Motor 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
28 65892 Washer 12 12 12 12 12
29 66021 Magnet 1 1 1 1 1
30 65888 Push-On Terminal 6 6 6 6 6 6 6 6 6 3 6 6 6 6 6 6 6 6
31 68623 Rectifier 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
32 69071 MountingBracket 1 1 1 1 1 1 1 1 1 1
69256 1 1 1 1 1 1 1 1
33 68977 Circuit Board 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
34 93949 Hex Nut 2 2 2 2 2 2 2 2
35 88032 RHMS 10-32 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
36 96164 Receptical 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
37 69236 GHSCS 10-24 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
38 69251 Receptical Cap 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
39 69234 Hex Jam Nut 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
40 68964 SCR Self Form 7 7 7 7 7 7 7 7 7 7
41 86512 Screw 1/4 - 20 4 4 4 4 4 4 4 4
42 69018 Motor Cover 1 1 1 1 1 1 1 1 1 1
43 68262 Wire #14 4 4 4 4 4 4 4 4 4 4 4 2 2 2 2 2 2 2
44 69235 Hose Clamp 1 1 1 1 1 1 1 1
45 68682 Cover Plate (All Others) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
68607 Cover Plate (1 Gal. Only) 1 1 1
46 5602012 O-Ring 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
47 65881 Back-Up Ring 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
SECTION VI
PUMP ASSEMBIES FOR 20 SERIES PUMPS

18718
46
21
35
36
37
38
43
18
46 14 38 11 12 13 10 1
15 16
8 9 34
7
25 6
5
3 4
2
31
21 26
25 27
28
22
32 30
24 17 18 19 45 29 44 18 33
20
41 23
51
40
50 (For 5 Gallon Reservoir
49 Only.)
48
47
SECTION VI

18718
ITEM PART NO. QTY. DISCRIPTION ITEM PART NO. QTY. DISCRIPTION
1 68835 1 Pump Body 45 68892 1 Retaining Ring

2 68360 1 Roller Bearing 46 81093 2 PIpe Plug
3 66033 1 Thrust Bearing 47 68004 1 Ext. Relief Seat
4 66474 2 Race Bearing 48 68003 1 Ext. Relief Cone
5 69082 1 Ecc. Shaft Assm. 49 66085 1 Valve Relief Spring
6 66106 1 Thrust Bearing 50 66083 1 Adjust Screw
7 66108 1 Race Bearing 51 68884 1 5 Gallon Sucton
8 68829 1 Adaptor Shaft Assm. Tube & Screw
9 56020322 1 O-Ring (For 5 Gallon Reser-
10 68978 1 Retaining Ring voir Only.)
11 68979 1 Adaptor Pump .187 Dia.
12 68980 1 Piston Pump .187 Dia
13 68340 1 Piston Spring
14 68810 1 Ball Stop
15 93950 1 1/4 Socket Pipe Plug
16 68535 1 Piston Unloading Assm.
17 66043 1 Ball Retainer
18 90906 5 803C-7D Ball Bearing
19 66046 1 Intake Seat
20 68851 1 Tube Assm.
21 91701 2 R102-10B Ball Bearing
22 68981 1 Spring
23 68242 1 Set Screw
24 68920 1 Nut-Hex Jam
25 97641 2 Soc Pipe Plug Steel
26 68848 1 Center Plate .11
27 68849 1 Bottom Plate
28 68883 2 Gear Pump
29 68850 1 Shaft-Idler
30 68921 1 Screen
31 68894 2 Guide Tube
32 68255 4 Screw
33 68927 1 Plate-Screen Mount
34 69513 1 Backup Washer
35 68225 1 Spring
36 81332 1 Roll Pin 1/8 x 15/16
37 68226 1 Ball Stop Screw
38 85726 2 Gasket
40 89148 1 Screw
41 68569 1 Return Tube
43 66042 1 Spring
44 68891 3 Bearing
SECTION VI

18852
46
21
35
36
37
38
43
18 38
46 14 11 12 13 10 9 42
15 16 1
8
7
25 6
55
5
3 4
2 53
31
54
26
21 25
27
28
22 30
24 33
17 18 19 20 45 29 44 18 32
23
41
56
34
50 (For 5 Gallon Reservoir
49 Only.)
48
47
SECTION VI

18852
ITEM PART NO. QTY. DISCRIPTION ITEM PART NO. QTY. DISCRIPTION
1 68507 1 2 Piston Pump Body 45 68892 1 Retaining Ring

2 68360 1 Roller Bearing 46 81093 2 PIpe Plug
3 66033 1 Thrust Bearing 47 68004 1 Ext. Relief Seat
4 66474 2 Race Bearing 48 68003 1 Ext. Relief Cone
5 69082 1 Ecc. Shaft Assm. 49 66085 1 Valve Relief Spring
6 66106 1 Thrust Bearing 50 66083 1 Adjust Screw
7 66108 1 Race Bearing 53 68502 1 Piston Block Assm.
8 68829 1 Adaptor Shaft Assm. 54 82892 2 SHCS 5/16-24 X 2
9 56020322 2 O-Ring 55 82687 2 Screw
10 68978 1 Retaining Ring 56 68884 1 5 Gallon Suction
11 68945 1 Adaptor Piston .225 Dia. Tube & Screen
12 67868 1 Piston .225 Dia (For 5 Gallon Reser-
13 68340 1 Piston Spring voir Only.)
14 68810 1 Ball Stop
15 93950 1 1/4 Socket Pipe Plug
16 68535 1 Piston Unloading Assm.
17 66043 1 Ball Retainer
18 90906 5 803C-7D Ball Bearing
19 66046 1 Intake Seat
20 68851 1 Tube Assm.
21 91701 2 R102-10B Ball Bearing
22 68981 1 Spring
23 68242 1 Set Screw
24 68920 1 Nut-Hex Jam
25 97641 2 Soc Pipe Plug Steel
26 68848 1 Center Plate .11
27 68849 1 Bottom Plate
28 68883 2 Gear Pump
29 68850 1 Shaft-Idler
30 68921 1 Screen
31 68894 2 Guide Tube
32 68255 4 Screw
33 68927 1 Plate-Screen Mount
34 89148 1 Screw
35 68225 1 Spring
36 81332 1 Roll Pin 1/8 x 15/16
37 68226 1 Ball Stop Screw
38 85726 2 Gasket
41 68569 1 Return Tube
42 69513 2 Backup Washer
43 66042 1 Spring
44 68891 3 Bearing
PEM 20 & 70 SERIES ELECTRIC POWER PUMPS
Assembly #68829
1
Item Part Description Qty.
No.
1 68219 Adapter-Shaft 1
2 66030 Bearing 1
3 68901 Seal 1
Assembly #68535
No.
1 68209 Piston 1
2 5602010 O-Ring 1
3 68145 Back-Up Ring 1
4 4 93837 Roll Pin 1
1 2 3
4 3 2 1
Assembly #69082
No.
1 68859 Shaft Ecc. 1
2 69081 Ecc. Bearing Assembly 1
3 66108 Race Bearing 1
4 67863 Retaining Ring 1
1 15 Assembly #68502 (70 Series)
4
Item Part No. Description Qty.
68502
16 1 68501 Piston Block 1
14 3 2 90906 Ball St 803C-7D 2
13
3 66042 Spring 1
2 4 68810 Ball Stop 1
5 66043 Ball Retainer 1
6 66046 Intake Seat 1
5
12 7 86269 Gasket 1
2
8 68825 Screw 1
9 85727 Gasket 1
11
10 68915 Adapter 1
6
10 11 68340 Spring Piston 1
12 67868 Piston (Pump) 1
7 13 68445 Adapter Assembly 1
14 14 5602008 O-Ring 3
8 15 93949 SOC Pipe Plug 1/8 1
9
16 56080087 Back-Up Ring 2
No.
1 69092 2 Way Valve Block 1
69094 2
3
69095
5602111
Valve Stem
O-Ring
1
1
4 5608111 Back-Up Washer 8-111 1
2 WAY VALVE 5
6
91701
93835
Ball 5/16 R102
Pin Roll 1/8 x 1/2 LG
1
1
7 69091 Valve Handle 1
8 85961 Screw 1
9 68004 Seat-External Relief 1
10 68003 Cone-External Relief 1
1 66085 Spring Relief Valve 1
12 69104 Adjusting Screw 1
13 5623007 Spring 1
14 68963 Adapter Assembly 1
17 40049 1/16 Pipe Plug Flush 1
18 69105 Acorn Nut 1
19 87145 Hex St. Pipe Plug 2
20 69124 Washer 7/16 Nylon 1
2
6
17
4
9
3
19 12 0
5
1
13
11
13
14
10
18379 VALVE ASSEMBLY
68349 RETRACTOR VALVE ASSEMBLY
18 19 20
10
17
16
9
15
8
7
5 A
6 21
"A" "A"
5
14
13 22 2
23
4
12
11
View "A-A"
1
3
2
68349 - Use 11
18379 - Use 2
ITEM PART NO. QTY. QTY. DESCRIPTION

18379 68349
1 68160 1 1 Rotor Assembly
2 56020112 4 2 O-Ring
3 68180 1 1 Subplate-Valve.
4 5602225 1 1 O-Ring
5 68026 2 2 Thrust Washer
6 68155 1 1 Thrust Bearing
7 5602012 1 1 O-Ring
8 68035 1 1 Upper Valve Blk.
9 68024 1 1 Detent & Stop Plt.
10 93804 1 1 Driv-Lok Pin
11 5602011 3 6 O-Ring
12 65882 3 4 Back-up Washer
13 68181 3 4 Shear Seal
14 68028 3 4 Spring Washer
15 68025 1 1 Detent Spring
16 92549 1 1 Ball .250 Dia.
17 68032 1 1 Washer-Handle
18 68157 1 1 Flat Grip
19 68033 1 1 Handle
20 68034 1 1 Acorn Nut 1/2-20
21 85317 2 2 Soc. Hd. Capscrew
22 5602008 1 1 O-Ring
23 93598 4 4 Valve Mounting
3 WAY & 4 WAY LOCKING VALVE MANIFOLD
1 2 3 4 5
Assembly #68581 4 Way Lock Valve Manifold

