Mo 0431 0 Sopladores Flakt

IAHMX - 9544 - HA - EN - 01 - MO-0431-0-1906 Instalation, Operation
Cliente: Petro-Chem Mexicana & Maintenance Manual

Referencia Cliente: -
Planta Cliente: - Centrifugal Fan
Modelo Ventilador: HABB-100-141-13-1-1-1
HA
Flkt Mxico Fans. S.A. de C.V.

We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure
to third parties without express authority is strictly forbidden. Flkt Group 2003.
Nos reservamos todos los derechos para este documento y para el objeto representado en el mismo. Queda
prohibido, sin nuestro consentimiento expreso, la reproduccin, la comunicacin a terceros o el empleo de su
contenido. Flkt Group 2003.
2
Contents
Page
I. General Information.
1.1 Frame of reference. 5
1.2 Introduction. 5
1.3 Description of fan. 5
1.4 Condition of delivery. 7
II. Installation.
2.1 Foundation. 9
2.2 Anchoring frame to foundation. 9
2.3 Transmission alignment Shaft - Coupling Motor. 10
2.4 Impeller assembly. 11
2.5 Adjustment of clearances and tolerances. 12
2.6 Bearings . 12
2.7 Vibration and Sound Insolation . 13
III. Operation.
3.1 Connection to general networks. 16
3.2 Precautions prior to first start-up. 16
3.3 Start-up test. 17
3.4 Troubleshooting. 17
IV. Maintenance.
4.1 Casing. 18
4.2 Impeller. 18
4.3 Bearing housings. 18
4.4 Coupling. 19
4.5 Motor. 19
4.6 Impeller replacement. 19
V. Drawings included.
General Arrangement Drawing 23
Flkt Mxico Fans

3
Hoja de Identificacin / Leaf of Identification
Designacin / Designation
Cliente / Client: Petro-Chem Mexicana
Su referencia / Its reference: - Nuestra referencia / Our reference: 051542-07
Nmero de Maquina / Number of Machine:
Planta Cliente / Plant Client: -
TAG F-1857/IDF H-10001 A
Descripcin del Ventilador / Description of the Fan
Serie / Series: HABB-125-172-13-6-1-7 Arreglo / Arrangement: 7
Rotacin / Rotation (Vista Lado Motor / Motor Side) CCW
Datos Principales / Main data
Aerodinmica / Aerodynamic Unidad / Unit
Flujo / Flow: 33.5 m/seg
Temperatura / Temperature: 191 C
Presin Esttica a la Succin / Pressure Static to the Suction -1668 PA
Presin Esttica a la Descarga / Pressure Static to the Discharge 0 PA
Consumo de Potencia / Absorbed Power 152 kW
Velocidad / Velocity: 1200 RPM
Peso / Weight Unidad / Unit
Motor / Motor 3237 lb
Rotor Completo / Rotor Complete 2342 lb
Ventilador / Fan 15792 lb
Descripcin Mecnica / Mechanical description
Chumacera Libre / Bearing Free: SONL 220-520 Rodamiento / Bearing: 22
Chumacera Fija / Bearing Fixed: SONL 220-520 Rodamiento / Bearing: 22
Manguito / Sleeve: HE Anillo / Ring: FRB Flecha / Shaft: 3-35/64"
Engrasado / Greased
Grasa o Aceite Utilizada / Grease or Oil Utilized SAE 30
Intervalo de Lubricacin / Interval of Lubrication -
Cantidad de Grasa / Quantity of Grease -
Cantidad de Aceite P/Llenado / Oil quantity to fill 0.6 l
Descripcin de la Transmisin Poleas y Bandas / Description of the Transmisin Poleas and Bands
Polea Motriz: Manguito: Barreno: Juego de _____SP
Polea Conducida: Manguito: Barreno: C/c entre Ejes:
Tensin Inicial To:
Descripcin de la Transmisin por Cople / Description of the Transmission by Coupling
Marca / It marks: Rexnord Modelo / Model: Thomas 412 Serie 71
Motor Elctrico / Motor Electric
Marca / It marks: WEG Armazn / Frame: 586/7T
Potencia / Power: 250 HP Velocidad de Rotacin / Velocity of Rotation: 1200 RPM
4
For reference to the equipment, section VI
of this manual includes the General
Arrangement drawing.
As equipment manufacturers, we
recommend contracting our specialized
service Supervision of equipment
installation and start-up. When you
contract this service, you are provided with
the necessary assistance as well as the
supervision of a technician in your plant
during installation, test runs and start-up.
The cost of this assistance is minimal
compared to the savings you can obtain in
terms of time, materials, labor and out-of-
service systems.
SECTION I Please contact our Industrial Fans Sales
General Department at:
Telephone: +52 (55) 5899-1330

Information Fax: +52 (55) 5899-1348
1.3 Description of fan.

The specifications of HA fans vary to suit
different conditions and the individual
1.1 Reference Frame. requirements of each customer. Certain
parts therefore differ design.
Company name: Petro-Chem The casing (1) is all-welded in its
Mexicana construction (see fig. 1.5), and if required, it
Customer reference: - can be bipartite. It is equipped with an
Our reference: 051542-07
Model: HABB-125-172-13-6-1-7 inspection door, which bolts on for easy
handling, as well as drain boss.
The inlet and outlet ducts are supplied with
1.2 Introduction. flanges that have bored holes, which allow
This manual was prepared by Flkt for the attachment of accessories and/or
ducts used in the system.
Mxico Fans, S.A. de C.V. It serves two
functions: as technical support, and to The fan impeller (3) is balanced both
cover the different alternatives available for statically and dynamically.
the installation, operation and maintenance The construction of the shaft is designed
of your centrifugal fan. according to the temperature and speed of
operation. It comes with key seats on the
ends for assembly.
Flkt Mxico Fans

5
The impeller is attached to the transmission Machined surfaces are provided on the
shaft by means of a safety washer and a stand for plummer blocks and motor.
wedge. Ensure that the wedge is
completely lodged in the key seats of the
hub and the transmission shaft.
1=0 2=45 3=90 4=135

Types and classes of impeller designs
Impeller Applications/features
type
General uses e.g. forced
draught fans for boilers.
Backward-curved blades
5=180 6=225 7=270 8=315

For handling clean gases
and gases with low (non- Fig.1.1 Clockwise Rotation (CW).
sticking) dust content.
Low noise level. The bearings can be oil-lubricated or
B
Self-limiting power grease-lubricated, depending on the fan

characteristics.
speed and loading. The fan unit incorporate
two plummer blocks for spherical roller
Induced draught fans for bearings designed for fitting to the shaft on
oil-fired boilers. adapter sleeves.
Flat Backward-inclined
For gas transportation in

process industries.
For handling gases with
blades
moderate dust content.

P
Self-limiting power
characteristics.
Good self-cleaning 1=0 2=45 3=90 4=135
characteristics (not for

moist dust)
Induced draught fans.
Gas transportation in
Flat radial blades
process industries.
For handling gases with 5=180 6=225 7=270 8=315
higher dust content or Fig.1.2 Counter Clockwise Rotation (CCW).

S
moist dust.
Very good self-cleaning
The transmission is mounted on the frame
self-characteristics
Withstands high (2) in order to achieve uniform settling of
temperatures. the bearing housings and the motor. The
bases of the bearing housings are
machined.
The transmission (fan shaft) to motor
connection is direct driven across a flexible
coupling. This coupling absorbs Flkt Mexico discharge angles for
misalignment between the shafts, and has centrifugal fans (side-view of motor)
an axial displacement. Its design permits
installation by means of wedges, and it can
also support great loads.
6
f=1 (0 ) f=2 (45 ) f=3 (90 ) f=4 (135 )
f=5 (180 ) f=6 (225 ) f=7 (270 ) f=8 (315 )
Fig.1.3 Flkt Mexico angles for inlet box

(side-view of motor).
Fan components
01. Casing 10. Shaft cover Fig.1.6 HAB Fan.
02. Frame 11. Coupling cover
03. Impeller 12. Coupling
04. Suction cone 13. Motor
05. Mechanical seal 14. Reduction*
06. Safety washer 15. Inspection door*
07. Shaft 16. Suction box*
08. Bearing housings 17. Hub*
09. Identification plaque 18. Cooling disk**
*Optional accessories
**Cooling disk required for temperatures greater than 100 C
Fig.1.7 Inlet Vane control (only for fan sizes

031, 035 and 045).
1.4 Condition of delivery.
Flkt Mexico Fans, S.A. de C.V.

delivers HA fans, with impeller diameter
less than 1655 mm, in assembled condition
Fig.1.4 HAC Fan: Short frame. since it can be acomodated within
permissible transport load profiles.
Larger sizes, with impeller diameters of
1655 mm or above, are delivered in
dismantled condition for assembly at site,
ease of transportation and handling.
The bolt supply, packing and accessories
are adequately packaged for their
transportation.
When the equipment is loaded on the
Fig.1.5 HAC Fan: Long frame. transport, it then becomes property and
Flkt Mxico Fans
7
responsibility of the client. Therefore, it
must be inspected before and after
accepting the equipment from the
transporter.
Any missing, broken or damaged

parts must be noted at the moment
of receipt of the equipment. This
must be stated on the bill of lading,
and ensure that the transporter or a
representative recognize this with a
signature. The Transportation
Company must then be notified so
that it can then prepare a written
report of the damages that occurred.
If the fan is not to be put in use

immediately, proper storing
methods should be provided.
Bearings should be well protected
against moisture and foreign
material and exposed metal
protected against rusting. Rotation
of bearings at least once per week
is mandatory to maintain protective
coating on bearing raceways.
When a crane or hoist is used in

handling the fan, care should be
taken to prevent distortion of any
part of the fan equipment. Use
lifting eyes provided for this
purpose. If slings are used around
the bearings base or housings,
take care that sling does not touch
fan shaft. Make sure all-lifting
equipment and techniques conform
to current safety standards and
local codes.
8
For specific design details and to determine
appropriate size of hydraulic cylinders,
please refer to figures 2.2 and 2.3.
Section II
Installation Fig. 2.1 Anchoring (Suggestion).
Mounting and bolting down.
Weight Q of the foundation below 50,000

kg, number of holes: approximately
Q/5000.
2.1 Foundation
The fan should be installed on a foundation
of reinforced concrete.
It is highly important to inspect and check
for the correct location of the anchoring,
making use of the dimensional
arrangement drawing of the equipment. Fig. 2.2 Holes for lifting equipment.
Please refer to section VI of this manual.
Weight Q of foundation above 50,000 kg,
Number of holes 4
2.2 Anchoring frame to foundation.
The anchoring bolts and the reinforcements
must be placed within the foundation (see
Fig. 2.1).
The foundation should have support holes
for lifting the equipment, for example, using Weld a 5/8 plate to the structure before pouring grout
hydraulic cylinders.
Fig. 2.3 Holes for lifting equipment.
Flkt Mxico Fans

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The foundation is the responsibility
Level the frame with chocks, leaving a of customer, who is responsible for
space of approximately 70 mm for the designing, constructing and
grout, between the base and the concrete. providing the anchoring and
This way you ensure horizontal adjustment foundation required by the
and leveling. This must be checked with an equipment.
engineers level, along the two principal Thus, taking into account the fact that a
axes. rigid and well-leveled foundation is the
most adequate for any type of fan. This
The chocks should be placed around the ensures permanent alignment, as well as
base at intervals of 300 to 400 mm. vibration-free operation. Subsoil
characteristics should be sufficiently rigid
Apply grout. Allow for it to set by letting it so as to avoid settling of the foundation.
dry normally.
No details concerning the civil
works will be provided.
The grout must be completely
uniform, without irregularities. For
2.3 Transmission alignment: fan
this reason, using quick-setting
Shaft Coupling Motor shaft.
cement is not advisable. It is
suggested that a specialist select Both the transmission and motor shafts
the adequate materials, to ensure must be perfectly aligned and should be
that the grout is properly applied, taken as a reference for the alignment of
and is also resistant to both the the coupling, which can be aligned in the
static and dynamic loads of the following manner.
equipment. The couplings halves should be aligned
axially as well as radially by means of a dial
If shock-absorbing components are used, gauge secured to one coupling half, using a
the foundation must be perfectly encased large hose clip or some other suitable
for these to settle well. method of clamping. A magnetic base is
If the shock-absorbing components are not usually sufficiently strong to keep the
supplied by Flkt Mxico Fans, S.A. de dial gauge securely in place.
C.V., these must be installed according to Fit a coupling bolt loosely so that the two
the position indicated and the instructions coupling halves will rotate together during
provided. alignment.
Align the coupling in accordance with Fig.
It is very important for the fan to be firmly 2.4 and Table 2.1 or as specified in the
supported, and to the greatest extent manufacturer's instructions.
possible, to be isolated from other
equipment, so as to prevent vibrations No lubricant should be allowed to
transmitted by these. come into contact with any of the
rubber components of the coupling.
The foundation described
previously is only a suggestion.
10
temperature, the correct alignment of all of
its components will result.
2.4 Impeller assembly

Place the impeller on the extreme end of
the shaft, and attach the safety washer (06)
Fig. 2.4 Reading Indicator Method. exactly as indicated in fig. 1.5. Lubricate
(Flexible Couplings) the end of the axis with oil (for example).
Following this, assemble the impeller with
The position of the fan half of the coupling adjustment tools, exactly as indicated in fig.
is determined by the alignment of the shaft 2.5.
and the bearing housings of the same.
Moving the motor must carry out any Notes:
necessary alignment of the coupling. 1. Check the rotation direction of the
Correct alignment is when both hubs (of the impeller (please refer to fig. 2.6).
coupling) are concentric and their faces 2. Assemble the suction cone (04), the
parallel. In order to achieve parallelism and back cover, if there is one and the upper
precise linear alignment. half of the casing.
3. Adjust the height of the casing with
Table 2.1 leveling plates.
Out side 4. Adjust the space between the impeller
Dial gauge readings (mm) and the inlet cone(please refer to fig. 2.7).
Diameter B (mm)
D (mm) 5. The anchoring of the fan will be carried
Radial run-out Axial run-out out exactly as indicated previously.
< 500 3
0.1 0.1
>500 5
Once the motor has been perfectly

mounted, aligned and all the bolts
tightened, carry out the electrical
installation to the line of current. Add a
safety switch and a starter with short circuit
and overload protection to the installation.
Every motor must be connected according Fig. 2.5 Assembly of impeller to
to the instructions on the plaque and the transmission
applicable electrical codes. Also, adequate
insulation must be considered in terms of
operating temperature.
Once the equipment has been operating for

a period of time sufficient to permit the
Fig. 2.6 Rotation of impellers
stabilization of conditions and operating
Flkt Mxico Fans

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2.5 Adjustment of clearances and Average Minimum
tolerances Fan size clearance S clearance S
mm mm
071 090 26 1
Fans for gas temperatures below than 100 100 125 38 1.5
C. 140 180 4 10 2
Adjust the inlet in such a way that the free
radial clearance S (please refer to fig. 2.6 Bearings.
2.7), is equal along the periphery of the
inlet. Determine the average free clearance In order for rolling bearings to function
s by measuring 8 points along the inlet. without fail and achieve the service life
When the impeller of the fan is static, the expected it is important that correct tools
minimum space allowed must be within the are used and cleanliness is observed
limits listed below (table 2). during installation and maintenance of the
Center the mechanical seal (05) (figs. 1.5 bearings.
and 2.7) on the casing and lock it into To protect the bearings from impurities they
position. should only be removed from their original
packing immediately before mounting. The
Fans for gas temperatures between 100 C anti-corrosion agent with which new
and 350 C. bearings are treated does not normally
Adjust the inlet in such a way, that the free have to be removed; suffice is to wipe it off
space S (fig. 2.7) is greater in the upper from the outside of the rings. However, if
section than in the lower section. The the bearing is to be lubricated with grease
space in the lower section must be equal to for use at very high or low temperatures or,
half the space in the upper section. if the grease (e.g. grease with a polyurea
base) is not suitable for mixing with the
Place the mechanical seal (05) in such a anti-corrosion agent, the bearing must be
way that space T in the lower section washed and wiped off thoroughly to prevent
(please refer to fig. 2.7, between the seal any harmful effect on the lubricating
and the hub of the impeller) is properties of the grease. Bearings made
approximately double the space as in the dirty by improper handling (e.g. damaged
upper section. packing) should also be washed and wiped
off before mounting.
Mounting Mounting bearings onto an
adapter sleeve
Forcing small and medium sized bearings
on to an adapter sleeve is usually done by
means of the adapter sleeve nut.
Fig. 2.7 Impeller clearance.
Table 2
12
permissible.
To achieve a correct fit on the shaft when
bearings with larger internal clearance than
normal are driven -e.g. C3 or C4 - it is
recommended to aim for the upper half of
the clearance reduction range.
Fig. 2.8 Adapter Sleeve.