No.
1 68591 Valve Body 1
2 92549 Ball - 1/4 3
3 68637 Release Gland 1
4 5602113 O-Ring 2-113 1
8 5 89435 Release Screw Assm. 1
6 6 56021115 O-Ring 2-111 1
8 5602010 O-Ring 2-010 1
14 2 15 16 17
10 66085 Relief Valve Spring 1
11 68003 Relief Valve Cone 1
12 68004 Relief Valve Seat 1
13 5608106 Back-Up Washer 8-106 2
14 68589 Ball retainer 2
15 5602106 O-Ring 2-106 1
16 68636 Spool 1
17 68590 Ball Seat 2
2
9 10 11 12 13
Assembly #69621 3 Way Lock Valve Manifold

3 4 5 6 1
2 11 No.
18
19 1 69573 Valve Body 1
2 68004 Seat-Ext. Relief 1
7
3 68003 Cone-Ext. Relief 1
4 66085 Spring Rel. Valve 1
B
21
B
6 69124 Washer 7/16 Nylon 1
24
SECTION B-B
7 69620 Retaining Sleeve 1
8 5602010 O-Ring 1
9 68145 Back-up Washer 1
16 22 10 56020125 O-Ring 1
14 13 9 12 A
10 8 15 17 11 87145 Hex St. Pipe Plug 1
12 69574 Spool 1
13 68183 Gasket-Plug 1
21
14 68184 Plug-Spool 1
23 20 15 92550 Ball 3/8 1
A 16 68080 Gasket Washer 1
SECTION A-A
17 68187 Port Adapter 1
19 68197 Nozzle-Valve 1
20 84084 Flush SOC 3/8-18 PTF 2
21 81093 1/8 SOC Pipe Plug 3
22 40049 1/16 Pipe Plug-Flush 2
23 68188 Compression Spring 1
24 41828 Loctite #RC/609 .10oz
3 WAY & 4 WAY VALVE MANIFOLD
9 2 10 1
8 6 5 4 3
11
SECTION A-A SECTION B-B

Assembly #69570 3 Way Manifold
8
7 A B 69570
1 69569 Ret. Valve Manifold 1
R A R 2 68197 Nozzle-Valve 1
3 68004 Seat-Ext. Relief 1
4 68003 Cone-Ext. Relief 1
7
A B
7 84084 Flush SOC 3/8-18 PTF 3
8 97641 1/16 SOC Pipe Plug 2
9 5602014 O-Ring 1
10 69124 Washer 7/16 Nylon 1
Assembly #69100 4 Way Manifold

69100
1 69099 4 Way Valve Manifold 1
3 69105 Acorn Nut 1
4 69124 Washer 7/16 Nylon 1
6 68003 Cone - Ext. Relief 1
7 68004 Seat - Ext. Relief 1
8 84084 Flush SOC 3/8-18 NPTF 2
8 4 5 6 7
8
B A A
3
1
WIRING DIAGRAM FOR SOLENOID VALVE ASSEMBLY
PENDANT SWITCH
WHITE ADV.
3 BLACK
RET.
BLACK
WHITE
CORD GREEN
GREEN
6 15 ADVANCE COIL RETRACT COIL 15

3
8 7
5 9
14 2
4 14
10
16
11 12 13
1
Part List For Solenoid Valve Assembly 3 Way/4Way
ITEM PART NO. QTY. DESCRIPTION
1 68710 1 Valve Assembly

2 66467 1 Pendant Switch
3 66132 2 Connector-Butt
4 68375 2 Fitting-Cord
5 66026 1 Cord
6 65887 1 Spade Terminal
7 98250 4 Screw, Fill Hd.
8 93943 4 Lock Washer
9 68388 1 Cover
10 68389 1 Gasket, Cover
11 5603910 2 O-Ring
12 68711 2 Spring
13 68730 2 Sol. Coil Assembly 115V
14 85510 2 Lock Nut
15 68093 2 Wire Nut
16 68729 2 Pusher Assembly
68710 VALVE ASSEMBLY
14
10
4 12
1 7
18 11
16
9
8 5 6
17
13
Part List For 68710 Valve Assembly 3 Pos./4 Way & 3 Pos./3 Way
ITEM PART NO. QTY. DESCRIPTION
1 68708 1 Body-Valve
2 68709 1 Slider
3 90548 1 Ball 303A-39B 3/16
4 40254 1 Set Screw 1/4-28 x 1/4
5 5602009 3 O-Ring
6 68391 3 Back-up Washer
7 68458 1 Plate-Shear Seal
8 68383 3 Shear Seal
9 68384 3 Spring
10 5602038 1 O-Ring
11 68385 4 Bearing Roller
12 68390 2 Pin Bearing
13 97641 1 Plug-Pipe 1/16
14 68264 2 Screw 10/32-1 SHC
15 68381 1 Top Plate (not shown)
16 84405 4 SCHD CP SCR 6-32 x 1/2
17 5602008 1 O-Ring
18 69636 2 Roll Pin .125 x .25
RDA2002, 2006, 20013
TON CYLINDER
A Division Of Templeton, Kenly & Co., Inc.
REPAIR PART SHEET
PART SHEET # 86183
REV. B
07/04
5
6
11 12
4 7
8
14 17
16
2 15
18
9
10
9
15
16
3
13 7
8 SERVI CE ASS
ENT OC
I
PM
AT
UI
EQ
ION
R EB
UI LD NT
ER S OF TOOLS & EQUI P ME
US
A
AD
A
N
MEMBER CA
RDA 2002, 2006, 20013 CYLINDER
MODELS
ITEM DESCRIPTION RDA2002 RDA2006 RDA20013 QTY
01 HOUSING 44829 87717 87723 1.00
02 PISTON 44828 87719 87725 1.00
03 BOTTOM 87722 87722 87722 1.00
04 RETAINING NUT 87720 87720 87720 1.00
05 LOAD CAP 87721 87721 87721 1.00
06 SHCS 1/2-13X1.00 95509 95509 95509 2.00
07 O-RING 5602263 5602263 5602263 2.00
08 BU-WASHER 5608263N 5608263N 5608263N 2.00
09 U-SEAL 87714 87714 87714 2.00
10 WEAR RING 87716 87716 87716 1.00
11 WIPER RNG 5601303 5601303 5601303 1.00
12 T-SEAL 5601185 5601185 5601185 1.00
13 FLUSH SOC 3/8-18PTF 84084 84084 N/A 1.00
14 WARNING DECAL 80827 80827 80827 2.00
15 FEMALE COUPLER 40858 40858 40858 2.00
16 DUST CAP CR215 CR215 CR215 2.00
17 RELIEF VALVE 10,500 PSI 84027 84027 84027 1.00
18 SIMPLEX LOGO LARGE 89967 89967 89967 1.00
PACKING KIT (* = CONTENTS) 54376 54376 54376 1.00
US T R Y W SIMPLEX products are warranted to be free of defects in materials and workmanship under normal use for as long as the original purchaser owns them,
IN D IT subject to the guidelines and limitations listed. This warranty does not cover: normal wear & tear, cosmetic items, abuse, overloading, alterations,
G
improper fluid, or use in a manner for which they are not intended. If the customer believes a product is defective, the product must be delivered, or
H
R V IN
P R I DE
shipped freight prepaid, to the nearest SIMPLEX Authorized Service Center for evaluation and repair.
SINCE - 1899
SE
Tem c.
pl eton ., I n
Kenly & Co
Q U A L IT Y 2525 GARDNER ROAD * BROADVIEW * ILLINOIS * 60155 * PHONE (708) 865-1500 * FAX (708) 865-0894
A Division Of Templeton, Kenly & Co., Inc.
HYDRAULIC CYLINDERS
CONTENTS Part #: 86183
English ...................................................... 2-6

Deutsch .................................................. 7-11
Franais ................................................ 12-16
Espaol ................................................ 17-21
Italiano .................................................. 22-26
Nederlands ........................................... 27-31
1
IM P OR TANT R E C E IVING INS T R UC T IONS
Vis ually ins pect all components for s hipping damage.

If any s hipping damage is found, notify carrier at once.
S AF E T Y INF OR M AT ION
WA R N I N G
S TAY C L E AR OF L OADS S UP P OR T E D B Y HY-
DR AUL IC S .
A cylinder, s hould never be us ed as a load holding

device. After rais ing the load, it s hould be s upported
by blocks or by cribbing.
WA R N I N G
DO NOT E XC E E D E QUIP M E NT R AT ING S .
Never attempt to lift a load weighing more than the

capacity of the cylinder. Overloading caus es
equipment failure and pos s ible pers onal injury.
8000
6000 10000
D
PSI
A N G E R
4000
2000
T hes e cylinders are des igned for a maximum

pres s ure of 10,000 ps i (700 bar). Do not us e thes e
cylinders in a s ys tem with a higher pres s ure rating.
WA R N I N G
B E S UR E T HE C Y L INDE R IS S TAB L E B E F OR E
L IF T ING L OAD.
T he cylinder s hould be placed on a flat s urface that

can s upport the load.
Loads mus t be centered on the cylinder plunger.

WRONG RIGHT
Off-center loads will damage cylinders and plung-
ers . In addition, the load may s lip or fall, caus ing
potentially dangerous res ults .
Dis tribute the load evenly acros s the entire s addle

s urface. Tilt s addles are available to reduce offs et
loading.
RIGHT WRONG
2
CAUTION
DO NOT KINK HYDRAULIC HOSE.
Avoid sharp bends and kinks when routing hydraulic

hoses. Sharp bends and kinks will internally
damage the hose leading to premature failure.
Do no drop sharp or heavy objects on hose. This

will cause internal damage to hose wire strands.
Applying pressure to a damaged hose may cause it
to rupture.
Do not use the hydraulic hose to carry a hydraulic

component (i.e. pumps, cylinders and valves).
CAUTION
KEEP HYDRAULIC EQUIPMENT AWAY FROM
FLAMES AND HEAT.
Excessive heat will damage hydraulic equipment.