Adapter sleeve.
Clean the shaft so that there is no oil left
between shaft and sleeve. Mount the
adapter sleeve onto the shaft with the Fig. 2.9 Bearing clearance.
thread outward as shown in figure 2.8.
Push the sleeve along the shaft to its
approximate position. The sleeve is easier
2.7 Vibration and Sound Insulation.
to push if the slit is opened slightly with a
screwdriver. The outside of the sleeve may General.
be coated with thin oil to facilitate mounting Machines with rotating components give
and removal of the bearing. rise to vibrations and if the machine is
rigidly mounted, these vibrations may be
propagated through floor and walls.
Clearance.
Damaging vibrations and disturbing noise
Since the reduction of internal clearance is
may then be caused. As a general rule,
a measure of the tightness of the fit, the
vibrations which are liable to cause
clearance should be measured by means
damage to the building, have the same
of a feeler gauge before the bearing is
frequency as the frequency of rotation of
mounted.
the machine. However, noise transmitted
Place the bearing on a clean surface and
through the shell of the building may also
rotate the inner ring a few turns. Use a
be generated by high-frequency vibrations
gauge slightly thinner than the minimum
from motors, gears, etc. Such vibrations
clearance before mounting. Insert the
can be significantly reduced by elastic
gauge between the second to uppermost
mounting of the machine, i.e. the machines
roller and the outer ring. Continue to
can be mounted on flexible elements. Fans
measure with gradually thicker gauges until
installed in the vicinity of spaces which are
a slight resistance is felt when the gauge is
sensitive to noise must therefore have good
withdrawn. See figure 2.9.
dynamic balance as well as good vibration
Drive the bearing onto the shaft verifying
and noise insulation by means of anti-
the reduction of clearance by measuring
vibration mountings and flexible connecting
between the bottom roller and the outer
pieces. Of the six different modes of
ring, see figure 2.9. Verify that the internal
vibration possible on a machine, a
clearance remaining is not below minimum
Flkt Mxico Fans
13
conventional fan installation need generally Installation considerations.
only take into account the vertical In all cases of vibration and noise
vibrations. insulation, it is important to ensure that the
vibration system has freedom of movement
Vibration insulation.
in all directions. No rigid connections
Vibration insulation can be provided by
should exist between the vibrating system
mounting the fan and motor on a common
and the shell of the building (see figure).
foundation and supporting this foundation
Ducts connected to the fan should be
on a number of elastic elements which
provided with soft, flexible connecting
must be designed with care.
pieces. In addition, ducts in which there is a
An insulated system of this type will
high level of noise should not be rigidly
describe a vibratory motion whereby
connected to floors and walls which are in
residual unbalance forces will be absorbed
direct communication with noise-sensitive
by inert forces associated with the mass of
spaces, even if the fan is provided with
the system. If vibration insulation is applied,
flexible connecting pieces. In the event of a
the amplitude of vibration of the system will
high level of noise in the ducts, vibrations
be higher than in the case of rigid
may be induced into the ducts and if the
mounting, although in favourable cases, the
duct is rigidly fixed, noise may be
force transmitted through the elastic
propagated through the shell of the
elements to the foundation can be reduced
building. This applies to boiler rooms in
to no more than a few percent of the force
domestic premises, for instance, where
transmitted in a rigid installation.
ducts connected to the flue gas fan may
In the case of vibration insulation of fans,
transmit noise. On its passage through a
standardised elastic elements made of
concrete wall, sound insulation of the duct
rubber are normally used. In the case of
can be provided by a 25 mm thick layer of
fans operating at extremely low speeds,
mineral wool packed between the duct and
vibration insulation is seldom required,
the wall. If a fan is installed with the
except in cases where the foundation is
insulating material covered by an external
especially sensitive to vibration. In such
metal housing, this must not extend beyond
cases it may sometimes be advantageous
the flexible connecting pieces, since direct
to employ steel coil springs since these
contact can then readily occur between the
impart an extremely low natural frequency.
vibrating system and the rigid shell of the
Noise insulation. building.
In the case of rigid installation, noise may
be propagated even by low-speed fans due
to the high-frequency vibrations from
motors, bearings, etc. As a result, such
fans must also be isolated from the
foundation, when located close to noise-
sensitive spaces. Such insulation should
preferably be carried out by means of
rubber elements which provide
incomparably better sound insulation than
steel.
14
Fig. 2.9 Diagrammatic arrangement of fan
mounting with sound insulation.
1. Anti-vibration mounting.
2. Foundation.
3. Flexible connecting pieces.
4. Supporting pads of soft material.
5. Hanger with soft material.
6. Mineral wool mat, approx. 25 mm thick
Flkt Mxico Fans

15
3.2 Precautions prior to first start-up
It is very important to take the greatest
possible precautions. That is why a re-
check of all the steps covered in this
manual is recommended. The most
important checks are:
Test the anchoring of the bearing

housings and electrical motor.
See that the coupling is securely
installed.
Test the anchoring of the frame to the
Section III foundation.
Ascertain that the ducts are firmly
Operation secured and adjusted against the fan,
without resting their weight against the
fan.
Ensure that the inspection door
functions properly.
Make sure that there are no objects or
tools, either inside or outside of the
3.1 Connection to general networks
equipment, which could interfere with
As soon as the electrical connections have start-up or running. General cleaning.
been completed, under strict safety norms: Make certain that there is no water
accumulated in the interior of the
Check to see that the motor turns in the equipment.
direction of the equipment (with the Ensure that the protection covers are
coupling open and comparing it with the installed and securely attached.
rotation direction indicator arrow of the fan). Check that the inspection doors are
The rotation direction of the impeller is tightly shut.
indicated on the side of the casing. Ascertain that all rotating parts can
freely rotate, without scraping against a
It is recommended that flexible joints be non-moving part.
placed where the fan (inlet and outlet) is Ensure that the bearing housings are
joined to the system (ductwork), for the lubricated. Please refer to the
purpose of insulating the fan from information included in section V of this
vibrations, which could be transmitted by manual.
other equipment.
Check to see that the ducts are fastened
well and adjusted against the fan, but 3.3 Start-up test
without resting their weight against the fan.
16
Manually rotate the impeller to ensure that Deficient or abrupt connections at
it does not scrape against the suction inlet and/or outlet ducts.
cones or have any interference. Air leaks in the system.
Incorrect rotation direction.
It is absolutely necessary to install an
emergency stop switch as close to the Vibration and noise:
equipment as possible, and to have one of Misalignment in bearing housings,
the persons in charge of start-up to stay couplings or impeller.
close to the switch during start-up time. Inadequate foundation.
Foreign bodies causing impeller
During the acceleration phase, pay strict unbalance.
attention to any abnormal noises. Transmission or motor shaft worn
down.
Check the temperature and vibration level Unbalance of impeller or motor.
of the bearing housings. Fan giving more capacity than what
was calculated.
If it is possible to measure the non-balance Vibration transmitted to the
residual by means of vibration amplitude, equipment from other equipment.
this should be compared to the in-factory The rotation direction in the suction
test results, and must be the same or less. cone is incorrect.
Setbolts or other bolts are broken or
Ensure that both the temperature and loose.
energy consumption of the motor is normal. Speed too high.
Motor scraping against suction cone.
Remember that the first start-up lasts
approximately 30 minutes. If the operation Motor overload:
is normal, allow the equipment to operate Resistance of the system is less than
from 5 to 6 hours. what was calculated, which causes
the quantity of air handled by the
system to be greater than what was
3.4 Troubleshooting
foreseen.
In this section we present the most Air density greater than what was
common problems that can be encountered calculated in the design.
during equipment start-up. Incorrect rotation direction.
In the event of equipment functioning Defective alignment.
failure, you should consider the following Poorly connected motor.
points to locate the possible problem. Equipment speed too high.
Scarce air quantity or pressure:

Resistance of the system is greater
than what was calculated.
Fan speed is less than what was
calculated.
Flkt Mxico Fans

17
Section IV The bearings must be lubricated with
grease at regular intervals.
Maintenance The casings of the bearing housings
include greasers. The required amount of
grease must be used.
Always wipe the grease nipples

clean before greasing, so that no dirt
4.1 Casing will enter the bearing with the
grease.
The casing should be inspected periodically
to check for wear or accumulation of dust. Type of grease. Re-lubrication interval and
This should be cleaned with either exact quantity of grease are determined by
pressurized air or a wire brush. Also check the operation of the bearing
drainage for possible accumulation of
condenses (liquids). Speed and temperature are critical factors.
4.2 Impeller If the bearing housings are exposed to

dusty or contaminated environments, or
The impeller should be inspected for wear operated at high temperatures, they will
or excessive accumulation of dust. It should require shorter re-lubrication intervals.
be cleaned periodically with either A tentative re-lubrication guide for bearing
pressurized air or a wire brush. Once it is housings follows:
clean, carefully check the condition of all
impeller parts, particularly the blades.
Replace those which are worn down or
Table 2
which could come loose, causing Shaft diameter, mm
considerable damage. Whenever any r/min
65 80 90 100 110 125 135 140 150 160
repairs are made to the impeller, it is Lubrication interval

735
980

7

6
8
6
8
5
7
4
6

5

5

4

in weeks *
absolutely necessary to rebalance it. 1480 5 4 4
240 310 340 380 470 680 850 1000 1800 2200
Required amount At mounting
of grease in grams At
relubrication 20 40 55 70 80 110 130 150 130 150
4.3 Bearing housings * Continuous operation
The bearing housings must be handled

carefully and protected from dust and 4.4 Coupling
humidity. Therefore, the original packaging
should not be removed until the time these A basic maintenance procedure is to
are to be installed. Unless the bearing regularly inspect and correct the alignment
housings were to become contaminated, of the shafts. Lubricate with grease.
the anti-corrosive agent will not be
removed. Neither will the bearings and/or 4.5 Motor
accessories be removed.
Use solvent to clean the bearings.
18
The exterior surface and the internal parts
should be air blown, where possible. Use
clean, dry air with a pressure of less than 3
kg/cm2.
Pay special attention to the bearings, which

should operate noiselessly and without
vibrations.
To grease the bearings, follow the

instructions in the maintenance manual,
taking into consideration the hours of
operation and type of grease specified.
Periodically, check the alignment and
tighten all fastening bolts, regularly
preparing a report, which should also Fig. 4.1 Radial dismantling.
include readings on current and entry
voltage. D. Pull the suction cone (4) outward,
enough so that the impeller and the
shaft (7) can be lifted axially (upwards
4.6 Impeller replacement
or sideways).
When necessary to replace the impeller, E. If there is no flexible joint, remove the
apply the following procedure (Fig. 4.1): first section of the ductwork.
A. Remove the bolts (1) between the
casing and the suction cone (4).
B. Remove the mechanical seal (2) from
the hub.
C. Remove the bolts (3) where the upper
and lower sections of the casing are
joined. Separate the upper section Fig. 4.2 Dismounting impeller from
(bipartition) transmission.
F. Remove the bolts (5) from the coupling.
G. Remove any oil conduit connected to
the tops of the bearing housings. Cover
the ends of the conduits to prevent dust
from entering.
H. Remove the tops (6) of the bearing
housings. (Note: the bearings and
boxes must be well protected to prevent
dust from entering.)
I. Lift the impeller and the shaft (7).
Flkt Mxico Fans

19
J. Remove the impeller and the shaft;
using an extractor or a hydraulic
cylinder (please refer to fig. 4.2).
Table 3
Hole of Hole on D, mm
Shaft diameter extraction on shaft (see fig.
hub (UNC), in (UNC), in 4.2)
2 1/2 5/8 5/8 100
3 5/8 124
2 1/2 144
4 150
4 1/4 1 174
5 1 1 180
5 7/16 1 1 200
5 1/2 1 1 204
150 mm 1 1 208
160 mm 1 1 226
170 mm 1 1 232
180 mm 1 1 237
20
Section V
Drawings
Included
Flkt Mxico Fans