Heat also weakens hose materials and packings. DO
NOT expose equipment to temperatures of 150F
(65C) or higher. Protect hoses and cylinders from
weld splatter.
3
INSTALLATION
1. Make hydraulic connections. Use a pump with a

release valve or a 3-way valve and one hose
for single-acting cylinders (1). Use a pump with
a 4-way valve and two hoses for double-acting
cylinders (2).
IMPORTANT
Double-acting cylinders must have both couplers
connected.
Fully hand-tighten all couplers. Loose coupler

connections can block the flow of oil.
2. Bleed air from the cylinder as shown below.
Single-acting cylinders: Position the cylinder so that

the plunger is pointed down and the cylinder lower
than the pump. Fully extend and retract the cylinder
2 or 3 times.
Double-acting cylinders: Lay the cylinder on its side

and have the couplers facing up. Fully extend and
retract the cylinder 2 or 3 times.
NOTE
Collar threads are rated for the full capacity of the
cylinder when fully engaged.
4
OPERATION
WARNING
DO NOT HANDLE PRESSURIZED HOSES.
Escaping oil under pressure can penetrate the
skin, causing serious injury or death. If oil is
injected under the skin, see a doctor immediately.
Operate the hydraulic pump to advance and retract

the cylinder. Some single-acting cylinders are spring-
return, others are load return. The speed of retraction
is affected by the length of the hose and other
restrictions in the line. Double-acting cylinders are
powered in both directions by the pump.
The cylinder stop ring is designed to take the full load.

However, to reduce cylinder wear, use less than full
stroke when possible.
MAINTENANCE
1. Use only Simplex oil with these cylinders.
2. Use dust caps when cylinders are disconnected

from the hose. Keep entire cylinder clean to prolong
cylinder life.
3. Store cylinders up-right and fully retracted to

prevent seal distortion.
5
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSES

Cylinder will not advance. Pump release valve open.
Coupler not fully tightened.
Oil level in pump is low.
Cylinder advances part way. Oil level in pump is low.
Cylinder advances in spurts. Air in hydraulic system.
Cylinder advances slower
than normal. Leaking connection.
Pump malfunctioning.
Cylinder advances but will
not hold. Cylinder seals leaking.
Pump malfunctioning.
Leaking connection.
Cylinder leaks oil. Worn or damaged seals.
Internal cylinder damage.
Cylinder will not retract or
retracts slower than normal. Narrow hose restricting flow.
Broken or weak retraction spring.
Cylinder damaged internally.
Oil leaking from external
relief valve. Coupler not fully tightened.
6
INSTRUCCIONES IMPORTANTES PARA LA RECEPCIN
Inspeccione visualmente todos los componentes para

ver si han sufrido daos durante el transporte. Si
existe algn deterioro comunquelo inmediatamente al
transportista.
INFORMACIN SOBRE SEGURIDAD
ADVERTENCIA
MANTNGASE ALEJADO DE LAS CARGAS
SOSTENIDAS POR DISPOSITIVOS HIDRULICOS.
Nunca debe usarse un cilindro hidrulico como

dispositivo para sujetar cargas. Despus de levantar
la carga, sta debe ser sustentada por bloques o por
un armazn de sustentacin.
ADVERTENCIA
NO EXCEDA LAS CAPACIDADES DEL EQUIPO
Nunca intente levantar una carga que exceda la

capacidad del cilindro. La sobrecarga puede causar
6000
8000
10000
fallos del equipo y lesiones personales.
D
ANGER
4000 PSI
2000
Estos cilindros estn diseados para una presin

mxima de 10.000 psi (700 bar). No use estos
cilindros en un sistema cuya presin nominal sea
mayor.
ADVERTENCIA
ANTES DE LEVANTAR LA CARGA, ASEGRESE
DE QUE EL CILINDRO SEA ESTABLE.
El cilindro debe estar colocado sobre una superficie

plana capaz de soportar la carga.
Las cargas deben estar centradas sobre el mbolo del

cilindro. Las cargas descentradas daarn los cilindros
y los mbolos. Adems, la carga podra resbalar y
caerse, con resultados potencialmente peligrosos.
Distribuya la carga uniformemente sobre toda la

superficie del asiento del cilindro. Se puede
disponer de asientos inclinables que ayudan a
reducir el descentrado de las cargas.
17
PRECAUCIN
NO RETUERZA LA MANGUERA HIDRULICA
Evite las curvas pronunciadas y no retuerza las

mangueras hidrulicas al colocarlas. Este tipo de
deformaciones causar daos internos a la
manguera, provocando fallos prematuros de la
misma.
No deje caer objetos pesados ni afilados sobre una

manguera. Esto causar daos internos en los
alambres de la manguera. Si se aplica presin a
una manguera daada, se podra causar su rotura.
No utilice una manguera hidrulica para acarrear

un componente hidrulico (es decir, bombas,
cilindros y vlvulas).
PRECAUCIN
MANTENGA EL EQUIPO HIDRULICO ALEJADO
DEL FUEGO Y DEL CALOR.
El calor excesivo daar el equipo hidrulico. Tambin

debilitar el material y las empaquetaduras de las
mangueras. NO exponga el equipo a temperaturas de
150F (65C) o superiores. Proteja las mangueras y
los cilindros de las salpicaduras de soldadura.
18
INSTALACIN
1. Conecte los componentes hidrulicos. Use una

bomba con una vlvula de alivio o una vlvula de 3
vas y una manguera para los cilindros de accin
nica (1). Use una bomba con una vlvula de 4
vas y dos mangueras para los cilindros de doble
accin (2).
IMPORTANTE
Los cilindros de doble accin deben tener ambos
acopladores conectados.
Apriete todos los acopladores manualmente. Las

conexiones flojas pueden bloquear el flujo del
aceite.
2. Purgue el aire del cilindro como se muestra a

continuacin.
Cilindros de accin nica: Coloque el cilindro de

modo que el mbolo apunte hacia abajo y el
cilindro est ms bajo que la bomba. Extienda y
retraiga el cilindro del todo 2 3 veces.
Cilindros de accin doble: Coloque el cilindro sobre

el costado con los acopladores hacia arriba.
Extienda y retraiga el cilindro del todo 2 3 veces.
NOTA
Las roscas del collarn estn graduadas para la
capacidad total del cilindro cuando estn
totalmente engranadas.
19
FUNCIONAMIENTO
ADVERTENCIA
NO MANIPULE MANGUERAS PRESURIZADAS.
Un escape de fluido hidrulico a presin puede
penetrar la piel, causando lesiones graves o la
muerte. Si se inyectase fluido bajo la piel,
consulte a un mdico de inmediato.
Accione la bomba hidrulica para extender y retraer el

cilindro. Algunos cilindros de accin nica tienen
retorno por resorte; otros tienen retorno por accin de
la carga. La velocidad de retraccin se ve afectada
por la longitud de la manguera y otras restricciones
en la lnea. Los cilindros de doble accin son
impulsados en ambos sentidos por la bomba.
El casquillo de tope del cilindro est diseado para

aceptar la carga total. Sin embargo, para reducir el
desgaste del cilindro, use menos del total de la
carrera siempre que sea posible.
MANTENIMIENTO
1. Utilice solamente aceite Simplex con estos

cilindros.
2. Use tapas guardapolvo cuando los cilindros estn

desconectados de la manguera. Mantenga limpio el
cilindro en su totalidad para prolongar la vida til
del mismo.
3. Guarde los cilindros en posicin vertical y

totalmente retrados para evitar que lo sellos se
deformen.
20
LOCALIZACIN DE AVERAS
PROBLEMA CAUSAS POSIBLES

El cilindro no avanza. La vlvula de alivio de la
bomba est abierta.
El acoplador no est
totalmente apretado.
Nivel bajo de aceite en la bomba.
El cilindro avanza parcialmente. Nivel bajo de aceite en la bomba.
El cilindro avanza de forma
irregular. Aire en el sistema hidrulico.
El cilindro avanza ms
lentamente que lo normal. Fugas en la conexin.
Mal funcionamiento de la bomba.
El cilindro avanza pero no
retiene su posicin. Fugas en los sellos del cilindro.
Mal funcionamiento de la bomba.
Fugas en la conexin.
Fugas de aceite en el cilindro. Sellos desgastados o daados.
Daos internos en el cilindro.
El cilindro no se retrae, o se
retrae ms lentamente Una manguera demasiado
que lo normal. delgada limita el flujo .
Resorte de retraccin roto
o debilitado.
Daos internos en el cilindro.
Fugas de aceite por la vlvula El acoplador no est
de alivio externa. apretado del todo.
21
PART NO. 70 - 6000 F2-200 (REV-G)
STANDARD REGENAIR BLOWER

OPERATION & MAINTENANCE MANUAL
Model R1 Shown Model R6P350A Shown Model R7P Shown
Thank you for purchasing this Gast product. It is manufactured to the highest standards
using quality materials. Please follow all recommended maintenance, operational
and safety instructions and you will receive years of trouble free service.
IMPORTANT: PLEASE READ THIS MANUAL AND SAVE FOR FUTURE REFERENCE.
General information
This manual does not apply to:
SDR Series blowers without motors

Blowers powered with Explosion Proof Motors
Product Use Criteria:
Pump only clean, dry air.

Operate at 32F - 104F (0C - 40C).
Protect unit from dirt & moisture.
Do not pump flammable or explosive gases or
use in an atmosphere that contains such gases.
Protect all surrounding items from exhaust air. This
exhaust air can become very hot.
Corrosive gases and particulate material will
damage unit. Water vapor, oil-based contaminants
or other liquids must be filtered out.
The blower must be installed with the properly sized inlet and inline filters, gauges and
relief valves to protect the product from dirt and over-heating.
Consult your Gast Distributor/Representative
before using at high altitudes.
ISO 9001 & 14001 CERTIFIED www.gastmfg.com
Registered Trademark/Trademark of Gast Manufacturing Inc., Copyright 2002 Gast Manufacturing Inc. All Rights Reserved. 1
Your safety and the safety of others Mounting
is extremely important. The single impeller blower should be oriented with the
shaft in a horizontal position, unless the models product
We have provided many important safety messages features state otherwise. The dual impeller models
in this manual and on your product. Always read must be mounted with the shaft in a horizontal position.
and obey all safety messages. Mounting the product to a stable, rigid operating surface
and using shock mounts will reduce noise and vibration.
This is the safety alert symbol. This symbol Rotation
alerts you to hazards that can kill or hurt you and From the motor side of the blower, check that the blower
others. The safety alert symbol and the words is rotating clockwise. (The motor side is marked with an
DANGER and WARNING will precede all safety arrow on most models.) Proper rotation can also be
messages. These words mean: checked by the air flow at the IN and OUT ports. On
blowers powered by a 3-phase motor, incorrectly
DANGER connecting any two power lines can reverse direction.
You will be killed or seriously injured if you dont Plumbing

follow instructions. Remove any foreign material (burrs, chips, welding
drops, slag, pipe cuttings, excess sealant, sand or
lime) from plumbing.
WARNING
Check motor mounting and rotation before connecting to
You can be killed or seriously injured if you dont
plumbing. Inlet and outlet ports are not designed to
follow instructions.
support plumbing.
All safety messages will identify the hazard, tell you
how to reduce the chance of injury, and tell you Remove plugs from the IN and OUT ports. Use a small
what can happen if the safety instructions are not amount of pipe thread lubricant when connecting
followed. plumbing to protect the aluminum blower threads.
Connect with pipe and fittings that are the same size or
larger than the products threaded ports. When
installing two blowers in parallel, use plumbing that is
INSTALLATION two whole pipe sizes larger in diameter than that of the
blower. Be sure to connect the intake and exhaust
plumbing to the correct inlet and outlet ports.
WARNING Plumbing to remove the hot discharge air of larger

blowers may be required to help maintain proper room
ambient temperature. Use a relief valve to discharge
excess air into the atmosphere. If the blower will be
operated at 125mbar (50 H2O) or higher, metal pipe is
required for hot exhaust air.
Accessories
Electrical Shock Hazard Install two vacuum gauges, one before and one after
filter, to monitor restriction through filters. As filters
Disconnect electrical power at the circuit breaker become clogged, performance efficiency will be
or fuse box before installing this product. reduced. Filters should be checked periodically and
Install this product where it will not come into replaced when necessary. See page 7 for installation.
contact with water or other liquids.
Install a relief valve to avoid changes in pressure or
Install this product where it will be weather vacuum that can cause overloading of large blowers.
protected. Install an intake filter with a relief valve to prevent
Electrically ground this product. foreign material from entering blower if blower is used in
Failure to follow these instructions can result in a vacuum application in a dirty environment. In
death, fire or electrical shock. applications where there is high humidity or liquids
being used in the process, install a moisture separator.
Correct installation is your responsibility. Make sure See Recommended Accessories on pages 7-9 or
you have the proper installation conditions and that consult your Gast Distributor/Representative for
installation clearances do not block air flow. additional filter and accessories recommendations. Do
Not install check valves that close with a strong spring.
Blocking air flow over the product in any way can The recommended check valves (page 7) provide
cause the product to overheat. minimal pressure drop, positive sealing and are
resistant to the high discharge temperatures of large
The blower must be installed with the properly sized blowers.
inlet filter, gauge and relief valve to protect the
Motor Control
product from dirt and over-heating.
It is your responsibility to contact a qualified
electrician and assure that the electrical installation
is adequate and in conformance with all national
and local codes and ordinances.
2
Select fuses, motor protective switches or thermal Model with a power supply cord:
protective switches to provide protection. Fuses act as This product must be grounded. For either 120-volt or
short circuit protection for the motor, not as protection 220/240-volt circuits connect power supply cord
against overload. Incoming line fuses must be able to grounding plug to a matching grounded outlet. Do not
withstand the motors starting current. Motor starters use an adapter. (See DIAGRAM A)
with thermal magnetic overload or circuit breakers
protect motor from overload or reduced voltage In the event of an electrical short circuit, grounding
conditions. Motors without automatic restart require reduces the risk of electric shock by providing an
thermal protection or magnetic over-current cutout to escape wire for the electric current. This product may
prevent motor overloading from one phase in a 3-phase be equipped with a power supply cord having a
circuit, high starting frequency or jammed blower. grounding wire with an appropriate grounding plug.
The plug must be plugged into an outlet that is properly
The power required will rise as differential pressure installed and grounded in accordance with all local
increases. The wiring diagram attached to the product codes and ordinances.
or on page 6 of this manual provides required electrical
Check with a qualified electrician or serviceman if
information. Large motors have two diagrams, one for
the grounding instructions are not completely
50Hz wiring specifications and the other for 60Hz wiring
understood, or if you are not sure whether the
specifications. Check that the power source is correct
product is properly grounded. Do not modify the
to properly operate the dual-voltage motor. If additional
plug provided. If it will not fit the outlet, have the
information is required, please consult your Gast
proper outlet installed by a qualified electrician.
Distributor/Representative.
Model that is permanently wired:
This product must be connected to a grounded, metallic,
Electrical Connection permanent wiring system, or an equipment grounding
terminal or lead on the product.
WARNING Power supply wiring must conform to all required safety

codes and be installed by a qualified person. Check
that supply voltage agrees with that listed on product
nameplate.
Extension cords:
Use only a 3-wire extension cord that has a 3-blade
grounding plug. Connect extension cord plug to a
Electrical Shock Hazard matching 3-slot receptacle. Do not use an adapter.
This product must be properly grounded. Make sure your extension cord is in good condition.
Check that the gage wire of the extension cord is the
Do not modify the plug provided. If it will not
correct size wire to carry the current this product will
fit the outlet, have the proper outlet installed
draw.
by a qualified electrician.
If repair or replacement of the cord or plug is An undersized cord is a potential fire hazard, and will
necessary, do not connect the grounding wire cause a drop in line voltage resulting in loss of power
to either flat blade terminal. The wire with causing the product to overheat. The following table
insulation that is green or green with yellow indicates the correct size cord for length required and
stripes is the grounding wire. the ampere rating listed on the product nameplate. If in
Check the condition of the power supply wiring. doubt, use the next heavier gage cord. The smaller
Do not permanently connect this product to the gage number, the heavier the wire gage.
wiring that is not in good condition or is
inadequate for the requirements of this product. Minimum gage for extension cords
Failure to follow these instructions can result in Amps Volts Length of cord in feet
death, fire or electrical shock. 120v 25 50 100 150 200 250 300 400 500
240v 50 100 200 300 400 500 600 800 1000
0-2 18 18 18 16 16 14 14 12 12
DIAGRAM A 2-3 18 18 16 14 14 12 12 10 10
3-4 18 18 16 14 12 12 10 10 8
4-5 18 18 14 12 12 10 10 8 8
5-6 18 16 14 12 10 10 8 8 8
6-8 18 16 12 10 10 8 6 6 6
8-10 18 14 12 10 8 8 6 6 4
10-12 16 14 10 8 8 6 6 4 4
12-14 16 12 10 8 6 6 6 4 2
14-16 16 12 10 8 6 6 4 4 2
Grounded Plug 16-18 14 12 8 8 6 4 4 2 2
Grounding Pin 18-20 14 12 8 6 6 4 4 2 2
120-volt grounded connectors

shown. 220 /240-volt grounded
connectors will differ in shape. Grounded Outlet
3
OPERATION MAINTENANCE
WARNING WARNING

Injury Hazard
Install proper safety guards as needed to prevent
any close contact with blower suction area.
Keep fingers and objects away from openings and
rotating parts.
Product surfaces become very hot during operation,
allow product surfaces to cool before handling.
Electrical Shock Hazard
Air stream from product may contain solid or liquid Disconnect electrical power supply cord before
material that can result in eye or skin damage, performing maintenance on this product.
wear proper eye protection. If product is hard wired into system, disconnect
Wear hearing protection. Sound level from some electrical power at the circuit breaker or fuse box
models may exceed 85 dBA. before performing maintenance on this product.
Failure to follow these instructions can result in Failure to follow these instructions can result in
burns, eye injury or other serious injury. death, fire or electrical shock.
It is your responsibility to operate this product at

recommended pressures or vacuum duties and WARNING
room ambient temperatures. Do not operate R4P or
larger size blowers without air flowing through the Injury Hazard
blower. Do not throttle discharge or suction pipe to Product surfaces become very hot during operation,
reducer capacity. Throttle will increase differential allow product surfaces to cool before handling.
pressure causing increasing power absorption and
Air stream from product may contain solid or liquid
working temperatures.
material that can result in eye or skin damage,
Start Up wear proper eye protection.
Operate blower for an hour and then check: Failure to follow these instructions can result in
1. Ambient temperature Check room and discharge burns, eye injury or other serious injury.
air temperatures. Increased room temperatures may
require stronger ventilation especially for larger
blowers. Exhaust air should not exceed 215F It is your responsibility to regularly inspect and
(102C) for all blowers less than 3.5 Hp. Exhaust air make necessary repairs to this product in order to
should not exceed 275F (135C) for all blowers maintain proper operation. Make sure that pressure
above 3.5 Hp. and vacuum is released from product before
2. Working pressure and vacuum values Adjust starting maintenance.
relief valve pressure or vacuum setting, if needed.
3. Motor current Check that supply current matches Check filter elements and noise absorbing foam used in
recommended current rating on product nameplate. mufflers and clean motor and blower after first 500
4. Electrical overload cutout Check that current hours of operation. Replace filter elements and
matches rating on product nameplate. determine how frequently mufflers should be checked
during future operation. This one procedure will help
If motor fails to start or slows down significantly under assure the products performance and service life.
load, shut off and disconnect from power supply. Check
that the voltage is correct for motor and that motor is When there is an increase in the differential pressure
turning in the proper direction. across the inlet filter it is beginning to clog with dirt.
Replace the cartridge when the filter will not come
clean.
Small motor bearings (less than 5.5 Hp) never need to

be greased. Larger motor bearings (greater than 5.5 Hp)
have alemite grease fittings. Use a grease gun and
apply one or two strokes of Exxon POLYREX grease
to the fittings to lubricate larger motor bearings.
4
Hours of Service Relubrication
Per Year Intervals
5,000 3 years
Continual Normal Service 1 year
Seasonal Service (motor 1 year at beginning of
idle for 6 months or more) season
Continuous-high ambients, 6 months
dirty or moist applications
Check that all external accessories such as relief

valves and gauges are not damaged before re-
operating product.
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. Gasts
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. GASTS 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, BUYERS
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 GASTS 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 customers responsibility.
CUSTOMER IS RESPONSIBLE FOR DETERMINING THE SUITABILITY OF GAST PRODUCTS FOR CUSTOMERS
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.
5
ELECTRICAL WIRING DIAGRAMS
Models Model
R1102, R2103, R2105, R3105-1, R3105-12, R4110-2, R4P115, R5125-2, R6125-2 R1S103
Low Voltage High Voltage Volt Volt