21
Mounting of SKF bearings Page 1 of 3
Print page
Use of these instructions is governed by the warranty disclaimer and limitations that are to be found under "Legal notice" on
skf.com/mount.
Housings
Housing type: SONL housings
Variant: Mounting of housing
Carefully read the complete instructions prior to starting work.
The mounting and dismounting of rolling bearings involve the handling of sometimes heavy
weights, the use of tools and other devices, and in some cases the use of high pressure oil. In
order to avoid accidents, injuries or damage to property please follow carefully the prescribed
methods.
_______________________________________
1. Make sure that the work area is clean. Check the dimensional and form accuracy of the shaft
seating. For bearings mounted on adapter sleeves, seatings machined to tolerance h9, having a
cylindricity tolerance to IT 5/2 and a surface roughness Ra 3,2 m will be satisfactory. For
bearings mounted on cylindrical seatings follow the guidelines in the catalogue "Rolling bearings".
2. Check that the roughness of the support surface Ra 12,5 m. The flatness (planicity) tolerance
should be to IT7.
3. If the bearing is mounted on an adapter sleeve, determine the position of the sleeve on the shaft.
4. Position the housing base on the support surface. Fit the

attachment bolts but do not tighten them. The side with the
boss at the bearing seating must be placed to the inner side
of the bearing arrangement.
When oil bath lubrication is used, install the oil level gauge (1)
on the housing base. Whenever possible install the oil level
gauge on the side opposite the oil pick up ring so that the
reading is not affected by the eddies caused by the ring.
If an oil cooling cartridge is used, install it now (see "Installing
the oil cooling cartridge").
Note: To avoid oil leakage, apply an oil resistant sealant on
the threads of all attached components like the oil level gauge
or oil pipes.
5. Slide the inner labyrinth ring (2) together with the seal ring
(4) and O-ring (5) on the shaft and place the oil pick up ring
(3) in position on the labyrinth ring.
Note: When a circulating oil lubrication system is used, omit
the oil pick up ring (3) from the assembly.
6. Mount the bearing on the shaft - either directly on a
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stepped shaft or using an adapter sleeve.
7. Slide the outer labyrinth ring (6) on the shaft and place the
seal ring (7) incl. O-ring (8) in position on the labyrinth ring. If
the housing is at the end of the shaft, omit the second seal
and insert the end cover in the seal groove.
8. Push the seals against the bearing. For arrangements with bearings on adapter sleeves, tighten
the labyrinth ring set screws. The recommended tightening torque is 8 Nm up to and including size
26 and 18 Nm for size 28-32.
9. Put the shaft with bearing and seal assemblies in the housing base. Note: The oil pick up ring
must be on the side of the bearing seat with the widest reservoir i.e. the inner side of the bearing
arrangement.
10. For locating bearing arrangements and bearing

arrangements with CARB bearings put one locating ring on
each side of the bearing.
11. Carefully align the housing base. Vertical markings at the

middle of the housing base end faces can facilitate this. Then
lightly tighten the attachment bolts.
12. When circulating oil lubrication is used connect the oil inlet and outlet pipes to the housing.
Note: Be sure that the outlet pipe(s) can drain properly or the housing may become overfilled.
13. When oil bath is used, fill the housing to the indicated
maximum level. The oil level gauge and cast markings inside
the housing base indicate the maximum level, see table.
Note: Do not overfill the housing or leaks may result.
14. Cover the mating surfaces of the housing with an oil-resistant sealant like Loctite or
equivalent.
15. Place the housing cap over the base and tighten the cap
bolts (to join cap and base) according to the torque values
specified in the table. The cap and base of one housing are
not interchangeable with those of other housings. Check the
cap and the base to see that they bear the same
identification.
Note: Place the housing cap on the base carefully so as not
to damage the O-rings.
16. Check alignment and fully tighten the attachment bolts in

the housing base to the torque values specified in the table.
Print page
skf.com/mount.
Dismounting
Carefully read the complete instructions prior to starting work, the instructions may
contain alternative tools and measuring methods.
Illustrations are not always proportional and are not always showing the exact design.
The instructions are valid for SKF bearings only.
Where tool recommendations are made, please check the actual dimensions against the
bearing and any other components which may interfere with the use of the tool.
methods.
_______________________________________
Precautions
Arrange for a clean working place.
An undamaged bearing should be remounted in the same shaft position and orientation. Mark
each bearing's relative position, i.e. which section of the bearing is up, which side is in front etc.
In case of bearing damage it might be necessary to analyse the bearing components to find the
cause and to take corrective actions, so dismount with care.
Review the actual drawing and study the bearing arrangement.
Make sure that shaft or housing is properly supported during dismounting.
Dismounting procedure
Dismounting can be achieved by hammer blows applied directly to a sleeve abutting the lock nut
or the inner ring.
Mark the adapter sleeve's position on the shaft so that it can be remounted in the same position.
Disengage the tab of the locking washer.
Loosen the nut a few turns but leave it on the sleeve.
Use a hammer and a sleeve abutting the lock nut or the adapter
sleeve.
A suitable dismounting sleeve, such as those provided by SKF in the fitting tool kit, should have a
cover so that hammer blows will be dampened.
Give the sleeve a couple of sharp blows so that the bearing comes loose.
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Use a dead blow hammer and strike firmly in the centre.
Place the sleeve against the bearing inner ring if the nut is located
inward.
Bearings mounted so that it is impossible to use a hammer and

sleeve can be dismounted with a special segmental drift. Only a few
hammer blows to the inner ring face are required.
Do not use a sharp-formed drift, since the bearing or adapter sleeve may be easily damaged.
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Print page
skf.com/mount.
Mounting
Carefully read the complete instructions prior to starting work, the instructions may
contain alternative tools and measuring methods.
Illustrations are not always proportional and are not always showing the exact design.
The instructions are valid for SKF bearings only.
Where tool recommendations are made, please check the actual dimensions against the
bearing and any other components which may interfere with the use of the tool.
methods.
_______________________________________
Precautions
Mount the bearing in a clean environment. Housings, shafts and other components of the bearing
arrangement should be checked to see that they are clean.
The bearings should be left in their original packages until

immediately before mounting so that they do not become dirty.
The dimensional and form accuracy of all components which

will be in contact with the bearing should be checked.
The diameter of cylindrical shaft seatings is usually checked

using a micrometer at four positions in three planes. The
measurement form available here or similar should be used in
the measuring process and for future follow-up.
The diameter of cylindrical housing seatings is usually checked

using an internal gauge at four positions in three planes. The
measurement form available here or similar should be used in
the measuring process and for future follow-up.
Mounting procedure
Wipe the preservative from the bore and outside diameter of

the bearing.
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If the bearing is to be grease lubricated and used at very high or very low temperatures, or if the
grease is not compatible with the preservative, it is necessary to wash and carefully dry the
bearing.
Wipe the preservative from the surfaces of the sleeve.
Lightly oil the bore of the bearing with a thin mineral oil.
Open the adapter sleeve by inserting a screwdriver or other

suitable tool in the slit and slide the sleeve along the shaft to
the correct position.
Place the bearing on the sleeve.
Using an adapter sleeve when the bearing is mounted against

an abutment requires a spacer sleeve. The spacer sleeve must
be designed in such a way that the adapter sleeve can move
under the spacer to allow the bearing to contact the spacer
sleeve. The dismounting distance required is greater than the
drive-up distance.
Screw on the nut with its chamfer facing the bearing but do not mount the locking washer.
Use hook spanner SKF HN or HN .. B to tighten the nut
Tighten the nut until the bearing is driven up to the correct position. To determine the correct
position see below.
Measuring using the tightening angle
Tighten the nut by hand just enough to achieve proper contact between the bearing and the shaft,
i.e. the bearing inner ring cannot be rotated relatively to the shaft.
If a sleeve with inch thread is used, tighten the nut through the
angle 135 using the inch size nut AN 17.
If a sleeve with metric thread is used, tighten the nut through the angle 145 using the nut KM 17.
Re-position the spanner at 180 to its original position and

tighten the spanner a few degrees more by tapping the spanner
handle lightly with a hammer. This will straighten up the bearing
if it has become skewed on the shaft.
_______________________________________
Measuring the axial drive-up using shims
If mounting against an abutment and there is sufficient space between the bearing and the spacer
sleeve, two shims can be used and to be positioned 180 to each other. These should each have
a thickness equal to the required axial drive-up 0.0276 inch.
The drive-up value is valid for solid steel shafts only.
Insert the adapter sleeve under the spacer sleeve, press the
shims against the spacer sleeve and push the bearing on to the
adapter sleeve until it makes contact with the shims.
Tighten the lock nut, but not more than it is still possible to remove the shims. Remove the shims
and drive the bearing up until it contacts the spacer sleeve by tightening the nut using the
spanner.
_______________________________________
Measuring residual clearance using feeler gauges
The initial clearance before mounting must be measured and the clearance must also be
measured as the bearing is driven up on to its seating until the prescribed clearance reduction has
been achieved.
The reduction in radial internal clearance should be minimum 0.0018 inch and maximum 0.0024
inch.
The clearance should always be measured between the outer

ring and an unloaded roller, either the uppermost ....
.... or the lowest one when the bearing is on the shaft.
Before measuring, the bearing should be rotated a few times to ensure that the rollers have
assumed their correct position.
During the measurement, the roller at the measuring point should be lightly pressed against the
guide ring between the two roller rows and the feeler gauge blade be inserted to the middle of the
roller. The measured internal clearance must be the same for both rows of rollers.
The residual radial clearance should be minimum:
0.0014 inch for Normal clearance bearing.
0.002 inch for C3 clearance bearing.
0.0032 inch for C4 clearance bearing.
_______________________________________
Unscrew the nut. The bearing will not come loose.
Place the locking washer in position.
Tighten the lock nut firmly but make sure that the bearing is not driven any further up the sleeve.
Lock the nut by bending one of the locking washer tabs down
into one of the slots in the nut. Do not bend it to the bottom of
the slot.
Check that the shaft or outer ring can be rotated without any
disturbances.
If the bearing is to be oil lubricated take care that the right quantity of the right oil is used.
If the bearing is to be grease lubricated, now is the time to put in the grease.
Normally the bearing should be filled completely with grease unless it is to operate at high speeds.
The free space in the housing should only be partly filled (between 30 and 50 %).
The grease meter SKF LAGM 1000E is a helpful tool for keeping track of the supplied
quantity.
For "normal" operating conditions the grease SKF LGMT 2 may be used. For selection of suitable
grease considering the actual operating conditions see SKF Quick grease selection guide.
If the bearing is to be fitted in a plummer block housing, see

instructions for mounting the housing.
Relubrication intervals for SKF 22217 EK
Relubrication interval in operating hours for the bearing when it is grease lubricated, operating
temperature is below 70 C (158 F) and operating conditions are "normal". In many cases the
relubrication interval may be longer than stated here. For more detailed information, see the SKF
Interactive Engineering Catalogue or contact your SKF representative.
Speed rating for grease lubrication: 2800 r/min
Rotational speed, r/min Relubrication interval, operating hours
560 (20 % of speed rating) 5000

Grease quantity to be used when relubricating: 0.95 ounce
At bearing temperatures over 70 C (158 F), the relubricating

interval should be reduced by half for each 15 C (27 F)
increase in temperature. Intervals may be extended for
temperatures under 70 C (158 F).
It is necessary to lubricate more frequently in applications

where there is a risk of heavy contamination. The same applies
to bearings in wet environments. For bearings on vertical shafts
the intervals should be halved.
The SYSTEM 24 automatic grease dispenser secures the

supply of lubricant to the bearing and is specially suitable in
locations that are difficult to access.
1998 Rexnord Corporation
THOMAS FLEXIBLE DISC COUPLINGS
SPACER TYPE SERIES 71
THE SERIES 71 coupling is designed for applications requiring a

spacer-type coupling such as ANSI, API and other process pumps. The
Series 71 is most commonly applied on motor, turbine, and gear driven
pumps, compressors and blowers.
The Series 71 is a simple three piece design. Hubs are piloted fit to the
factory assembled center member. The piloting provides repeatable
assembly of components for better dynamic balance characteristics. The
center assembly simply "drops out" for fast installation or removal
without special tools. The disc design allows for low flexing forces and
high overload capacity.
The hubs and center member are manufactured from carbon steel. Bolts
and capscrews are high strength alloy steel and flexing elements are
300-series stainless steel.
WHEN SPECIFIED, SERIES 71 COUPLINGS MEET ALL

REQUIREMENTS OF API 610, 8TH EDITION OR API 671.
BENEFITS
Fewer parts - three piece design features unitized Optimized 4, 6 & 8 bolt design
center member assembly and two piloted fit hubs
Disc design provides low flexible forces with high
Quick installation - no special wrenching, easily overload capacity
accessible bolting
Across-the-line starting dose not require torque
Easy alignment - piloted flanges, common reference de-rating
surface
Meets AGMA Class 9 Balance Specification when
Unique jacking bolt feature compresses coupling for finished bored..
easy installation and removal of center member
assembly
17
1998 Rexnord Corporation
MONITORING AND INSPECTION
Installation Instructions
I. PURPOSE III. DETECTION

Monitoring and inspection of the Thomas disc pack in The Thomas disc coupling is easily inspected. Visual
the field. analysis may point to possible drive system problems.
Proper evaluation of the disc packs and connecting
II. GENERAL INFORMATION parts may save considerable maintenance costs and
The flexible disc-type coupling is designed for long life downtime. When a disc coupling starts to fail, it is usually
when operated within the torque and alignment limits from the outer disc of the laminated pack and pro-
as outlined in the Catalog Bulletin No. 2000 5/93. The gresses towards the center of the pack. See figure 1.
information provided here may also be used for visual
determination of the condition of the disc packs.
A well chosen flexible disc coupling operates indefi-

nitely with low cross loading of the connected shafts,
has low power absorption, and induces no vibrations
or resonances into the system.
The installation of a flexible disc coupling is critical.

Various problems could arise during mounting of the
hubs and the coupling assembly process. Burrs, dirt
and grit on either the shaft or in the bores can cause
the hubs to gall during mounting. Poorly-fitted keys
can also gall and not seat correctly.
FIGURE 1
Concentrated heat on the hubs will cause distortion.
The coupling must be properly assembled and the Because of this progression, the deterioration of the
locknuts tightened in accordance with the installation coupling disc pack may be detected before ultimate
instructions. Loose bolts will cause elongation of the failure.
disc bolt holes and eventual failure.
The most common forms of failure in disc fatigue due

to excessive flexure. This is usually caused by poor
initial alignment of the connected machines. It also can
be brought about by operational conditions. The
following gives some ideas to assure the coupling is
operating satisfactorily.
1
A. Detection of trouble with the equipment in operation. 3. Disc pack is wavy and dimension between
flange faces N is smaller than indicated in the
1. Monitored Equipment. Most equipment of this installation instructions or applicable assembly
type is continuously monitored with vibration drawing. See Figure 3. This indicates that the
sensors. As a coupling disc pack deteriorates, it coupling has been installed in a compressed
loses some pieces of the disc pack which causes condition or equipment has shifted axially during
unbalance. This unbalance can be detected by operation. Check for shaft thermal growth con-
the vibration monitoring equipment. This piece- ditions. Realign axial position of equipment so the
by-piece deterioration allows controlled shut- coupling operates with a neutral, flat disc pack.
down before ultimate disc pack failure.
2. Unmonitored Equipment. Couplings using a

guard with either an open bottom (U Type) or
open mesh can give early visual warnings.
Pieces of the disc pack found under the open
U guard or seen lying inside the expanded
metal guard are a good reason to shut the unit
down. Now inspect the coupling, replace the disc
packs, and realign the equipment.
B. Detection of trouble with equipment out of service

and guard removed:
Here are some of the more evident visual inspection
criteria and recommended corrective procedures. COMPRESSION
1. Reddish brown color bleeding out between disc FIGURE 3
laminations at the O.D. of the pack. This is an indi-
cation of fretting and/or chemical attack of the
4. Disc pack is wavy and dimension between flange
disc material. See Figure 2.
faces N is larger than specified on installation
instructions or applicable assembly drawing.
2. Fine line crack starting in the outer disc, tangent
See Figure 4. This indicates that the coupling has
to the washer O.D. This is an indication of mis-
been installed in an elongated position or equip-
alignment and can be seen by looking at the outside
ment has shifted axially during operation.
edge of the disc pack. See Figures 2, 8 and 9.
Realign axial position of equipment so coupling
operates with a neutral, flat disc pack.
ELONGATION
FIGURE 2 FIGURE 4
2
5. Disc packs (both ends) are wavy. One end is 3) If the discs in the pack are permanently
compressed, and the other end is elongated. deformed, replace the disc pack with a new
(See Figure 5). The conditions can be reversed one and reassemble the coupling.This perma-
by moving the center member towards the elon- nent deformation could be caused by a
gated end. This is called oil canned disc packs. severe torque overload, abnormal axial loads,
The disc pack has no neutral center where it or even loose bolts. The cause of the defor-
remains flat and parallel with the end flanges. mation must be corrected before restart.
The coupling, as finally assembled, should have