Single Phase Single Phase High Low
Blue P1 Line P1 Line Line A 1 1, 3, 5

Brown P2 P2 Insulate
Line B 4 4
Black 5 Tie together 5
Orange 3 & Insulate 3 Tie together Join 2, 3, 5
White 2 2 & Insulate
Yellow 4 Tie together Line 4 Line Join J, 8 2, J, 8
Models
R2303A, R3305A-1, R3305A-13, R4310A-2, R4P315A, R6350A-2, R6P350A, R6PP3110M,
R6PS3110M, R7100A-3, R7P3180M, R7S3180M, R93150A
Note: Model R6P355A has two additional leads labeled J for an external thermal motor protection circuit.
Connections for 3-Phase, 9 Leads

Model R9P3300M Only
T6 T5 T4 T6 T5 T4 T7 T8 T9 T6 T5 T4
T9 T8 T7 T9 T8 T7 T6 T4 T5 T9 T8 T7
T3 T2 T1 T3 T2 T1 T1 T2 T3 T3 T2 T1
Line Line Line Line

Low Voltage High Voltage Low Voltage High Voltage
Connections for 3-Phase, 12 Leads

Models R6335A-2, R6P335A Models R5325A-2, R6325A-2
T10 T11 T12 T10 T11 T12 T14 T15 T16 T14 T15 T16
T4 T5 T6 T4 T5 T6 T4 T5 T6 T4 T5 T6
T7 T8 T9 T7 T8 T9 T7 T8 T9 T7 T8 T9
T1 T2 T3 T1 T2 T3 T1 T2 T3 T1 T2 T3
Line Line Line Line

Low Voltage High Voltage Low Voltage High Voltage
To reverse rotation on any 3-Phase motor, interchange any two external motor line connections to any two line leads.
6
RECOMMENDED ACCESSORIES
The following diagrams are only suggested configurations for these accessories. These accessory configurations may
vary depending upon a particular units application.
MOISTURE SEPARATOR (FOR VACUUM)

This moisture separator removes liquids from the gas stream in a vacuum process.
This helps protect the blower from corrosion and the build up of mineral deposits.
For Model Number R3, R4, R5 R4, R4H, R4H, R4M, R4M, R6,
R4P, R5 R5, R6, R6P, R6PP,
R6P, R6PS, R7, R7H,
R7H R7P, R7S,
R9, R9S
Part Number RMS160 RMS200 RMS300 RMS400
CFM capacity 160 200 300 400
Liquid capacity (gal.) 10 19 19 40
Diameter (A) 14.8 19.7 19.7 24
Dimension (B) 37.5 35 35 44
NPT outlet (C) 2 2 2.5 3
Inlet diameter (D) 2 2 2.5 3
Dimension (E) 7.5 7.5 7.5 9.7
Dimension (F) 26.6 26.6 26.6 29 Explosion-proof, high level
float switch AJ213 (optional).
Maximum vacuum allowed: 22 Hg.
HORIZONTAL SWING TYPE CHECK VALVE

This check valve prevents backwash of fluids from entering the blower and air back-streaming.
The check valve can be mounted to discharge or inlet either vertically or horizontally. The check
valve will open with 3 of water pressure or vacuum.
Model Number R1, R2 R3 R4, R5, SDR4, R6, R6P, SDR6P, R7, R7S
SDR4, R4P SDR6, R6PS
Part Number AH326B AH326C AH326D AH326F AH326G
Dimension (A) 3.57 4.19 4.50 5.25 8.00
Dimension (B) 2.32 2.69 2.94 3.82 5.07
Dimension (C) 1.00 NPT 1.25 NPT 1.50 NPT 2.00 NPT 2.50 NPT
7
PRESSURE VACUUM GAUGE
Pressure/Vacuum Gauges
AJ496 2.50 Dia. Pressure 1/4 NPT 0-60 in. H2O and 0-150 mbar
AE133 2.50 Dia. Pressure 1/4 NPT 0-160 in. H2O and 0-400 mbar
AE133A 2.50 Dia. Pressure 1/4 NPT 0-200 in. H2O
AE133F 3.50 Dia. Pressure 1/4 NPT 0-15 PSI
AJ497 2.50 Dia. Vacuum 1/4 NPT 0-60 in. H2O and 0-150 mbar
AE134 2.50 Dia. Vacuum 1/4 NPT 0-160 in. H2O and 0-400 mbar
AE134F 3.50 Dia. Vacuum 1/4 NPT 0-15 in. HG
PRESSURE VACUUM RELIEF VALVE
Pressure/Vacuum Relief Valves
AG258 1.50 NPT Adjustable 30-200 in. H2O; 200 cfm max
AJ121D Silencer for AG258 Relief Valve
AG258F 2.50 NPT Adjustable 25-200 in. H2O; 560 cfm max
AJ121G Silencer for AG258F Relief Valve
INLINE FILTERS (FOR VACUUM)

The impeller of a blower passes very closely to the housing. It is recommended
to have an inlet or in-line filter to ensure a trouble-free service life.
MPT = Male Pipe Thread

FPT = Female Pipe Thread
Model Number R1 R2 R3 R4 SDR4, R4P, SDR5, SDR6, R6, R6PP, SDR6P, R7S, R9,
R4H, R5 R6P, R7H, R7M R6PS, R7, R7S R9P, R9S
Part Number AJ151A AJ151B AJ151C AJ151D AJ151E AJ151G AJ151H AJ151M
Dimension (A) 5.88 7.38 7.38 7.38 8.75 8.75 14.00 18.50
Dimension (A1) 16.25 20.75
Dimension (B) 4.50 6.81 6.81 6.81 10.25 10.50 27.13 28.13
Dimension (C) 2.75 4.62 4.62 4.62 5.00 5.50 18.50 19.50
Dimension (D) 1.00 FPT 1.00 FPT 1.25 FPT 1.50 FPT 2.00 FPT 2.50 FPT 3MPT 5 MPT
Dimension (E) 1.00 FPT 1.00 FPT 1.25 FPT 1.50 FPT 2.00 FPT 2.50 FPT 3MPT 5 MPT
Replacement AJ135D AJ135E AJ135E AJ135E AJ135F AJ135G AJ135C AJ135H

Element
Micron 10 10 10 10 10 10 10 10
8
INLET FILTERS (FOR PRESSURE)

All filters are heavy duty for high-particulate service. Inlet filters for
Regenair blowers are drip-proof when mounted as shown..
MPT = Male Pipe Thread

FPT = Female Pipe Thread
Model Number R1, R2 R3 R4, R4H, R4P SDR5, R6, SDR6, SDR6P, R7, R7H, R9, R9P,
SDR4, R5 R5P, R6PP, R6PS R7P, R7S R9S
Part Number AJ126B AJ126C AJ126D AJ126F AJ126G AJ126M
Dimension (A) 6.00 6.00 7.70 10.62 10.00 16.00
Dimension (B) 4.62 7.12 7.12 4.81 13.12 14.62
Dimension (C) 1.00 MPT 1.25 MPT 1.50 MPT 2.00 FPT 2.50 MPT 5 MPT
Replacement AJ134B AJ134C AJ134E AG340 AJ135A AJ135H

Element
Micron 10 10 10 10 10 10
MUFFLERS
Designed to reduce noise by up to 5 dbA and remove
high-frequency sound associated with all blowers.
Model Number R1, R2 R3 R4, SDR4, R4H, R6, R6P, R6PS R7, R7S R6PP, R9 R7P R9P R7
R4P, R5 SDR6P, SDR6 R7H Exhaust Exhaust Exhaust Exhaust
Part Number AJ121B AJ121C AJ121D AJ121F AJ121G AJ121H AJ121M AJ121N AJ121GE
Dimension (A) 7.46 7.94 12.75 17.05 17.44 20.30 33.60 39.00 17.63
Dimension (B) 2.38 2.62 3.25 3.63 4.25 4.75 6.00 7.00 4.28
Dimension (C) 1.00 NPT 1.25 NPT 1.50 NPT 2.00 NPT 2.50 NPT 3 NPT 4NPT 5NPT 2.50 NPT
PARTS & ORDERING INFORMATION
Please reference the exploded view on Page 11 for the following model and parts table.
REF# ITEM QTY R1102 R1S103 R2103 R2105 R2305B R3105-1

R1102C R2303A R3305A-1
R1102K R3305B-1
1 COVER 1 AJ101A AJ101AS AJ101B AJ101B AJ101B AJ101C
2 LOCK NUT 1 BC187 BC187 BC187 BC181 BC181 BC181
3 IMPELLER 1 AJ102A AJ102A AJ102BQ AJ102B AJ102B AJ102C
4 SQUARE KEY 1 AH212C AH212C AH212 AB136A AB136A AB136A
5 SHIM SPACER AE686-5 AE686-3 AJ109 AE686-3 AJ109
6 RETAINING RING 1 AJ145 AJ145 AJ149 AJ145 AJ149
7 HOUSING 1 AJ103A AJ103AS AJ103BQ AJ103B AJ103B AJ103C
8
9
10A FOAM AJ112A(4) AJ112BQ(6) AJ112BQ(6) AJ112BQ(6) AJ112C(4)
10B FOAM 2 AJ112CQ
11 MUFFLER EXTENSION 1 AJ106A AJ106BQ AJ106BQ AJ106BQ AJ106CQ
As required.
Parts listed are for stock models. For specific OEM models, please consult the factory.
When corresponding or ordering parts, please give complete model and serial numbers. 9
PARTS & ORDERING INFORMATION
Please reference the exploded view on the next page for the following model and parts tables.
REF# ITEM QTY R3105-12 R4110-2 R4P115 R5125-2 R6125-2 R6P335A R6135J-10
R3305A-13 R4310A-2 R4P315A R5325A-2 R6150J-2 R6P350A
R4310B-1 R5325B-1 R6325A-2 R6P350B
R6335A-2
R6335B
R6350A-2
R6350B-2
1 COVER 1 AJ101C AJ101D AJ101L AJ101EQ AJ101FB AJ101K AJ101FB
2 LOCK NUT 1 BC181 BC181 BC181 AJ259 AJ259 AJ259 AJ259
3 IMPELLER 1 AJ102CA AJ102D AJ102L AJ102E AJ102FR AJ102K AJ102FR
4 SQUARE KEY 1 AB136A AB136D AB136D AB136 AB136 AB136 AB136
5 SHIM SPACER AJ109 AJ109 AJ109 AJ109 AJ109 AJ109 AJ260A
5 SHIM SPACER 1 AJ109A
6 RETAINING RING 1 AJ149 AJ149 AJ149
7 HOUSING 1 AJ103C AJ103DR AJ103L AJ103EQ AJ103FQ AJ103K AJ103FQ
8 MUFFLER BOX 1 AJ104K
9 SPRING 2 AJ113DR AJ113DQ AJ113DQ AJ113FQ AJ113FQ AJ113FQ
9A SCREEN 2 AJ123EQ AJ123EQ AJ123FB AJ123FB
10A FOAM AJ112C(4) AJ112DS(4) AJ112ER(6) AJ112ER(6) AJ112FC(6) AJ112K(8) AJ112FC(6)
10B FOAM 2 AJ112CQ AJ112DR
11 MUFFLER EXTENSION 1 AJ106CQ AJ106DQ AJ106EQ AJ106EQ AJ106FR AJ106FR
REF# ITEM QTY R6P355A R6PP3110M* R6PS3110M* R7100A-3 R7100B-1

R6P350A
R6P350B
1 COVER 1 AJ101K AJ101KA(2) AJ101KA(2) AJ101G AJ101G
2 LOCK NUT/BOLT 1 AJ259 BB750(2) BB750(2) BB750 BB750
3 IMPELLER 1 AJ102K AJ102KA(2) AJ102KA(2) AJ102GZ AJ102GA
4 SQUARE KEY 1 AB136 AB136(2) AB136(2) AC628 AC628
5 SHIM SPACER AJ109 AJ169F AJ169F AJ110 AJ110
6 RETAINING RING 1
7 HOUSING 1 AJ103K AJ103KD(2) AJ103KD(2) AJ103GA AJ103GA
8 MUFFLER BOX 1 AJ104K AJ104GA AJ104GA
8A SCREEN 2 AJ998G AJ998G
9 SPRING 2 AJ113FQ
10A FOAM AJ112K(8) AJ112GA(8) AJ112GA(8)
10B FOAM 2
11 MUFFLER EXTENSION 1
12 ** O-RING 2 AJ175
13 GASKET 4 AJ107F AJ107F
REF# ITEM QTY R7P3180M* R7S3180M* R9P3300M* R9S3300M* R93150A
1 COVER 1 AJ101G(2) AJ101G(2) AJ100M(2) AJ100M(2) AJ101M

2 LOCK NUT/BOLT 1 BB750(2) BB750(2) BB707(2) BB707(2) BB707
3 IMPELLER 1 AJ102GZ(2) AJ102GZ(2) AJ102M(2) AJ102M(2) AJ102M
4 SQUARE KEY 1 AC628(2) AC628(2) AE130A(2) AE130A(2) AE130A
5 SHIM SPACER AJ110 AJ110 BJ110 BJ110 BJ110A
6 RETAINING RING 1
7 HOUSING 1 AJ103GA(2) AJ103GA(2) AJ103M(2) AJ103M(2) AJ103M
8 MUFFLER BOX 1 AJ104MP
8A SCREEN 2 AJ998M
9 SPRING 2
10A FOAM AJ112M(10)
10B FOAM 2
11 MUFFLER EXTENSION 1
12 ** O-RING 2 AJ175G AJ175G
R4P315A only.

* Dual models.
** Not shown.
As required.
Parts listed are for stock models. For specific OEM models, please consult the factory.
10 When corresponding or ordering parts, please give complete model and serial numbers.
EXPLODED PRODUCT VIEW
11
PART NO. 70 - 6000 F2-200 (REV-G)
TROUBLESHOOTING CHART
Problem Reason Remedy
Increased sound. Noise absorbing foam is damaged. Replace foam.

Impeller rubbing inside. Send unit to a Gast Authorized
Service Facility.
Excessive vibration. Damaged impeller. Replace impeller.

Motor and/or impeller are dirty. Clean motor and impeller periodically.
Ambient and exhaust temperature Motor and/or blower are dirty. Clean motor and blower periodically.
increases. Filters dirty. Replace filters.
Decreased inlet air pressure Inlet air filter is clogged. Clean inlet filter. Replace cartridge.
Unit is very hot. Wrong wiring. Check wiring.

Low voltage. Supply proper voltage.
Inlet air filter is clogged. Clean inlet filter. Replace cartridge.
Motor and/or blower are dirty. Clean motor and blower periodically.
Operating at too high a pressure or Install a relief valve and pressure or
vacuum. vacuum gauge.
Unusual sound. Impeller is damaged or dirty. Clean or replace impeller.

Bearing going bad. Send unit to a Gast Authorized
Service Facility.
Motor overload Low voltage. Check power source.