a neutral center where the center member is free
to float axially with out snapping from one end
to the other when moved by hand.
IV. ANALYSIS OF FAILED DISC COUPLINGS
In the event of a coupling failure, a thorough investi-

gation should be made to determine the cause. The
most common causes of failure are improper coupling
selection, improper assembly, excessive misalign-
ment, and corrosive attack.
OIL CAN 1. Disc broken through the bolt hole indicates loose
FIGURE 5 coupling bolts. See FIgure 5. Replace disc pack and
tighten locknuts to specified torque value.
This condition can be the result of:
1) Tightening the disc pack locknuts while the

disc packs are in the compressed or elongated
coupling position. See Figure 3 and/or 4.
2) Tightening of disc pack locknuts while coupling

is misaligned or other end of spool is hanging
unsupported.
3) Bound up bolt(s) in the bolt hole(s).
4) Damaged discs which could be caused by LOOSE BOLTS

abnormal running conditions, misuse, or
loose bolts. FIGURE 6
To correct oil canned disc pack: 2. Discs embedded into bolt body are usually the result
of a loose bolt or a severe torque overload. See
1) Loosen all the disc pack locknuts. Correct the Figure 7. Replace bolt and disc pack. Tighten locknut
axial spacing of the coupling as necessary to proper torque. Do not torque the bolt as insuffi-
with the coupling aligned and spacer fully cient bolt stretch may occur.
supported. If oil canned conditions disap-
pears, retorque locknut while coupling is in its
neutral position.
2) If (1) above is not successful, determine that

all bolts, with locknuts loose, can be turned
by hand. If any bolts are tight, the bolt holes
should be cleaned out by lightly reaming the
flange so that the bolt turns by hand in the
hole. Reassemble and torque the locknuts
while coupling is in its neutral position. LOOSE BOLTS
FIGURE 7
3
3. Disc broken adjacent to washer face usually indicates 5. The disc pack has a bulge near the center or is bowed
excessive shaft misalignment during operation. See toward one flange in alternate chordal sections. See
Figures 1 & 8. This type of disc failure usually starts Figure 10. This condition is a result of a large torque
with outer disc and progresses through the disc overload, induced into the system, beyond the peak
pack. Realign equipment and replace both disc overload capacity of the coupling. The remaining disc
packs. Make hot check of alignment to assure it is pack chordal sections will be straight and tight. This
within coupling misalignment capacity. indicates improper coupling selection or a momentary
system torque overload. If bulged or bowed condi-
tions appears in one chordal section only, there may
be a loose bolt on one side of the distortion. Loosen
all coupling locknuts and unseat the bolts. The bulge
should release and flatten out. Retorque locknuts. If
distortion does not disappear, replace disc pack and
retorque locknuts.
EXCESSIVE MISALIGNMENT
FIGURE 8
4. Disc broken adjacent to washer face with fretting
corrosion present in the area of crack usually indi-
cates excessive shaft misalignment during operation.
Also, iron oxide will most likely be evident on outside
of disc pack. See Figures 2 & 9. This is sometimes
associated with a coupling that has been in service
for several years and/or operating in a corrosive
atmosphere. Breaks will first appear in outer discs TORQUE OVERLOAD
and progress through the disc pack. Replace both
disc packs and realign the equipment. Different disc FIGURE 10
pack material may also be considered.
SUMMARY
Thomas disc couplings are designed for infinite life. They
must be properly selected, installed and aligned to assure
reliable service. Because of the design principles, cata-
strophic failures are very rare. Sufficient time usually exists to
repair or correct a deteriorating situation before ultimate failure.
EXCESSIVE MISALIGNMENT
WITH CORROSION
FIGURE 9
For further assistance, call Rexnord Corp. Coupling Operation

Warren, PA 814-723-6600, Fax - 814-726-1740
4
INSTRUCTION MANUAL
Universal Pneumatic Rotary Actuator

Type UP
PN25059
Trademarks and Registrations
Registrations and trademarks used in this document include:
Dow Corning is a registered trademark of Dow Corning Corporation.

GE and Silmate are registered trademarks of General Electric Corporation
Loctite is a registered trademark of the Loctite Corporation.
WARNING notices as used in this manual apply to hazards or unsafe practices which could result in personal
injury or death.
CAUTION notices apply to hazards or unsafe practices which could result in property damage.
NOTES highlight procedures and contain information which assist the operator in understanding the informa-
tion contained in this manual.
All software, including design, appearance, algorithms and source codes, is copyrighted by ABB Inc. and is
owned by ABB Inc. or its suppliers.
WARNING
POSSIBLE PROCESS UPSETS. Maintenance must be performed only by qualified personnel and only after
securing equipment controlled by this product. Adjusting or removing this product while it is in the system may
upset the process being controlled. Some process upsets may cause injury or damage.
NOTICE
The information contained in this document is subject to change without notice.
ABB Inc., its affiliates, employees, and agents, and the authors of and contributors to this publication specifi-
cally disclaim all liabilities and warranties, express and implied (including warranties of merchantability and fit-
ness for a particular purpose), for the accuracy, currency, completeness, and/or reliability of the information
contained herein and/or for the fitness for any particular use and/or for the performance of any material and/or
equipment selected in whole or part with the user of/or in reliance upon information contained herein. Selection
of materials and/or equipment is at the sole risk of the user of this publication.
This document contains proprietary information of ABB Inc., and is issued in strict confidence. Its use, or repro-
duction for use, for the reverse engineering, development or manufacture of hardware or software described
herein is prohibited. No part of this document may be photocopied or reproduced without the prior written con-
sent of ABB Inc..
Copyright 2002 ABB Inc. [August, 2002]

Table of Contents
Page
SECTION 1 - INTRODUCTION............................................................................................... 1-1
OVERVIEW .................................................................................................................... 1-1
INTENDED USER .......................................................................................................... 1-1
EQUIPMENT DESCRIPTION......................................................................................... 1-1
FEATURES..................................................................................................................... 1-2
EQUIPMENT APPLICATION.......................................................................................... 1-2
INSTRUCTION CONTENT............................................................................................. 1-2
HOW TO USE THIS INSTRUCTION.............................................................................. 1-3
REFERENCE DOCUMENTS ......................................................................................... 1-3
NOMENCLATURE.......................................................................................................... 1-4
SPECIFICATIONS.......................................................................................................... 1-6
OPTIONS AND ACCESSORIES .................................................................................... 1-8
SHIPPING WEIGHTS................................................................................................... 1-10
STROKE TIME GRAPHS ............................................................................................. 1-11
SECTION 2 - DESCRIPTION AND OPERATION ................................................................... 2-1

INTRODUCTION ............................................................................................................ 2-1
Types UP__A and UP__ B Actuators ...................................................................... 2-2
Types UP__ C and UP__ D Actuators ..................................................................... 2-2
Type UP__ E Actuators............................................................................................ 2-2
Types UP__5, UP__8 and UP__F Actuators ........................................................... 2-2
Types UP__6, UP__9 and UP__G Actuators .......................................................... 2-2
Type UP6_0 Actuators ............................................................................................ 2-3
SECTION 3 - INSTALLATION................................................................................................ 3-1

INTRODUCTION ............................................................................................................ 3-1
UNPACKING AND INSPECTION................................................................................... 3-1
LOCATION CONSIDERATIONS .................................................................................... 3-1
ENCLOSURE REMOVAL............................................................................................... 3-2
Type UP1 Actuator ................................................................................................... 3-2
Type UP2 Actuator ................................................................................................... 3-2
Side Panel ......................................................................................................... 3-2
Top Cover .......................................................................................................... 3-2
Types UP3 and UP4 Actuator .................................................................................. 3-3
Side Cover ......................................................................................................... 3-3
Top Cover .......................................................................................................... 3-4
Types UP5 and UP6 Actuator .................................................................................. 3-6
Bottom Side Cover............................................................................................. 3-6
Top Cover .......................................................................................................... 3-7
Top Side Cover.................................................................................................. 3-7
WIRING CONNECTIONS, TUBING CONNECTIONS AND CABLING .......................... 3-7
Connecting Tubing ................................................................................................... 3-7
Connecting Wiring .................................................................................................... 3-8
Grounding ........................................................................................................................ 3-8
Air Quality............................................................................................................... 3-10
Characterizable Pneumatic Positioner Tubing ....................................................... 3-11
Types UP1 And UP2 Actuators........................................................................ 3-11
Types UP3 And UP4 Actuators ....................................................................... 3-12
i
Table of Contents (continued)
Page
Types UP5 AND UP6 Actuators ...................................................................... 3-12
Characterizable I/P Positioner Tubing and Wiring ................................................. 3-13
Solenoid Tubing and Wiring ................................................................................... 3-14
Master/Slave Tubing Connections for Type UP6 Actuators ................................... 3-17
INSTALLATION OF OPTIONAL EQUIPMENT............................................................. 3-19
Reserve Air Tank Tubing and Wiring ..................................................................... 3-19
Type UP2 Actuators......................................................................................... 3-19
Types UP3 Through UP6 Actuators ................................................................ 3-21
Air Failure Lock Tubing .......................................................................................... 3-22
Type UP1 Actuator .......................................................................................... 3-23
Type UP2 Actuator .......................................................................................... 3-24
Pneumatic Shaft Position Transmitter Tubing for Types UP2 through UP6 Actuators ..
3-30
Types UP2, UP3 And UP4 Actuators .............................................................. 3-31
Volume Booster Tubing for Type UP6 Actuators ................................................... 3-31
Alarm/Travel Switch Contact Wiring for Types UP1 through UP6 Actuators ......... 3-31
Type UP1 Actuator .......................................................................................... 3-32
Type UP2 Actuator .......................................................................................... 3-33
Electric Shaft Position Transmitter Wiring for Types UP1 through UP6 Actuators 3-34
Type UP1 Actuator .......................................................................................... 3-35
Type UP2 Actuator .......................................................................................... 3-35
Reverse Loading Wiring For Electric Shaft Position Transmitters ................... 3-37
Strip Heater Wiring for Types UP2 through UP6 Actuators ................................... 3-37
Type UP2 Actuator .......................................................................................... 3-38
PRE-OPERATING ADJUSTMENTS ............................................................................ 3-38
Control Loading Arrangements .............................................................................. 3-38
Positioner Control Loading Arrangements....................................................... 3-38
Solenoid Valve Control Loading Arrangements............................................... 3-39
Operating Lever Adjustment .................................................................................. 3-40
Type UP1 Actuator .......................................................................................... 3-40
Type UP2 Actuator .......................................................................................... 3-40
Types UP3/4/5/6 Actuators.............................................................................. 3-41
Position Indicator.................................................................................................... 3-41
ii
Page
Types UP3/4/5/6 Actuators.............................................................................. 3-41
Mechanical Stop Adjustment for Types UP1 and UP2 Actuators .......................... 3-42
SECTION 4 - CALIBRATION ................................................................................................. 4-1

INTRODUCTION ............................................................................................................ 4-1
EQUIPMENT REQUIRED FOR CALIBRATION............................................................. 4-1
CALIBRATION PROCEDURES ..................................................................................... 4-1
Positioner Access..................................................................................................... 4-1
Zero Adjustment for Positioner-Equipped Types UP1 through UP6 Actuators ........ 4-1
Span Adjustment for Positioner-Equipped Types UP1 through UP6 Actuators ....... 4-2
Speed Adjustment for Positioner-Equipped Types UP1 through UP6 Actuators ..... 4-3
Gain Adjustment for Positioner-Equipped Types UP1 through UP6 Actuators ........ 4-3
OPTIONAL EQUIPMENT CALIBRATION ...................................................................... 4-3
Electric Shaft Position Transmitter Calibration for Types UP1 through UP6 Actuators .
4-4
Alarm/Travel Switch Calibration ............................................................................... 4-4
Pneumatic Shaft Position Transmitter Calibration.................................................... 4-5
Reserve Air Tank Calibration ................................................................................... 4-5
Volume Booster Calibration ..................................................................................... 4-5
Air Failure Lock Calibration ...................................................................................... 4-5
Trip Valve Adjustment For Types UP1 Through UP6 Actuators........................ 4-6
Lock Valve Adjustment For Types UP3/4/5/6 Actuators.................................... 4-7
SECTION 5 - OPERATING PROCEDURES ........................................................................... 5-1

INTRODUCTION ............................................................................................................ 5-1
NORMAL OPERATING CONSIDERATIONS................................................................. 5-1
TYPES UP1 AND UP2 ACTUATOR OPERATION ........................................................ 5-2
Positioner-Equipped Types UP1 and UP2 Actuators without Air Failure Lock Transfer
from Automatic to Manual Operation ....................................................................... 5-2
from Manual to Automatic Operation ....................................................................... 5-4
Solenoid-Equipped Types UP1 and UP2 Actuators without Air Failure Lock Transfer
Remote Reset Air Failure Lock Equipped Types UP1 and UP2 Actuators Transfer
TYPES UP3 AND UP4 ACTUATOR OPERATION ........................................................ 5-6
METHOD A CHANGING THE INPUT SIGNAL TO MATCH THE ACTUATOR POSITION 5-7
Method B Manually Positioning The Actuator To Match The Input Signal...... 5-7
iii
Page
from Manual to Automatic Operation ..................................................................... 5-10
TYPES UP5 AND UP6 ACTUATOR OPERATION ...................................................... 5-10
from Automatic to Manual Operation ..................................................................... 5-10
Method A Changing The Input Signal To Match The Actuator Position ....... 5-12
Method B Manually Positioning The Actuator To Match The Input Signal.... 5-12
SECTION 6 - TROUBLESHOOTING ...................................................................................... 6-1

INTRODUCTION ............................................................................................................ 6-1
PROBLEM DETERMINATION AND VERIFICATION PROCEDURE............................. 6-1
SECTION 7 - MAINTENANCE................................................................................................ 7-1

INTRODUCTION ............................................................................................................ 7-1
PERIODIC MAINTENANCE ........................................................................................ 7-1
ANNUAL OR SEMIANNUAL MAINTENANCE ............................................................... 7-2
MAINTENANCE AS REQUIRED.................................................................................... 7-3
SECTION 8 - REPAIR AND REPLACEMENT PROCEDURES .............................................. 8-1