Check wire size and wire connections.
Unit does not start. Incorrect electrical connection or Check wiring diagram, circuit fusing
power source. and circuit capacity.
Impeller is damaged. Clean or replace impeller. Install
proper filtration.
AUTHORIZED SERVICE FACILITIES
Gast Manufacturing Inc. Gast Manufacturing Inc. Brenner Fiedler & Assoc. Gast Manufacturing Co., Ltd
2550 Meadowbrook Road 505 Washington Ave 13824 Bentley Place Beech House, Knaves Beech
Benton Harbor, MI 49022 Carlstadt, NJ 07072 Cerritos, CA 90701 Business Centre, Loudwater
TEL: 269-926-6171 TEL: 201-933-8484 TEL: 800-843-5558 High Wycombe, Bucks HP 10 9SD
FAX: 269-927-0808 FAX: 201-933-5545 TEL: 310-404-2721 England
www.gastmfg.com FAX: 310-404-7975 TEL: 44 628 532600
FAX: 44 628 532470
Wainbee Limited Wainbee Limited Japan Machinery Co., Ltd. General Correspondence
215 Brunswick Blvd. 5789 Coopers Avenue Central PO Box 1451 should be sent to:
Pointe Claire, Quebec Mississauga, Ontario Tokyo, 100-91 Japan Gast Mfg. Inc./A Unit of IDEX Corporation
Canada H9R 4R7 Canada L4Z 3S6 TEL: 81-3-3573-5421 P O Box 97
TEL: 514-697-8810 TEL: 905-568-1700 FAX: 81-3-3571-7865 Benton Harbor, MI 49023-0097
FAX: 514-697-3070 FAX: 905-568-0083 or: 81-3-3571-7896
ISO 9001 & 14001 CERTIFIED www.gastmfg.com
12
BLOWERS UK10103 10/99 D
For pressure applications always fit a relief valve set For products protected by thermal overloads within RESERVES THE RIGHT, AT ITS SOLE DISCRETION, TO
- ENGLISH - to the maximum working pressure but never higher the motor (Refer to motor label) ensure the product REFUND THE PURCHASE PRICE IN LIEU OF REPAIR
ORIGINAL INSTRUCTIONS than the maximum permitted pressure specified on the has not failed due to overheating or overload. OR REPLACEMENT.
technical data sheet. Automatic reset overloads will restart the product
Read these instructions carefully before you attempt to use this For vacuum applications it is recommended a relief when it has cooled down. GAST WILL NOT BE RESPONSIBLE OR LIABLE FOR
product. Only qualified engineers/electricians suitably trained valve is fitted set to the duty vacuum required. When INDIRECT OR CONSEQUENTIAL DAMAGES OF ANY
should undertake the installation and commissioning of this an intermittent vacuum is advised the product is only MAINTENANCE & SERVICE KIND, however arising, including but not limited to those for
product. permitted to operate at this level for short cyclic Switch the electricity supply "OFF" and isolate the use of any products, loss of time, inconvenience, lost profit,
periods. product. labour charges, or other incidental or consequential damages
USE OF PRODUCT Vent all pressure/vacuum from the product. with respect to persons, business, or property, whether as a
Wear eye protectors. ROTATION Inspect inlet filter/exhaust muffler elements and result of breach of warranty, negligence or otherwise.
This product must only be used for the purpose of For 3 phase electrical motors refer to the technical replace when necessary. Notwithstanding any other provision of this warranty,
section/product label for correct rotation. Filters will become blocked quickly in dirty BUYERS REMEDY AGAINST GAST FOR GOODS
pumping/evacuating air.
SUPPLIED OR FOR NON-DELIVERED GOODS OR
Do not pump or evacuate any other gases or liquids. environments. Establish service periods by checking
MOUNTING FAILURE TO FURNISH GOODS, WHETHER OR NOT
The performance of the product will be adversely condition after 200 hours.
effected at high altitudes. Supply and use correct size fasteners. Connect electricity supply and switch "ON". BASED ON NEGLIGENCE, STRICT LIABILITY OR
Use the fixing holes provided to secure the product. BREACH OF EXPRESS OR IMPLIED. WARRANTY, IS
This product must be protected from inclement The product will start immediately.
LIMITED SOLELY, AT GASTS OPTION, TO
weather. It is not suitable for exterior use. Guard all rotating parts.
REPLACEMENT OF OR CURE OF SUCH NON-
Do not stay in line with the air stream. Mount the single impeller product in the horizontal or GAST WARRANTY
CONFORMING OR NON-DELIVERED GOODS OR
Do not try to obtain higher pressures or vacuums than vertical plane. Mount the twin impeller product in the
RETURN OF THE PURCHASE PRICE FOR SUCH GOODS
those recommended. Refer to technical data sheet horizontal plane only. Gast finished products, when properly installed and operated
AND IN NO EVENT SHALL EXCEED THE PRICE OR
supplied. under normal conditions of use, are warranted by Gast to be
CHARGE FOR SUCH GOODS. GAST EXPRESSLY
Damage will occur if the product is driven at higher INITIAL STARTING AND PUTTING INTO SERVICE free from defects in material and workmanship for a period of
DISCLAIMS ANY WARRANTY OF MERCHANTBILITY
speeds than those recommended. Refer to technical Wear eye protectors. twelve (12) months from the date of purchase from Gast or an
OR FITNESS FOR A PARTICULAR USE OR PURPOSE
date sheet supplied. Do not stay in line with the air stream. authorised Gast Representative or Distributor. In order to
WITH RESPECT TO THE GOODS SOLD. THERE ARE NO
The product will start as soon as the electricity is obtain performance under this warranty, the buyer must
WARRANTIES WHICH EXTEND BEYOND THE
INSTALLATION switched "ON". promptly (in no event later than thirty (30) days after discovery
of the defect) give written notice of the defect to Gast DESCRIPTIONS SET FORTH IN THIS WARRANTY,
Refer to the technical sheet supplied for full technical notwithstanding any knowledge of Gast regarding the use or
WORK STATION Manufacturing Company Limited, A Unit of IDEX
specification. uses intended to be made of goods, proposed changes or
Use pipes that are the same size or a size larger than Wear ear protectors if your work area is in the vicinity Corporation, Beech House, Knaves Beech Business Centre,
additions to goods, or any assistance or suggestions that may
of the installation. Loudwater, High Wycombe, Bucks HP10 9SD, U.K. or an
the product ports. have been made by Gast personnel.
authorised Service Centre (unless specifically agreed upon in
See initial starting and putting into service before
SHUTDOWN AND STORAGE writing signed by both parties or specified in writing as part of
connecting this product. Unauthorised extensions of warranties by the customer shall
Turn the electricity supply "OFF". a Gast OEM Quotation). Buyer is responsible for freight
Do not use a hammer on the shaft or any drive charges both to and from Gast in all cases.
remain the customers responsibility.
coupling being fitted to the shaft. Vent all pressure/vacuum from the product and/or
Only qualified electricians should undertake the system. CUSTOMER IS RESPONSIBLE FOR DETERMINING THE
This warranty does not apply to electric motors, electrical
wiring of the electric motor. Disconnect the product from the pipe work. SUITABILITY OF GAST PRODUCTS FOR CUSTOMERS
controls, and gasoline engines not supplied by Gast. Gasts
The wiring of the electric motor should be made in Do not stay in line with the air stream. USE OR RESALE, OR FOR INCORPORATING THEM
warranties also do not extend to any goods or parts which
accordance with local electrical regulations. Turn the electricity supply "ON" and run the product INTO OBJECTS OR APPLICATIONS WHICH CUSTOMER
have been subjected to misuse, lack of maintenance,
Ensure that the product ventilation grilles are kept free open to atmosphere for approximately 15 minutes.
neglect, damage by accident or transit damage.
DESIGNS, ASSEMBLES, CONSTRUCTS OR
from obstruction. Leave the product to cool down. MANUFACTURES.
Do not place any objects, fingers, metal tools etc., Turn the electricity supply "OFF" and disconnect the THIS EXPRESS WARRANTY EXCLUDES ALL OTHER
through the grille holes. motor from the electrical supply. This warranty can be modified only by authorised Gast
WARRANTIES OR REPRESENTATIONS EXPRESSED OR
Check that the mains supply voltage is correct for the Fit plastic port plugs - See installation procedure IMPLIED BY ANY LITERATURE, DATE, OR PERSON.
personnel by signing a specific, written description of any
product - see nameplate. Contact the factory above (Retain plugs). modifications.
GASTS MAXIMUM LIABILITY UNDER THIS
immediately if the voltage conditions are different. The unit is now ready for storage. EXCLUSIVE REMEDY SHALL NEVER EXCEED THE
Effective 01/01/9
Remove the plastic port plugs, retain if you are likely COST OF THE SUBJECT PRODUCT AND GAST
to decommission and store the product in the future.- PRODUCT FAILURE
See shutdown and storage. Should the product fail to operate for any reason:
Do not touch the product during and just after Disconnect the electricity supply. TROUBLE SHOOTING GUIDE
operation as all parts of the product get very hot. Do not attempt to dismantle any part of the product
Supply and install a check valve, minimum 30 cm before the electricity is disconnected.
from port to prevent back pressure. The product is fitted with an automatic thermal Possible Reason Abnormal Excessive Blown Over Heating
Do not lubricate any part of this product. overload which if the product has failed due to Sound Noise Fuse
Do not install with pipes that are smaller than the size overheating will cause the product to restart when it Damaged Impeller X X
at the head ports. has cooled down. Dirt In Body X
Do not use thread tape to seal pipe threads. Wait until the product has cooled down.
Dirty Muffler X
Use only the correct pipe sealant on the thread. Refer to the Trouble Shooting Guide.
High Pressure X
Fit a recommended filter/muffler to the inlet/exhaust Contact the factory or distributor for further advice.
High Vacuum X
port. When the fault has been rectified the product will
Not Wired Correctly X
operate as soon as the electricity supply is switched
"ON".
Gast Manufacturing Co Ltd, Beech House, Loudwater, High Wycombe, Bucks, England. HP10 9SD Tel: +44 (0) 1628 532600
SOPLANTES UK10103 10/99 D
Instrucciones De Servico R1, R2, R3, R4, R5, R6, R7, R8