INTRODUCTION ............................................................................................................ 8-1
ENCLOSURE REMOVAL............................................................................................... 8-2
POSITIONER REMOVAL AND REPLACEMENT .......................................................... 8-2
SOLENOID VALVE REMOVAL AND REPLACEMENT ................................................. 8-3
ROTARY VANE REMOVAL AND REPLACEMENT (TYPES UP1 AND UP2 ACTUATORS)
8-3
ROTARY VANE SEAL REPAIR AND HOUSING CLEANING........................................ 8-5
CYLINDER ASSEMBLY REPLACEMENT (TYPES UP3/4/5/6 ACTUATORS).............. 8-7
CYLINDER ASSEMBLY REPAIR AND CLEANING....................................................... 8-7
CLUTCH FORK INSPECTION AND REPLACEMENT (TYPES UP5 AND UP6 ACTUA-
TORS)........................................................................................................................... 8-13
ROLLER CHAIN ADJUSTMENT (TYPES UP5 AND UP6 ACTUATORS) ................... 8-14
OPTIONAL EQUIPMENT REPAIR/REPLACEMENT PROCEDURES ........................ 8-15
Reserve Air Tank Component Removal and Replacement (Types UP2 through UP6
Actuators) ............................................................................................................... 8-16
Trip Valve Removal And Replacement............................................................ 8-16
Pressure Switch Removal And Replacement .................................................. 8-16
iv
Page
Air Failure Lock Component Removal and Replacement (Types UP1 and UP2 Actua-
tors) ........................................................................................................................ 8-17
Trip Valve Replacement .................................................................................. 8-17
Latching Spring Return Cylinder Replacement................................................ 8-17
Automatic Mechanically Actuated Equalizing Valve Replacement .................. 8-18
Air Failure Lock Component Removal and Replacement (Types UP3 through UP6 Ac-
tuators) ................................................................................................................... 8-18
Lock UPValves Removal And Replacement.................................................... 8-19
Trip Valve Removal And Replacement............................................................ 8-19
Pressure Switch Removal And Replacement .................................................. 8-19
Electric Shaft Position Transmitter Assembly Removal and Replacement ............ 8-20
Feedback Potentiometer Removal and Replacement............................................ 8-21
Alarm/Travel Switch Removal and Replacement ................................................... 8-21
Pneumatic Shaft Position Transmitter Replacement (Types UP2 through UP6 Actua-
tors) ........................................................................................................................ 8-22
Strip Heater Replacement (Types UP2 through UP6 Actuators) ........................... 8-23
Thermoswitch Replacement (Types UP2 through UP6 Actuators) ........................ 8-24
Volume Booster Replacement (Type UP6 Actuators) ............................................ 8-24
SECTION 9 - SUPPORT SERVICES ...................................................................................... 9-1

INTRODUCTION ............................................................................................................ 9-1
REPLACEMENT PARTS................................................................................................ 9-1
TRAINING....................................................................................................................... 9-1
TECHNICAL DOCUMENTATION................................................................................... 9-1
APPENDIX A - SPARE PARTS............................................................................................. A-1

INTRODUCTION ........................................................................................................... A-1
TYPE UP1 ACTUATORS .............................................................................................. A-1
TYPE UP2 ACTUATORS ............................................................................................ A-15
TYPES UP3 AND UP4 ACTUATORS ......................................................................... A-39
TYPES UP5 AND UP6 ACTUATORS ......................................................................... A-62
PARTS KITS FOR ALL ACTUATORS......................................................................... A-96
APPENDIX B - DIMENSION DRAWINGS .............................................................................. B-1

DIMENSION DRAWINGS .................................................................................. B-1
v
List of Figures
No. Title Page
1-1. Stroke Times for Type UP1 Actuator Type AV2 Positioner - 5 to 95% of Stroke .. 1-11
1-2. Stroke Times for Type UP1 Actuator Type AV2 Positioner - 0 to 100% of Stroke. 1-12
1-5. Stroke Times for Type UP2 Actuator with Solenoid Valve - 0 to 100% of Stroke . 1-15
1-8. Stroke Times for Type UP3 Actuator Solenoid Valve - 0 to 100% of Stroke ......... 1-18
3-1. Type UP1 Actuator with Type AV Positioner, Electric Shaft Position
Transmitter and Alarm/Travel Switches............................................................. 3-3
3-2. Type UP2 Actuator with Type AV Positioner ........................................................ 3-4
3-3. Types UP3 and UP4 Actuators............................................................................ 3-5
3-4. Types UP5 and UP6 Actuators............................................................................ 3-6
3-5. Operating Torque Versus Air Supply Pressure (Types UP1 and UP2 Actuators) .... 3-9
3-6. Stall Torque Versus Air Supply Pressure (Types UP1 and UP2 Actuators) .......... 3-10
3-7. Operating Torque Versus Air Supply Pressure (Types UP3, UP4, UP5 and UP6
Actuators)........................................................................................................ 3-11
3-8. Stall Torque at Midstroke Versus Air Supply Pressure (Types UP3, UP4,
UP5 and UP6 Actuators) .................................................................................. 3-12
3-9. Type UP1 Actuator with Solenoid Valve and Air Failure Lock............................. 3-15
3-10. Type UP2 Actuator with Solenoid Valve ............................................................ 3-16
3-11. Master/Slave Tubing Connections.................................................................... 3-17
3-12. Reserve Air Tank Tubing for Type UP2 Actuators .............................................. 3-20
3-13. Reserve Air Tank Tubing for Types UP3 through UP6 Actuators ........................ 3-22
3-14. Reset Switch for Air Failure Lock .................................................................... 3-23
3-15. Tubing Schematic for Type UP1 Actuator with Air Failure Lock ......................... 3-25
3-16. Tubing Schematic for Type UP2 Actuator with Air Failure Lock ......................... 3-27
3-17. Tubing Schematic for Types UP3 and UP4 Actuators with Air Failure Lock........ 3-28
3-18. Tubing Schematic for Types UP5 and UP6 Actuators with Air Failure Lock........ 3-30
3-19. Electric Shaft Position Transmitter and Alarm/Travel Switches
(for nomenclature options 11 in the sixth and seventh positions) ...................... 3-32
3-20. Typical Wiring Loop Diagram for the Electric Shaft Position Transmitter ........... 3-35
3-21. Supply Voltage and Load Resistance Limits for the Electric Shaft Position
Transmitter ..................................................................................................... 3-36
3-22. Electric Shaft Position
Transmitter Circuit Board................................................................................ 3-37
5-1. Operating Controls - Types UP1 and UP2 Actuators............................................ 5-3
5-2. Operating Controls - Types UP3 and UP4 Actuators............................................ 5-8
5-3. Operating Controls - Types UP5 and UP6 Actuators.......................................... 5-10
8-1. Rotary Vane Removal and Seal Replacement....................................................... 8-4
8-2. Cylinder Assembly for Type UP3 Actuators ........................................................ 8-8
8-3. Cylinder Assembly for Type UP4 Actuators ........................................................ 8-9
8-4. Cylinder Assembly for UP6 Actuators .............................................................. 8-10
8-5. Cylinder Assembly for Type UP5 Actuators ...................................................... 8-11
8-6. Clutch and Clutch Fork Assembly .................................................................... 8-13
8-7. Roller Chain Adjustment forTypes UP5 and UP6 Actuators ............................... 8-15
A-1. UP1 with Positioner, Tables A-1 and A-2 ........................................................... A-2
A-2. UP1 with Solenoid Valve, Tables A-3 and A-4 .................................................... A-6
vi
List of Figures (continued)
No. Title Page
A-3. UP1 Alarm/Travel Switch Kit, Table A-5 ............................................................ A-9

A-4. UP1 Electric Shaft Position Transmitter Kit, Table A-6 .....................................A-11
A-5. UP1 Air Failure Lock Kit, Table A-7 .................................................................A-14
A-6. UP2 with Positioner, Tables A-9 and A-10 .......................................................A-18
A-7. UP2 with Solenoid Valve, Tables A-11 and A-12 ..............................................A-22
A-8. UP2 with Electric Shaft Position Transmitter and/or
Alarm/Travel Switches, Tables A-13, A-14, A-48 and A-49 .............................A-25
A-9. UP2 with Pneumatic Shaft Position Transmitter, Table A-15 ............................A-27
A-10. UP2 with Air Failure Lock, Table A-16 .............................................................A-31
A-11. UP2 Reserve Air Tank Kit, Table A-17 .............................................................A-34
A-12. UP2 with Heater, Table A-19 ............................................................................A-37
A-13. UP3 and UP4 with Positioner, Tables A-20 and A-21 ........................................A-46
A-14. UP3 and UP4 with Solenoid Valve, Tables A-22 and A-23 .................................A-52
A-15. UP3 and UP4 with Electric Shaft Position Transmitter and/or
Alarm/Travel Switches, Tables A-24, A-25, A-48 and A-49.......................... A-55
A-16. UP3 and UP4 with Pneumatic Shaft Position Transmitter, Table A-26............. A-57
A-17. UP3 with Air Failure Lock, Table A-27 ........................................................ A-59
A-18. UP4 with Air Failure Lock, Table A-28 ........................................................ A-61
A-19. UP3 with Reserve Air Tank, Table A-29 ...................................................... A-63
A-20. UP4 with Reserve Air Tank, Table A-30 ...................................................... A-65
A-21. UP3 and UP4 with Heater, Table A-31 ........................................................ A-66
A-22. UP5 and UP6 with Positioner, Tables A-34 and A-35 ........................................A-70
A-23. UP5 and UP6 with Solenoid Valve, Tables A-36 and A-37 ................................A-76
A-24. UP5 and UP6 with Electric Shaft Position Transmitter and/or
Alarm/Travel Switches, Tables A-38, A-39, A-48 and A-49 .............................A-79
A-25. UP5 and UP6 with Pneumatic Shaft Position Transmitter, Table A-40 ...............A-82
A-26. UP5 and UP6 with Air Failure Lock, Tables A-41 and A-42 ..............................A-86
A-27. UP5 and UP6 with Reserve Air Tank, Table A-43 .............................................A-89
A-28. UP5 and UP6 Actuators with Heater, Table A-46 ..............................................A-92
A-29. UP6 Actuators with Volume Boosters, Table A-47 ........................................ A-95
A-30. Alarm/Travel Switches and Electric Shaft Position Transmitter,
Tables A-48 and A-49 .............................................................................. A-98
B-1. Type UP1 Actuator with Type AV Positioner........................................................ B-1
B-2. Type UP1 Actuator with Type AV Positioner and Air Failure Lock........................ B-2
B-3. Type UP1 Actuator with Type AV Positioner, Electric Shaft Positioner
and/or Alarm/Travel Switches .......................................................................... B-2
B-4. Type UP1 Actuator with Solenoid Valve .............................................................. B-3
B-5. Type UP1 Actuator with Solenoid Valve and Air Failure Lock .............................. B-3
B-6. Type UP1 Actuator with Solenoid Valve, Electric Shaft Position
Transmitter and/or Alarm/Travel Switches ....................................................... B-4
B-7. Type UP2 Actuator with Type AV Positioner or Solenoid Valve ............................. B-4
B-8. Types UP3 and UP4 Actuators .......................................................................... B-5
B-9. Types UP3 and UP4 Actuators .......................................................................... B-6
B-10. Types UP5 and UP6 Actuators ........................................................................... B-6
B-11. 20.8 Liter (5.5 Gallon) Reserve Air Tank Option for Type UP2 Actuators.............. B-7
B-12. 30.3 Liter (8.0 Gallon) Reserve Air Tank Option for Types UP3,
UP4 and UP5 Actuators ..................................................................................... B-7
B-13. 64.4 Liter (17.0 Gallon) Reserve Air Tank for Type UP6 Actuators ... B-81-1.Reference
Documents1-4
1-2. Nomenclature ........................................................................................................1-4
1-3. Specifications.........................................................................................................1-6
1-4. Options and Accessories ........................................................................................1-8
vii
List of Tables
No. Title Page
1-5. Type UP Actuator Shipping Weights..................................................................... 1-10

1-6. Option Shipping Weights1 ................................................................................... 1-10
3-1. Tubing Sizes, Air Filters and Air Supply Regulators ............................................... 3-8
3-2. Suggested Maximum Operating Torque at Minimum and Maximum
Supply Pressure Limits.......................................................................................... 3-8
3-3. Master/Slave Installation Kit .............................................................................. 3-18
3-4. Wire Color Codes for Direct Versus Reverse Loading on the Electric
Shaft Position Transmitter ................................................................................... 3-37
4-1. Zero Elevation ....................................................................................................... 4-2
6-1. Fault Correction Chart ......................................................................................... 6-1
8-1. Parts List for Type UP3 Actuator Cylinder Assembly 1............................................ 8-8
8-2. Parts List for Type UP4 Actuator Cylinder Assembly 1............................................ 8-9
8-3. Parts List for Type UP6 Actuator Cylinder Assembly 1.......................................... 8-10
8-4. Parts List for Type UP5 ActuatorCylinder Assembly 1........................................... 8-11
A-1. UP1 with Positioner, Figure A-1 ........................................................................... A-1
A-2. UP1 Positioners, Figure A-1 ..........................................................................A-3
A-3. UP1 with Solenoid Valve, Figure A-2 ..................................................................... A-5
A-4. UP1 Solenoid Valves, Figure A-2 ............................................................................ A-5
A-5. UP1 Alarm/Travel Switch Kit, Figure A-3 ............................................................. A-8
A-6. UP1 Electric Shaft Position Transmitter Kit, Figure A-4 ...................................... A-10
A-7. UP1 Air Failure Lock Kit, Figure A-5 ................................................................... A-12
A-8. UP1 Rotary Vane Seal Repair Kit, Figure 8-1 ...................................................... A-15
A-9. UP2 Actuator with Positioner, Figure A-6 ........................................................... A-16
A-10. UP2 Positioners, Figure A-6 ........................................................................A-17
A-11. UP2 with Solenoid Valve, Figure A-7 .................................................................. A-20
A-12. UP2 Solenoid Valves, Figure A-7..................................................................A-23
A-13. UP2 Alarm/Travel Switch Kit, Figures A-8 and A-30 .......................................... A-24
A-14. UP2 Electric Shaft Position Transmitter Kit, Figures A-8 and A-30 .................... A-24
A-15. UP2 Pneumatic Shaft Position Transmitter Kit, Figure A-9 ................................. A-24
A-16. UP2 Air Failure Lock Kit, Figure A-10 ................................................................ A-29
A-17. UP2 Reserve Air Tank Kit, Figure A-11 ............................................................... A-33
A-18. UP2 Rotary Vane Seal Repair Kit, Figure 8-1 ...................................................... A-36
A-19. UP2 Heater Kits, Figure A-12 ............................................................................. A-36
A-20. UP3 and UP4 with Positioner, Figure A-13 ......................................................... A-39
A-21. UP3 and UP4 Positioners and Unique Items, Figure A-13 ................................A-42
A-22. UP3 and UP4 with Solenoid Valve, Figure A-14 .................................................. A-49
A-23. UP3 and UP4 Solenoid Valves and Unique Items, Figure A-14 .........................A-54
A-24. UP3 and UP4 Alarm/Travel Switch Kit, Figures A-15 and A-30 ......................... A-54
A-25. UP3 and UP4 Electric Shaft Position Transmitter Kit, Figures A-15 and A-30 .... A-55
A-26. UP3 and UP4 Pneumatic Shaft Position Transmitter Kits, Figure A-16 ............... A-56
A-27. UP3 Air Failure Lock Kits, Figure A-17 ............................................................... A-58
A-28. UP4 Air Failure Lock Kits, Figure A-18 ............................................................... A-60
A-29. UP3 Reserve Air Tank Kits, Figure A-19 ............................................................. A-62
A-30. UP4 Reserve Air Tank Kits, Figure A-20 ............................................................. A-64
A-31. UP3 and UP4 Heater Kits, Figure A-21 ............................................................... A-65
A-32. UP3 Cylinder Spare Parts Kit, Figure 8-2 ........................................................... A-67
A-33. UP4 Cylinder Spare Parts Kit, Figure 8-3 ........................................................... A-67
A-34. UP5 and UP6 Positioner, Figure A-22 ................................................................. A-67
A-35. UP5 and UP6 Positioners and Unique Items, Figure A-22 ................................A-72
A-36. UP5 and UP6 with Solenoid Valve, Figure A-23 .................................................. A-73
A-37. UP5 and UP6 Solenoid Valves and Unique Items, Figure A-23 .........................A-75
A-38. UP5 and UP6 Alarm/Travel Switch Kit, Figure A-24 ........................................... A-78
viii
List of Tables (continued)
No. Title Page
A-39. UP5 and UP6 Electric Shaft Position Transmitter Kit, Figure A-24 ......................A-78
A-40. UP5 and UP6 Pneumatic Shaft Position Transmitter Kit, Figure A-25 ..................A-81
A-41. UP5 and UP6 with Positioner Air Failure Lock Kit, Figure A-26 ...........................A-84
A-42. UP5 and UP6 with Solenoid Valve Air Failure Lock Kit, Figure A-26 .....................A-85
A-43. UP5 and UP6 Reserve Air Tank Kits, Figure A-27 ...............................................A-88
A-44. UP5 Cylinder Spare Parts Kit, Figure 8-5 ............................................................A-91
A-45. UP6 Cylinder Spare Parts Kit, Figure 8-4 ............................................................A-91
A-46. UP5 and UP6 Heater Kits, Figure A-28 ...............................................................A-91
A-47. UP6 Volume Boosters Kit, Figure A-29 ...............................................................A-93
A-48. Parts List for Alarm/Travel Switch Kit, Figure A-30 ............................................A-96
A-49. Parts List for Electric Shaft Position Transmitter Kit, Figure A-30 .......................A-97
ix
Read First
WARNING
INSTRUCTION MANUALS
Do not install, maintain or operate this equipment without reading,
understanding and following the proper factory-supplied instructions and
manuals, otherwise injury or damage may result.
RETURN OF EQUIPMENT
All equipment being returned to the factory for repair must be free of any
hazardous materials (acids, alkalis, solvents, etc.). A Material Safety Data
Sheet (MSDS) for all process liquids must accompany returned equipment.
Contact the factory for authorization prior to returning equipment.
Read these instructions before starting installation;

save these instructions for future reference.
Contacting the Factory . . .
Should assistance be required with any of the companys products, contact the following:
Telephone:
24-Hour Call Center

1-800-HELP-365
E-Mail:
ins.techsupport@us.abb.com
Read First I
SECTION 1 - INTRODUCTION
OVERVIEW
This instruction aims to acquaint all users with the Type UP Universal
Pneumatic Rotary Actuators. It has explanations of description and
operation, installation, calibration, operating procedures, trouble-
shooting, maintenance, repair/replacement procedures and support
services. There are also appendices that have parts lists, drawings
and other reference material. Upon completion of this instruction, you
will have a working knowledge of the actuators.
It is important for safety and operating reasons to read and under-

stand this instruction. Do not install or complete any tasks or proce-
dures related to operation, calibration, maintenance or repair until
doing so.
INTENDED USER
The information in this instruction is a guide for technical personnel

responsible for the installation, operation and upkeep of the Type UP
Universal Pneumatic Rotary Actuators.
EQUIPMENT DESCRIPTION
The actuators accept electric or pneumatic control signals. They pro-

vide modulating or on/off control power to position devices through
mechanical linkage, or by direct coupling.
If the actuator has a positioner (ordered by nomenclature), it offers a

selection of input ranges:
21 to 103 kilopascals (3 to 15 pounds per square inch gage),

Type AV11 Positioner.

Type AV12 Positioner.
4 to 20-milliamps, Types AV23 and AV33 Positioners.
Computer DDC, solid state, or contact input, Type AV44 Posi-

tioner.
The positioning function can be characterized for a unique applica-

tion. Cams for linear, square or square root relationships exist. Cus-
tom shaping the cam provides for user specific positioning. A
mechanical connection to the actuator shaft serves to feed back the
shaft movement.
OVERVIEW
1-1
INTRODUCTION
Actuators fitted with a solenoid valve provide on/off control. In this

case, positioning is at either of the extreme positions of travel (zero
percent or 100 percent).
FEATURES
Wide Range of Torque Ratings. Six actuator sizes available in

ratings from 122 to 6,372 Newton meters (90 to 4,700
foot-pounds).
Easy and Flexible Installation. Actuators can be placed in con-

venient locations and connected to the driven device by standard
linkage components (refer to the Connecting Linkage for Uni-
versal Rotary Actuators product specification).
Suitable for High Temperature Environments. Actuators can

be used in ambient temperatures up to 82C (180F).
Adjustable Relationship Between Control Signal and Out-

put Shaft Position. Easily adjusted by use of standard posi-
tioner cam characteristics (for linear, square and square root
relationship) or custom-shaped cam.
Wide Environmental Applications. Complete metal enclosures

offer superior strength, as well as high immunity to diverse atmo-
spheres and process materials.
Quick and Smooth Transfer. Easily shifted from automatic to

manual control.
Wide Range of Options Available. Factory-installed NEMA 4X

enclosure, pneumatic or electric shaft position transmitter, alarm/
travel switches, air failure lock, reserve air tank and heated enclo-
sures are available.
EQUIPMENT APPLICATION
The actuators provide regulation of dampers and fan inlet vanes.

They also control lever-operated valves, turbine governors, fluid
drives and other final control elements.
INSTRUCTION CONTENT
Introduction Provides a description of this instruction, its sections and their uses, and
a brief description of the actuator. Also included are instructions on how
to use this document, reference documents, nomenclature, specifica-
tions, options and accessories, shipping weights, and stroke time
graphs (Figures 1-1 through 1-17).
Description and Provides an overview of the actuators. A broad description of each

Operation type appears in this section.
FEATURES
1-2
INTRODUCTION
Installation Contains instructions for unpacking and inspection; location and

safety considerations; setup/physical installation including wiring,
cabling and tubing connections; connections for optional equipment;
and any required adjustments.
Calibration Provides calibration procedures required before placing the actuators

into operation and for optional equipment.
Operating Procedures Contains procedures for normal operation of the actuators. Descrip-
tions of the controls are found here.
Troubleshooting Provides procedures for isolating problems. It helps determine if the

driving mechanism or the driven device is at fault. A troubleshooting
table appears in this section.
Maintenance Contains maintenance information about the actuators and related

equipment.
Repair and Replacement Details the procedures for replacing actuator components.
Procedures
Support Services Includes information on how to order replacement parts.
Parts Drawings Contains information on available spare parts and kits.

and Parts Kits
Dimension Drawings Provides dimension drawings to aid in the installation process.
HOW TO USE THIS INSTRUCTION
This instruction pertains to Types UP1 through UP6 actuators. Infor-

mation pertains only to the actuators specified.
NOTE: This instruction applies only to the actuators and their

related options. All procedures involving positioners appear in the
appropriate positioner instruction.
The sections of this instruction are sequentially arranged as they

relate to initial start-up; from unpacking to repair and replacement
procedures. After initial start-up, refer to this instruction as needed by
section.
The word actuator is used throughout this instruction. Actuator refers

to rotary vane when discussing Types UP1 and UP2 actuators. Actu-
ator refers to cylinder when discussing Types UP3 through UP6
actuators.
REFERENCE DOCUMENTS
Table 1-1 is a list of ABB documents referred to in this instruction.
HOW TO USE THIS INSTRUCTION 1-3

INTRODUCTION
Table 1-1. Reference Documents
Document Description
C-E88-6 Type RQ Electronic Position Transmitter specification
C-P81-20 Universal Rotary Actuators Type UP Pneumatic specification
C-P88-21 Characterizable Positioner Type AV1, AV2, AV3, AV4 specification
G81-5-1 Connecting Linkage for Universal Rotary Actuators
PN25039 Characterizable Positioner Type AV1 and AV2 instruction
PN25058 Characterizable Positioner Type AV3 and AV4 instruction
P-E88-25-001 Closed Loop Control Using Type AV Positioner
P-P88-001 Installing a Type AV Positioner in a Hazardous Location
NOMENCLATURE
The Type UP actuator has nine nomenclature positions. Positions

three through nine each have customer selectable options. Use Table
1-2 to select or verify actuator type.
Table 1-2. Nomenclature
Position 1 2 3 4 5 6 7 8 9
Type U P Universal Rotary Actuators Type UP Pneumatic (All Metal Enclosure)

Next Page Rated Torque at 690 kPa (100 psig) Supply
1 122 Nm(90 ft-lbs)
2 610 Nm(450 ft-lbs)
3 1,085 Nm(800 ft-lbs)
4 1,966 Nm(1,450 ft-lbs)
5 3,796 Nm(2,800 ft-lbs)
6 6,372 Nm(4,700 ft-lbs)
Enclosure Rating
0 NEMA 3R (standard)
1 NEMA 4X (all except Type UP1__11__)
Control Input
0 None - slave drive (Type UP6 actuator only)
A 21 to 103 kPa (3 to 15 psig) Type AV1121__ Characterizable Pneumatic
Positioner
B 21 to 186 kPa (3 to 27 psig) Type AV1221__ Characterizable Pneumatic
Positioner
C 4 to 20-mA Type AV23 Characterizable I/P Positioner (goes to 0% or 100%
on loss of input signal)
D 4 to 20-mA Type AV33 Characterizable I/P Positioner (holds position on
loss of input signal)
E Type AV44 Characterizable Pulse Input Positioner (holds position on loss
of input signal)
5 On/off solenoid valve, 120 VAC, single coil
6 On/off solenoid valve, 115/125 VDC, single coil
8 On/off solenoid valve, 120 VAC, dual coil
9 On/off solenoid valve, 115/125 VDC, dual coil
NOMENCLATURE
1-4
INTRODUCTION
Table 1-2. Nomenclature (continued)

Position 1 2 3 4 5 6 7 8 9
Type U P Universal Rotary Actuators Type UP Pneumatic (All Metal Enclosure)