trabajo, pero nunca a una presin superior a la mxima energa elctrica en CONECTADO (ON).
- ESPAOL - permitida, especificada en la hoja de caractersticas
tcnicas.
En el caso de los productos protegidos por un protector
trmico contra sobrecarga colocado dentro del motor (Vea
En las instalaciones de vaco se recomienda la instalacin la etiqueta del motor) asegrese que el producto no se ha GAST NO SERA RESPONSABLE DE NINGUN DAO
Lea estas instrucciones cuidadosamente antes de usar este producto. INDIRECTO CONSECUENTE DE NINGUN TIPO, no importa
de una vlvula de seguridad tarada al vaco de trabajo parado debido a sobrecalentamiento o a sobrecarga. El
La instalacin y puesta en marcha de este producto solamente deben como surjan, incluido, pero sin lmite a los de uso de cualquier
requerido. Cuando se recomienda un vaco de trabajo rearme automtico del protector contra sobrecargas har
ser efectuadas por tcnicos/electricistas cualificados y entrenados producto, prdida de tiempo, inconveniencia, prdida de beneficio,
intermitente slo est permitido que el producto trabaje a que el producto se vuelva a poner en marcha al enfriarse.
adecuadamente. cargos de mano de obra u otro dao incidental o consecuente en
este nivel durante perodos cclicos cortos.
MANTENIMIENTO Y SERVICIO relacin con otras personas, empresas o propiedad, ya sea como
USO DEL PRODUCTO
SENTIDO DE GIRO Desconecte el interruptor de suministro de energa resultado o incumplimiento de garanta, negligencia o de otro modo.
Use gafas de seguridad.
En los motores elctricos trifsicos consulte la seccin de elctrica y asle el producto. A pesar de cualquier otra provisin de esta garanta, EL REMEDIO
Este producto solamente debe usarse para bombear/extraer datos tcnicos o la etiqueta del producto para ver el sentido Elimine toda la presin o vaco del producto. DEL COMPRADOR CONTRA GAST POR MATERIALES
aire. de giro correcto. Inspeccione los elementos del filtro de entrada y del SUMINISTRADOS O POR FALTA DE ENTREGA DE
No bombee ni extraiga ningn otro gas ni lquidos. MATERIALES O INCLUMPLIMIENTO DE ENTREGA DE
silencioso del escape y sustityalos cuando sea necesario.
Las prestaciones del producto se vern disminuidas a MATERIALES, SEA O NO SEA POR NEGLIGENCIA,
INSTALACION En los ambientes polvorientos los filtros se atascan
altitudes elevadas. Obtenga y use elementos de sujecin del tamao correcto. RESPONSABILIDAD ESTRICTA O INCUMPLIMIENTO
rpidamente. Establezca los perodos de servicio
Debe protegerse el producto de las inclemencias Para sujetar el producto use los orificios de fijacin comprobando su estado despus de 200 horas. EXPRESO O IMPLICITO, LA GARANTIA ESTARA
atmosfricas. No es adecuado para uso al aire libre. LIMITADA, UNICAMENTE, A LA OPCION DE GAST AL
existentes. Conecte la alimentacin de energa elctrica y coloque el
No permanezca enfrente del chorro de aire. Proteja todas las piezas giratorias. interruptor en CONECTADO (ON). RECAMBIO O REPARACION DE LOS MATERIALES
No intente conseguir presiones o vacos mayores de los Los productos con un solo impulsor se pueden montar en El producto se podr en marcha inmediatamente.
INCOMPLETOS O NO ENTREGADOS O REEMBOLSO DEL
recomendados. Consulte la hoja de caractersticas tcnicas el plano horizontal o en el plano vertical. Los productos PRECIO DE COMPRA DE DICHOS MATERIALES, Y EN
suministrada. con dos impulsores slo se pueden montar en el plano NINGUN CASO EXCEDERA EL PRECIO O COBRO DE
Garanta de GAST
Se producirn daos si se hace funcionar el producto a horizontal. DICHOS MATERIALES.
velocidades ms elevadas de las recomendadas. Consulte Los productos terminados de Gast, debidamente instalados y en
la hoja de caractersticas tcnicas suministrada. PUESTA EN MARCHA INICIAL Y OPERATIVA GAST RENUNCIA EXPRESAMENTE A CUALQUIER
funcionamiento en condiciones normales de uso, estn garantizados
GARANTIA DE COMERCIABILIDAD O APTITUD PARA UN
Lleve gafas de seguridad. por Gast en sus materiales y mano de obra, durante un perodo de
INSTALACIN USO O FIN EN PARTICULAR DE LOS MATERIALES
No se ponga delante del chorro de aire. doce (12) meses a partir de la fecha de compra a Gast o a un
Para ver la especificacin tcnica completa consulte la El producto se pondr en marcha tan pronto como se Representante o Distribuidor Autorizado de Gast. Para poder
VENDIDOS. NO HAY GARANTIAS QUE CUBRAN MAS
hoja de caractersticas tcnicas suministrada. ALLA DE LAS DESCRIPCIONES ESTABLECIDAS A
conecte la energa elctrica. obtener un rendimiento cubierto por esta garanta, el comprador
Use tuberas del mismo tamao que las conexiones del debe comunicar con toda urgencia (en ningn caso despus de
CONTINUACION EN ESTA GARANTIA, a pesar de cualquier
producto o del tamao inmediatamente superior. conocimiento de Gast en relacin con el uso o usos intencionados de
LUGAR DE TRABAJO treinta (30) das de descubrir el defecto) por escrito los defectos a
Antes de conectar este producto vea Puesta en marcha los materiales, cambios o adiciones propuestos a los materiales, o
Lleve auriculares protectores si su lugar de trabajo est Gast Manufacturing Corporation, PO Box 97, Benton Harbor
cualquier asistencia o sugerencia que se puedan haber hecho por el
inicial y operativa. cerca de la instalacin. Michigan EE.UU 49023-0097 o a un Centro de Servicio autorizado
No use martillos sobre el eje ni ningn acoplamiento de personal de Gast.
(a menos que se acuerde expresamente por escrito firmado por las
arrastre para montarlo sobre el eje. PARADA Y ALMACENAJE dos partes o establecido por escrito como parte del Presupuesto Gast
El cableado al motor elctrico solamente debe ser Las ampliaciones sin autorizacin de garantas por el cliente sern
Desconecte la alimentacin de energa elctrica ("OFF"). OEM). El comprador es responsable de los gastos de transporte en
responsabilidad de dicho cliente.
efectuado por un electricista cualificado. Elimine toda la presin o vaco del producto y/o el todos los casos entre su punto de destino y Gast en ambas
El cableado del motor elctrico debe efectuarse de acuerdo sistema. direcciones.
EL CLIENTE ES RESPONSABLE DE DETERMINAR LA
con las normas sobre instalaciones elctricas locales. Desconecte el producto de la instalacin de tuberas. APTITUD DE LOS PRODUCTOS GAST PARA EL USO O
Asegrese que las rejillas de ventilacin estn libres. No permanezca delante del chorro de aire.
Esta garanta no cubre los motores elctricos, controles elctricos ni
REVENTA DEL CLIENTE, O PARA SU INCORPORACION A
No introduzca ningn objeto, los dedos, herramientas Conecte la energa elctrica y deje que el producto
motores de gasolina que no estn suministrados por Gast. Las
LOS FINES O APLICACIONES QUE EL CLIENTE DISEE,
metlicas, etc. por los orificios de las rejillas. garantas de Gast tampoco cubren ningn material que se haya
funcione abierto a la atmsfera durante 15 minutos MONTE, CONSTRUYA O FABRIQUE.
Compruebe que la tensin de alimentacin de la red es la aproximadamente.
sometido a uso indebido, falta de mantenimiento, negligencia, dao
correspondiente al producto -vea la placa de por accidente o dao en trnsito.
Deje que el producto se enfre. Slo el personal autorizado de Gast podr modificar esta garanta
caractersticas. Si la tensin es diferente pngase en Desconecte la alimentacin de energa elctrica ("OFF") y firmando un descripcin de cualquier modificacin por escrito
contacto con la fbrica inmediatamente. ESTA GARANTA EXPRESA EXCLUYE CUALQUIER
desconecte el motor de la red de alimentacin de energa GARANTIA O MANIFESTACION EXPRESA O IMPLICITA
Desmonte los tapones de plstico de las conexiones. elctrica. Efectivo a partir del 1/1/98
Consrvelos si es posible que vaya a retirar de servicio y HECHA POR CUALQUIER INFORMACION, DATOS O
Coloque tapones de plstico en las conexiones - Vea el PERSONA. LA RESPONSABILIDAD MAXIMA DE GAST
almacenar el producto en el futuro. Vea parada y procedimiento de instalacin anterior (Guarde los
almacenaje. CONFORME A ESTA GARANTA NUNCA EXCEDERA EL
tapones). COSTE DEL PRODUCTO EN CUESTION Y GAST SE
No toque el producto durante el funcionamiento y justo La unidad est lista para almacenaje.
despus de ste ya que las piezas alcanzan temperaturas RESERVA EL DERECHO, A SU SOLA DISCRECION, DE
muy altas. REEMBOLSAR EL PRECIO DE COMPRA EN LUGAR DE
AVERIAS REPARACION O RECAMBIO.
Adquiera e instale una vlvula antirretorno, a una distancia En el caso de que el producto no funcione por cualquier causa:
mnima de 30 cm de la conexin para evitar la Desconecte el suministro de energa elctrica.
contrapresin. UIA DE LOCALIZACION DE AVERIAS
No intente desmontar ninguna parte del producto antes de
No lubrique ninguna parte de este producto. que la energa elctrica est desconectada.
No lo instale con tuberas menores que el tamao de las El producto est equipado con un protector trmico contra Causa posible Sonido Ruido Fusible Sobrecalentamient
conexiones de la culata. sobrecarga, que hace que el producto vuelva a ponerse en anormal excesivo fundido
No use cinta para roscas para sellar las roscas de la tubera. marcha al enfriarse, en el caso de que se haya parado Impulsor daado X X
Use en la rosca solamente el sellante para tuberas debido a sobrecalentamiento.
correcto. Suciedad en el cuerpo X
Espere a que el producto se haya enfriado. Silencioso sucio X
Coloque un filtro y un silencioso recomendados en las Consulte la Gua de Localizacin de Averas.
conexiones de entrada y de salida. Presin alta X
Para informacin adicional pngase en contacto con la Vaco alto X
En las instalaciones de presin coloque siempre una factora o con el distribuidor.
vlvula de seguridad tarada a la presin mxima de Conexionado incorrecto de los cables X
Una vez corregida la avera, el producto se pondr en
marcha tan pronto como se coloque el interruptor de
Gast Manufacturing Co Ltd, Beech House, Loudwater, High Wycombe, Bucks, England. HP10 9SD Tel: +44 (0) 1628 532600

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CHANCADOR TRAYLOR

MANUAL DE INSTALACION, OPERACION Y MANTENIMIENTO

COVER PAGE - VOLUME 2

FFE MINERALS USA., INC.

Volumen COMENTARIOS REV. POR FECHA

Distribucion: Cliente : 6 Copias & 3 Copias Electronica

DISTRIBUTION AND REVISION RECORD

El presente manual es un servicio de FFE Minerals U.S.A. Inc. A pesar de

FFE MINERALS U.S.A. INC., SUS AGENTES, REPRESENTANTES Y

Todos los contenidos dentro de este manual, incluyendo, aunque no limitado a,

AL USAR ESTE MANUAL UD RECONOCE HABER LEIDO, COMPRENDIDO Y

SE ESTABLECEN EN EL PRESENTE MANUAL REGLAS

A Spanish translation of this Installation, Maintenance and

In the event of any inconsistency or conflict between the English and

Se ha hecho llegar una versin en Espaol para el Manual de

En la eventualidad de existir alguna disconformidad o mala

INFORMACION ACERCA ESTE MANUAL

ESTE MANUAL CONSTA DE 3 VOLUMENES.

CADA VOLUMEN CONTIENE ESTA DESCRIPCIN & UNA TABLA

EL CONTENIDO DE LOS VOLUMENES ES:

VOLUMEN 1: INSTRUCCIONES DE INSTALACIN, OPERACIN

VOLUMEN 2: PLANOS E INSTRUCCIONES DE

ABOUT THIS MANUAL

RTD de Minco S56

Soporte de Minco FG110-1

3 UNIDAD HIDRAULICA Y DE LUBRICACION

1 Listado de Materiales 6.507158 0

- Hoja Tecnica, Motor MDSL0001-04

- Instrucciones de IOM, Motor

- Instrucciones de Lubricacion MDS-O-0001

5 VALVULA DE ALIVIO DE LUBRICACIN,

Contador de Flujo, Plano Serie MN 6.507816 3

Contador de Flujo, Catalago Serie SN

7 VALVULA DE BOLAS CON MOTOR,

Vlvula de bolas, Jamesbury, Manual de

Actuador, Jamesbury, Instrucciones de IMO-516 7065 12/01

Actuador Elctrico, Limitadores adicionales de IMO-505 01/02

ENSAMBLE VALVULA ALIVIO &

Lquidos a base de petrleo para ser usados en

Ensamble, Puesta en Marcha y Mantencin de

Ensamble, Puesta en Marcha & Servicio de

Vlvulas de Cartucho de 2 vas Espaol RS 21 050/02.03

Acumulador 9 535 233 184/01.04

Instrumento de Carga & Prueba de Acumulador 1 539 929 009

Bomba Electrica Rotatoria tipo FloMaster 422823

Interruptor Limitador Serie D 402877

11 SISTEMA INDICADOR DE POSICION DEL EJE

Transmisor de Seal, Sistema M, Modelo W2VS ES-5518 Rev 3

Bloque terminal montado sobre riel, 020000000

12 ACOPLAMIENTO DE ENGRANAJE &

S56PA124Z24 EXAMPLE OF MODEL NUMBER

S56 SPECIFICATIONS DRAWING NUMBER.

124 CASE LENGTH A IN .1O INCREMENTS (124 = 12.4O).

24 LEAD LENGTH B IN INCHES.

1. ELEMENTS (2): COPPER, NICKEL, OR PLATINUM.

Print Date: 05/20/2010 16:32

1. HOLDER IS EQUIPPED WITH AN O-RING TO SEAL AROUND PROBE.

Print Date: 05/20/2010 16:32

CH103P4T6 EXAMPLE OF MODEL NUMBER

CH103 SPECIFICATIONS DRAWING NUMBER.

P4 PIPE THREAD CODE:

T6 TYPE OF CONNECTION POINTS: 2

1. CONNECTION HEAD PROVIDES A WEATHERPROOF ENCLOSURE IN