PreviousPage F On/off solenoid valve, 220 VAC at 50 Hz/240 VAC at 60 Hz, single coil
G On/off solenoid valve, 220 VAC at 50 Hz/240 VAC at 60 Hz, dual coil
Shaft Position Transmitter
0 None
1 1 Electric, 4 to 20-mA (linear only)1
3 4 to 20-mA output, Type RQ10 Position Transmitter (LVDT, non-contact-
ing)2
4 1 4 to 20-mA output, Type RQ20 Position Transmitter with limit switches
(LVDT, non-contacting)1,2
A Potentiometric resistive output internal to Type AV positioner (Types AV1,
AV2 and AV3) (for actuator Types UP__A through D only)3
B 4 to 20-mA output internal to Type AV positioner (Types AV1, AV2 and
AV3) (for actuator Types UP__A through D only)3
C 21 to 103 kPa (3 to 15 psig) Type AV Pneumatic Position Transmitter out-
put (for Type UP__A only)4,5
D 21 to 186 kPa (3 to 27 psig) Type AV Pneumatic Position Transmitter out-
put (for Type UP__B only)4,5
Alarm/Travel Switches
0 None
1 Included (4 SPDT switches)
Air Control
0 None
1 Air failure lock (for all but Type UP6_0 actuators)
2 Volume boosters (to increase actuator stroke speed)
3 Air failure lock and volume boosters
4 Reserve air tank4 (goes to 0 or 100% on loss of air supply)
Heaters
0 None
1 120 VAC4
2 240 VAC4
NOTES:
1. A 1 or 4 in the sixth position provides limit switches (included with the position transmitter) and requires a 1 in the seventh position.
2. Type RQ Position Transmitters are special orders. Contact an authorized ABB sales/service representative for more information.
3. 4 to 20-mA output position transmitter is built into the Type AV4 positioner as a standard feature.
4. Not available on Type UP1 actuators.
5. The environmental rating on Types UP2, UP3 and UP4 actuators with a Type AV Pneumatic Position Transmitter is a function of the en-
vironmental rating of the Type AV Pneumatic Position Transmitter, since it is mounted outside the actuator enclosure. Refer to the Refer to
the Characterizable Positioner Type AV1, AV2, AV3, AV4 specification for hysteresis, resolution, deadband, repeatability, etc. for
the environmental ratings.
NOMENCLATURE 1-5
INTRODUCTION
SPECIFICATIONS
Table 1-3 lists the specifications for the Type UP actuators.
Table 1-3. Specifications
Property Characteristic/Value
Operating torque Refer to Table 3-2 for maximum values. Refer to Figures 3-5 and 3-7 for
operating torque versus air supply pressure.
Operating air supply pressure 276 to 690 kPa (40 to 100 psig)
Stroke times Refer to Figures 1-1 through 1-17.
Volume displacement for 90
mechanical output rotation
UP1 656 cm3 (40 in.3) rotary vane
UP2 1,966 cm3 (120 in.3) rotary vane
UP3 3,687 cm3 (225 in.3) cylinder [15 by 20 cm (6 by 8 in.)]
UP6 20,566 cm3 (1,255 in.3) cylinder [25 by 41 cm (10 by 16 in.)]
Temperature limits -40 to 82C (-40 to 180F)1
The low temperature operative limit can be extended below 0C (32F) with-
out heaters if the dew point of the air supply is maintained at least 10C
(18F) below the minimum expected ambient temperature.
Mechanical rotation
UP1 and UP2 Rotary vane stroke is nominally set for 90 rotation, but can be adjusted over
a range from 80 to 92 via adjustable mechanical stop.
UP3, UP4, UP5 and UP6 Stroke of the cylinder provides a 90 rotation of the output lever.
Positioner Refer to the Characterizable Positioner Type AV1, AV2, AV3, AV4
specification for details on Type AV positioners available for use with Type
UP actuators.
Positioner input signal AV1: 21 to 103 kPa (3 to 15 psig), 21 to 186 kPa (3 to 27 psig), 50% range
suppression and/or zero elevation capability.
AV2: 4 to 20-mA (goes to 0% (normal acting) or 100% (reverse acting) on
loss of input signal).
AV3: 4 to 20-mA (holds position on loss of input signal)
AV4: Computer DDC, solid state or switch contact (holds position on loss of
input signal)
Air consumption (nominal) Typical 188.8 cm3/sec (0.4 scfm) at 517.1 kPa (75.0 psig) supply, 283.2 cm3/
at balance with positioner sec (0.6 scfm) maximum at null
Positioner action Direct or reverse is standard
Performance specifications Refer to the Characterizable Positioner Type AV1, AV2, AV3, AV4
specification for hysteresis, resolution, deadband, repeatability, etc.
Solenoid valve type and coil 4-way, 2-position, 2-wire type (UP__5, UP__6 and UP__F)
requirements 4-way, 2-position, 4-wire type (UP__8, UP__9 and UP__G)
Types UP1 and UP2 NEMA 4X enclosure rating. CSA certified 120 VAC, 50/60 Hz, 10.5 W; 220
VAC at 50 Hz/240 VAC at 60 Hz, 5.25 W; or 125 VDC, 11.2 W
Types UP3, UP4, UP5 and NEMA 1 enclosure rating. CSA certified 120 VAC, 50/60 Hz, 10.5 W; 220
UP62 VAC at 50 Hz/240 VAC at 60 Hz, 5.25 W; or 125 VDC, 11.2 W
SPECIFICATIONS
1-6
INTRODUCTION
Table 1-3. Specifications (continued)
Property Characteristic/Value
External connections
Air supply UP1, UP2, UP3 and UP4: -18 NPT female
UP5 and UP6: -14 NPT female
Pneumatic signal -18 NPT female when using Types AV11 or AV12 positioners as the con-
trol input
External connections
Air failure reset -18 NPT female
Electrical conduit Cutouts for -in. and -in. female when using Types AV2, AV3 or AV4 posi-
tioners, or a solenoid valve for the control input
Manual operator
UP1 and UP2 Lever type with manual locking bolt
UP3 and UP4 Split nut with locking ratchet
UP5 and UP6 Gear type with self-locking ratchet
Materials of construction
Frame Carbon steel
Output shaft Carbon steel
Top covers Sheet metal
End covers Sheet metal
Actuators UP1 and UP2: Die cast aluminum rotary vane housing
UP3, UP4, UP5 and UP6: Carbon steel air cylinder housing and ductile iron
cylinder end flanges
Seals on vane, vane shaft, Nitrile rubber
piston and piston rod
Coating on metal parts Corrosion-resistant polyurethane
Storage Store in a dry, indoor location not subject to rapid temperature changes that
would cause condensation to form inside the unit.
Storage temperature limits -40 to 93C (-40 to 200F)
Enclosure classification NEMA 3R (standard)
NEMA 4X (optional).
Agency approvals Canadian Standards Association (CSA) certified for use in general purpose
(nonhazardous) locations.
Weight Refer to Tables 1-5 and 1-6
NOTES:
1. Some actuator/positioner combinations may have slightly higher minimum, and slightly lower maximum operating temperatures. Refer to
the Characterizable Positioner Type AV1, AV2, AV3, AV4 specification for temperature limitations.
2. The solenoid valve is mounted inside the actuator enclosure on these models; therefore, the environmental rating of the entire unit is a
function of the environmental rating of the actuator enclosure.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
SPECIFICATIONS 1-7
INTRODUCTION
OPTIONS AND ACCESSORIES
Table 1-4 lists the options and accessories available for use with the
actuators.
Table 1-4. Options and Accessories
Item Description
Shaft Position Transmitter
Electric (external to positioner) 2-wire unit requiring a 12 to 42 VDC supply and providing a 4 to 20-mA
linear output relative to the actuator shaft position.
Electric (internal to positioner) 2-wire unit requiring a 12 to 34 VDC supply and producing a 4 to 20-mA
linear output relative to the actuator shaft position.
Electric (Type RQ) Characterizable, LVDT, non-contacting, 2-wire unit requiring a 12 to 42
VDC supply and producing a 4 to 20 mA linear output relative to the
actuator shaft position.
Pneumatic Produces a 21 to 103 kPa (3 to 15 psig) or 21 to 186 kPa
(3 to 27 psig) linear output relative to the actuator shaft position. Mini-
mum required air supply is 138 kPa (20 psig). The output may be char-
acterized by the user (not available for Type UP1 actuators).
Potentiometric Resistive A potentiometer internal to the Types AV1, AV2 and AV3 positioners.
Gears connect the potentiometer to the positioner output shaft. The
position of the potentiometer shaft indicates the actuator shaft position.
The relationship between the potentiometer and the output shaft dic-
tates that one degree of rotation of the output shaft corresponds to
approximately 9.9 ohms of resistive change at the potentiometer. Refer
to the appropriate Type AV positioner instruction for more information.
Adjustable Alarm/Travel Switches Consists of four linkage-driven, cam-operated SPDT microswitches,
adjustable over the full stroke of the actuator. Used as alarm contacts
or for external indications.
Contact ratings C1, C4: 9 A at 125 VAC or VDC at 60C (140F)
C2, C3: 9 A at 125 VAC or 250 VDC at 60C (140F)
Air Failure Lock Locks actuator in its last position when the air supply falls below a pre-
set value. Each actuator includes a pneumatic pushbutton and contains
hardware for local or remote reset connection.
UP1 and UP2 Mechanical latch device with a 3-way pneumatic trip valve as the air
supply sensor.
UP3, UP4, UP5 and UP6 Uses a 3-way pneumatic trip valve as the air supply sensor, that trips
one 4-way (Types UP3 and UP4 actuators) or two 3-way (Types UP5
and UP6 actuators) lock-up valves to lock the actuator in the last posi-
tion. Includes a pressure switch used to signal an air failure alarm or for
a status light.
Alarm pressure switch contact 13.0 A at 115/230 VAC at 60C (140F)
ratings 0.5 A at 110/125 VAC at 60C (140F)
Switch contacts must be derated 1.5 A for every 10C (18F) rise above
60C (140F).
OPTIONS AND ACCESSORIES

1-8
INTRODUCTION
Table 1-4. Options and Accessories (continued)
Item Description
Reserve Air Tank Available for all except Type UP1 actuators.
Drives actuator into the full open or full closed position when the air
supply falls below a preset value. Uses a 3-way pneumatic trip valve as
the air supply sensor.
UP2 20.8 l (5.5 gal.) air tank
UP3, UP4 and UP5 30.3 l (8.0 gal.) air tank
UP6 64.4 l (17.0 gal.) air tank
Strip Heaters (thermostatically Available for all except Type UP1 actuators.
controlled) The low temperature operative limit can be extended below 0C (32F)
without heaters if the dew point of the air supply is maintained at least
10C (18F) below the minimum expected ambient temperature.
UP2 1 heater element, 500 W at 120 VAC or 240 VAC
UP3, UP4, UP5 and UP6 2 heater elements, 500 W (1000 W total) at 120 VAC or 240 VAC
Volume Boosters and Exhaust To increase stroke speed. Available only for Type UP6 actuators. Refer
Valves to Table 1-2 and Figure 1-16.
Accessories
Regulators1 Part No. 1951029_5 (standard capacity)
Part No. 1951439_1 (high capacity)
Supply air filters In-line coalescing filter for removal of solid and liquid contaminants in
compressed air. Filter comes with universal mounting bracket and
grade DX filter that is 93% efficient at 0.1 microns.
Part No. 5328563_1: 150 psig maximum inlet pressure, 54C (130F)
maximum temperature, NPT inlet/outlet connection size.
Part No. 5328563_2: 250 psig maximum inlet pressure, 121C (250F)
maximum temperature, NPT inlet/outlet connection size. This filter
has an anodized aluminum bowl guard.
Pressure switch Part No. 1941099_2 (Types UP1 and UP2 actuators) to sound an alarm
or for status lights to signal loss of air supply.
Pressure gages Part No. 5326605_4: instrument
Part No. 5326605_5: supply2
Part No. 5326605_6: output (two required)
Speed control orifices Regulate time constant of positioner and final control element. Installed
directly into positioner output ports.
Part No. 5327327_1: 1 mm (0.04 in.)
Part No. 5327327_2: blank (drill to suit)
NOTES:
1. A high capacity regulator is suggested for applications using Types UP5 and UP6 actuators where stroke speed is important. Refer to
Table 3-1 for regulator capacity information.
2. The manifold on the positioner provides gage ports, one for instrument (internal input signal) and two output gages. A supply gage can
be installed in the supply line (piping by customer).
OPTIONS AND ACCESSORIES 1-9

INTRODUCTION
SHIPPING WEIGHTS
Table 1-2 lists the shipping weights of the actuators including either a
positioner or a solenoid valve. Table 1-6 lists the shipping weights of
the various options.
Table 1-5. Type UP Actuator Shipping Weights
Shipping Weight
Actuator Type
kg (lb)
UP1_A/1_B/1_C/1_D/1_E 25 (55)
UP1_5/1_6/1_8/1_9/1_F/1_G 23 (50)
UP2_A/2_B/2_C/2_D/2_E 45 (100)
UP2_5/2_6/2_8/2_9/2_F/2_G 43 (95)
UP3_A/3_B/3_C/3_D/3_E 145 (320)
UP3_5/3_6/3_8/3_9/3_F/3_G 143 (315)
UP4_A/4_B/4_C/4_D/4_E 163 (360)
UP4_5/4_6/4_8/4_9/4_F/4_G 161 (355)
UP5_A/5_B/5_C/5_D/5_E 336 (741)
UP5_5/5_6/5_8/5_9/5_F/5_G 334 (736)
UP6_A/6_B/6_C/6_D/6_E 369 (814)
UP6_5/6_6/6_8/6_9/6_F/6_G 367 (809)
Table 1-6. Option Shipping Weights1
Shipping Weight kg
Option
(lb)
Electric Shaft Position Transmitter 1.8 (4.0)
Pneumatic Shaft Position Transmitter 5.0 (11.0)
Alarm/Travel Switches 1.1 (2.5)
Strip Heaters
UP2 1.1 (2.5)
UP3, UP4, UP5 and UP6 2.0 (4.5)
Air Failure Lock
UP1 3.6 (8.0)
UP2 5.0 (11.0)
UP3 and UP4 5.9 (13.0)
UP5 and UP6 6.8 (15.0)
Reserve Air Tank
20.8 l (5.5 gal.) for UP2 10.0 (22.0)
30.3 l (8.0 gal.) for UP3, UP4 and UP5 13.6 (30.0)
64.4 l (17.0 gal.) for UP6 22.7 (50.0)
Volume Boosters (UP6 only) 4.5 (10.0)
NOTE:
1. Add these values to those listed in Table 1-5 where applicable.
SHIPPING WEIGHTS
1 - 10
INTRODUCTION
STROKE TIME GRAPHS
Figures 1-1 through 1-17 show the stroke times for the various types
of actuators with positioners and solenoid valves.
2.5
40 PSI
60 PSI 80 PSI 100 PSI
2.0 (40 FT-LB)
(60 FT-LB) (75 FT-LB) (90 FT-LB)
1.5
STROKE TIME
FROM 5% TO 95%
OF FULL STROKE 1.0
(SECS)
0.5
0.0
0 10 20 30 40 50 60 70 80 90 100
LOAD
(FT-LB)
NOTES:
1. THESE CURVES WERE GENERATED FROM ACTUAL TESTS USING A TYPE AV232100 POSITIONER. STROKE TIMES SHOWN ARE FOR
ACTUATOR ROTATIONS OF 90% OF FULL STROKE (81 OF ROTATION), BEGINNING AT 5% OF FULL STROKE (4.5 OF ROTATION) WITH THE
ACTUATOR AT IDLE (SUPPORTING THE LOAD), AND ENDING AT 95% OF FULL STROKE (85.5 OF ROTATION). IN ORDER TO OBTAIN THE
STROKE TIMES SHOWN IN THE CURVES:
A. SUPPLY PRESSURE MUST BE MAINTAINED NOT ONLY AT THE SOURCE, BUT ALSO AT THE POSITIONER.
B. DIAMETER OF THE TUBING MUST BE AS SPECIFIED IN THE INSTALLATION SECTION OF THE INSTRUCTION MANUAL.
C. DELIVERY CAPACITY OF THE PRESSURE REGULATOR MUST BE AS SPECIFIED IN THE INSTALLATION SECTION OF THE
INSTRUCTION MANUAL.
2. VALUES IN PARENTHESES ARE MAXIMUM RECOMMENDED OPERATING LOADS AT THE SUPPLY PRESSURES SHOWN. TP20255A .
Figure 1-1. Stroke Times for Type UP1 Actuator with

Type AV2 Positioner - 5 to 95% of Stroke
STROKE TIME GRAPHS 1 - 11

INTRODUCTION
2.5
40 PSI
(40 FT-LB) 60 PSI 80 PSI
2.0
(60 FT-LB) (75 FT-LB) 100 PSI
(90 FT-LB)
1.5
STROKE TIME
FROM 0% TO 100%
OF FULL STROKE
(SECS) 1.0
0.5
0.0
0 10 20 30 40 50 60 70 80 90 100
LOAD
(FT-LB)
NOTES:
1. THESE CURVES WERE GENERATED FROM ACTUAL TESTS USING A TYPE AV232100 POSITIONER. THE STROKE TIMES SHOWN
REPRESENT WORST CASE INITIAL CONDITIONS, WITH THE FULL SUPPLY PRESSURE ON THE OPPOSING PORT OF THE ACTUATOR BEFORE
BEGINNING TO PRESSURIZE THE PORT NECESSARY TO MOVE THE LOAD FROM 0% TO 100% OF FULL STROKE (0 TO 90 OF ROTATION). THE
STROKE TIMES PRESENTED HERE ARE A COMBINATION OF THE TIME REQUIRED TO EXHAUST THE O2 PORT AND FILL THE O1 PORT AND
THE TIME FOR THE ACTUATOR TO TRAVEL FROM 0% TO 100% OF FULL STROKE (0 TO 90 OF ROTATION). IN ORDER TO OBTAIN THE STROKE
TIME SHOWN IN THESE CURVES:
A) SUPPLY PRESSURE MUST BE MAINTAINED NOT ONLY AT THE SOURCE, BUT ALSO AT THE POSITIONER.
B) DIAMETER OF THE TUBING MUST BE AS SPECIFIED IN THE INSTALLATION SECTION OF THE INSTRUCTION MANUAL.
C) DELIVERY CAPACITY OF THE PRESSURE REGULATOR MUST BE AS SPECIFIED IN THE INSTALLATION SECTION OF THE
INSTRUCTION MANUAL.
2. VALUES IN PARENTHESES ARE MAXIMUM RECOMMENDED OPERATING LOADS AT THE SUPPLY PRESSURES SHOWN.
TP20234A .

14
12
80 PSI 100 PSI
(353 FT-LB) (450 FT-LB)
10
40 PSI 60 PSI
(165 FT-LB) (256 FT-LB)
STROKE TIME 8
FROM 5% TO 95%
OF FULL STROKE
6
(SECS)
0
0 50 100 150 200 250 300 350 400 450 500
LOAD
(FT-LB)
NOTES:
INSTRUCTION MANUAL.

STROKE TIME GRAPHS

1 - 12
INTRODUCTION
14
12 100 PSI
80 PSI (450 FT-LB)
(353 FT-LB)
10 40 PSI
(165 FT-LB)
STROKE TIME 8 60 PSI
FROM 0% TO 100% (256 FT-LB)
OF FULL STROKE
6
(SECS)
0
0 50 100 150 200 250 300 350 400 450 500
LOAD
(FT-LB)
NOTES:
INSTRUCTION MANUAL.

14
12 100 PSI
(450 FT-LB)
10 80 PSI
60 PSI
40 PSI (353 FT-LB)
STROKE TIME (256 FT-LB)
8 (165 FT-LB)
FROM 0% TO 100%
OF FULL STROKE
(SECS) 6
0
0 50 100 150 200 250 300 350 400 450 500
LOAD
(FT-LB)
NOTES:
1. THESE CURVES WERE GENERATED FROM ACTUAL TESTS. THE STROKE TIMES SHOWN ARE FOR ACTUATOR ROTATIONS FROM 0% TO
100% OF FULL STROKE (0 TO 90 OF ROTATION). IN ORDER TO OBTAIN THE STROKE TIME SHOWN IN THESE CURVES:
A) SUPPLY PRESSURE MUST BE MAINTAINED NOT ONLY AT THE SOURCE, BUT ALSO AT THE SOLENOID VALVE.
INSTRUCTION MANUAL.
TP20235A .

Solenoid Valve - 0 to 100% of Stroke

INTRODUCTION
30
25
20
60 PSI
STROKE TIME
(470 FT-LB)
FROM 5% TO 95% 15 40 PSI
OF FULL STROKE (325 FT-LB) 80 PSI 100 PSI
(SECS) (630 FT-LB) (800 FT-LB)
10
0
0 100 200 300 400 500 600 700 800 900 1000
LOAD
(FT-LB)
NOTES:
C. DELIVERY CAPACITY OF THE PRESSURE REGULATOR MUST BE AS SPECIFIED IN THE INSTALLATION SECTION
2. VALUES IN PARENTHESES ARE MAXIMUM RECOMMENDED OPERATING LOADS AT THE SUPPLY PRESSURES SHOWN. TP202 7A .

30
100 PSI
25 (800 FT-LB)
(325 FT-LB) (470 FT-LB) (630 FT-LB)
20
STROKE TIME
FROM 0% TO 100%
15
OF FULL STROKE
(SECS)
10
0
0 100 200 300 400 500 600 700 800 900 1000
LOAD
(FT-LB)
NOTES:
INSTRUCTION MANUAL.

STROKE TIME GRAPHS

1 - 14
INTRODUCTION
30 100 PSI
80 PSI (800 FT-LB)
(630 FT-LB)
25 60 PSI
40 PSI (470 FT-LB)
(325 FT-LB)
20
STROKE TIME
FROM 0% TO 100% 15
OF FULL STROKE
(SECS)
10
0
0 100 200 300 400 500 600 700 800 900
LOAD
(FT-LB)
NOTES:
INSTRUCTION MANUAL.

25
20
15
STROKE TIME
FROM 5% TO 95% 60 PSI 80 PSI
40 PSI
OF FULL STROKE (850 FT-LB) (1150 FT-LB)
(550 FT-LB)
(SECS) 10 100 PSI
(1450 FT-LB)
0
0 200 400 600 800 1000 1200 1400 1600 1800 2000
LOAD
(FT-LB)
NOTES:
INSTRUCTION MANUAL.
2. VALUES IN PARENTHESES ARE MAXIMUM RECOMMENDED OPERATING LOADS AT THE SUPPLY PRESSURES SHOWN. TP20258B .


INTRODUCTION
80
60
100 PSI
STROKE TIME 80 PSI (1450 FT-LB)
40 PSI 60 PSI (1150 FT-LB)
FROM 0% TO 100%
(550 FT-LB) (850 FT-LB)
OF FULL STROKE 40
(SECS)
20
0
0 200 400 600 800 1000 1200 1400 1600 1800 2000
LOAD
(FT-LB)
NOTES:
INSTRUCTION MANUAL.

80
100 PSI
(1450 FT-LB)
60
80 PSI
STROKE TIME 40 PSI (1150 FT-LB)
FROM 0% TO 100% (550 FT-LB) 60 PSI
40 (850 FT-LB)
OF FULL STROKE
(SECS)
20
0
0 200 400 600 800 1000 1200 1400 1600 1800
LOAD
(FT-LB)
NOTES:
INSTRUCTION MANUAL.
TP20239A .

STROKE TIME GRAPHS

1 - 16
INTRODUCTION
18
40 PSI 60 PSI
(1060 FT-LB) (1620 FT-LB) 100 PSI
16
80 PSI (2800 FT-LB)
(2180 FT-LB)
14
STROKE TIME
FROM 5% TO 95%
OF FULL STROKE
(SECS) 12
10
8
0 300 600 900 1200 1500 1800 2100 2400 2700 3000
LOAD
(FT-LB)
NOTES:
INSTRUCTION MANUAL.

50
100 PSI
40
(2800 FT-LB)
60 PSI 80 PSI
(1620 FT-LB) (2180 FT-LB)
40 PSI
30 (1060 FT-LB)
STROKE TIME
FROM 0% TO 100%
OF FULL STROKE 20
(SECS)
10
0
0 300 600 900 1200 1500 1800 2100 2400 2700 3000
LOAD
(FT-LB)
NOTES:
INSTRUCTION MANUAL.
TP20242A .


INTRODUCTION
25
100 PSI
20 (2800 FT-LB)

STROKE TIME 15
(1060 FT-LB) (1620 FT-LB) (2180 FT-LB)
FROM 0% TO 100%
OF FULL STROKE
(SECS) 10
0
0 300 600 900 1200 1500 1800 2100 2400 2700 3000
LOAD
(FT-LB)
NOTES:
INSTRUCTION MANUAL.

25 40 PSI
(1900 FT-LB) 60 PSI 80 PSI
(3800 FT-LB) 100 PSI
(2850 FT-LB)
(4700 FT-LB)
20
15
STROKE TIME
FROM 5% TO 95% 85 PSI
OF FULL STROKE 10 (4000 FT-LB)
(SECS) THIS CURVE IS FOR TYPE UP6
ACTUATORS WITH VOLUME BOOSTERS.
REFER TO NOMENCLATURE.
5
0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
LOAD
(FT-LB)
NOTES:
INSTRUCTION MANUAL.
TP20260B .

STROKE TIME GRAPHS

1 - 18
INTRODUCTION
100
80 PSI 100 PSI

80 (3800 FT-LB) (4700 FT-LB)
60 PSI
40 PSI (2850 FT-LB)
(1900 FT-LB)
60
STROKE TIME
FROM 0% TO 100% THIS CURVE IS FOR TYPE
OF FULL STROKE 40 UP6 ACTUATORS WITH
VOLUME BOOSTERS. REFER
(SECS) TO NOMENCLATURE.
20
85 PSI
(4000 FT-LB)
0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
LOAD
(FT-LB)
NOTES:
INSTRUCTION MANUAL.
TP20244B .
Figure 1-16. Stroke Times for Type UP6 Actuator

with Type AV2 Positioner - 0 to 100% of Stroke
60
50 100 PSI
(4700 FT-LB)
40
STROKE TIME 80 PSI
FROM 0% TO 100% (3800 FT-LB)
30 60 PSI
OF FULL STROKE
(SECS) 40 PSI (2850 FT-LB)
(1900 FT-LB)
20
10
0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
LOAD
(FT-LB)
NOTES:
INSTRUCTION MANUAL.


SECTION 2 - DESCRIPTION AND OPERATION
INTRODUCTION
This section gives an overview of the Type UP Universal Pneumatic

Rotary Actuators. A broad description of each type is included.
Types UP1 and UP2 actuators have a double-acting rotary vane

power unit. The power units of Types UP3 UP4, UP5 and UP6 actua-
tors include a double-acting cylinder with a motion conversion mecha-
nism. This device converts linear motion to rotary motion. A
differential pressure from the positioner or solenoid valve, applied
across the double-acting power unit, causes rotary motion of the out-
put shaft.
Order the actuators with a positioner or an on/off solenoid valve.
The positioner is a push-pull action, force balance type control

device. The positioner offers a variety of input ranges:

Type AV11 positioner.

Type AV12 positioner.
4 to 20-milliamps, Types AV23 and AV33 positioners.
Computer DDC, solid state, or contact input, Type AV44 posi-

tioner.
The positioning function can be for a variety of applications. There

are standard cams for linear, square or square root relationships.
Custom shaping the cam provides application flexibility. A mechanical
connection to the actuator shaft feeds back the shaft position move-
ment. The positioner provides proportional control of the differential
pressure across the rotary vane or cylinder. It moves the output shaft
in accordance with the control signal.
Actuators with a solenoid valve provide on/off control. In this case,

positioning of the actuator is at either of the extreme ends of travel
(zero percent or 100 percent). There are solenoid valves for 220 VAC
at 50 Hertz, 120 VAC or 240 VAC at 60 Hertz, or 115/125 VDC ser-
vice, single or dual coil.
INTRODUCTION
2-1
DESCRIPTION AND OPERATION
Types UP__A and UP__ B Actuators
In Types UP__A and UP__B actuators, the positioner receives a pneu-

matic analog input signal. It adjusts the pressure to the power unit.
This moves the output shaft to the spot that matches the input signal.
Types UP__ C and UP__ D Actuators
These actuators change the four to 20-milliamp signal, applied at the

positioner current to pneumatic signal converter, into a pneumatic sig-
nal. A connection to the actuator shaft feed back the shaft movement.
When the controller calls for the actuator to change position, the posi-
tioner acts as a pneumatic relay. Through a separate air supply, it
moves the actuator into position.
Type UP__ E Actuators
These actuators have a pulse input positioner. This combines the

functions of a pulse-to-pneumatic signal converter, a pneumatic posi-
tioner and a position transmitter.
Types UP__5, UP__8 and UP__F Actuators
These actuators have single coil solenoid valves. These move the
actuator to either end of travel (zero percent or 100 percent). When
the solenoid valve is energized, the rotary vane goes to the full closed
position (Types UP1 and UP2 actuators) or the cylinder retracts com-
pletely (Types UP3 through UP6 actuators). The actuators stay in
their positions until the solenoid is de-energized at which time the
rotary vane goes to the full open position or the cylinder extends com-
pletely.
NOTE: This description is for direct acting and actuators (as

shipped). The description for reverse acting applications would be
opposite of that described here. Refer to Section 3 for more informa-
tion on reverse acting actuators with solenoid valves.
Types UP__6, UP__9 and UP__G Actuators
These actuators have dual coil solenoid valves. These move the
actuator to either end of travel (zero percent to 100 percent). Ener-
gizing solenoid A causes the rotary vane to go to the full closed posi-
tion (Types UP1 and UP2 actuators) or the cylinder to retract
completely (Types UP3 through UP6 actuators). Energizing solenoid
B causes the rotary vane to go to the full closed position or the cylin-
der to extend completely. The solenoids do not need to be kept ener-
gized to maintain the last position.
NOTE: Do not energize both coils at the same time. Doing so will
cause unpredictable actuator movement.
INTRODUCTION
2-2
DESCRIPTION AND OPERATION
Type UP6_0 Actuators
Type UP6_0 master/slave actuators are for installations that need

more torque than a single Type UP6 actuator supplies. Two or more
Type UP6 actuators can be connected in parallel to drive the same
load. This provides more torque than a single Type UP6 actuator. The
master is a standard Type UP6 actuator with a Type AV positioner or
solenoid valve. The slave drive is a standard Type UP6 actuator with-
out a positioner or solenoid valve.
Order the master using the standard nomenclature for the actuator
desired. For the additional slave drive, refer to nomenclature Type
UP6_0__0_ - slave actuator. An installation kit, supplied as part of the
slave actuator (kit number 258548_1), is required to install the master/
slave arrangement.
The slave drive can be used alone for special applications using an
external solenoid valve or other control device.
INTRODUCTION 2-3
SECTION 3 - INSTALLATION
INTRODUCTION
This section contains procedures for unpacking and inspection, loca-

tion, and safety considerations. There are also instructions for setup
and physical installation, including wiring, cabling and tubing connec-
tions. Finally, it covers connections for optional equipment, and any
adjustments that make the unit operational.
UNPACKING AND INSPECTION
Before unpacking, check the outside of the shipping carton for signs
of in-transit damage. Pay special attention to punctures, tears or
other damage to the outer carton. Look for signs of water damage. If
damaged, notify the carrier and ABB immediately.
Check the data on the nameplate, located on the actuator mounting

frame. Be sure the unit is suited for the desired application.
LOCATION CONSIDERATIONS
Locate the actuator according to the linkage arrangement desired

(refer to Connecting Linkage for Universal Rotary Actuators). For
dimensions and required clearances, refer to the dimension drawings
in DIMENSION DRAWINGS in Appendix B.
Protect the air lines and equipment from freezing in tempera-

CAUTION tures below 0C (32F). Failure to do so can damage the equip-
ment.
Protger les conduites dair et lquipement contre le gel lor-

sque la temprature est infrieure 0C (32F). Toute ngli-
ATTENTION
gence cet gard risque de provoquer des dommages
matriels.
Actuators are designed for use in ambient temperatures of -40 to 82

degrees Celsius (-40 to 180 degrees Fahrenheit).1 Unless using air
dryers or heaters, impose a low temperature operating limit of zero
degrees Celsius (32 degrees Fahrenheit).
1. Some actuator/positioner combinations may have a slightly lower maximum or higher minimum operating temperature. Refer to the Char-
acterizable Positioner Type AV1, AV2, AV3, AV4 specification for temperature limitations.
INTRODUCTION
3-1
INSTALLATION
ENCLOSURE REMOVAL
Do not operate this equipment unless the covers are in place.

WARNING The covers prevent access to moving components that pose a
risk of entanglement of body parts.
Ne faites fonctionner cet quipement que si les couvercles

sont en place. Les couvercles empchent laccs des com-
AVERTISSEMENT
posantes en mouvement qui prsentent un risque demmle-
ment des membres.
Use the enclosure removal procedures in this section to access com-

ponents for wiring and tubing installation, calibration, maintenance,
repair and replacement.
Type UP1 Actuator
NOTE: Refer to Figure 3-1.
Only Type UP1 actuators with alarm/travel switches and/or the elec-
tric shaft position transmitter require disassembly to access compo-
nents. The alarm/travel switches reside in an enclosure attached to
the actuator frame.
1. Remove the four enclosure mounting screws holding the enclo-

sure to the actuator frame.
2. Remove the enclosure.
Type UP2 Actuator
The Type UP2 actuator has a removable side panel and top cover.
SIDE PANEL
1. There are six side panel screws that hold the side panel to the
actuator frame. Remove these six screws.
2. Remove the side panel.
TOP COVER
1. There are four link lock fasteners that secure the top cover to the
actuator two on each side near the top of the actuator. Unsnap the
link lock fasteners.
2. Remove the top cover.
ENCLOSURE REMOVAL
3-2
INSTALLATION
-18 NPT O1 AND O2

POSITION OUTPUT CONNECTIONS
INDICATOR (NOTE 3) MANUAL
LOCK BOLT
CUTOUT FOR
CUSTOMER CONDUIT
CONNECTION FOR
UP1! C " " " 0,
UP1! D " " " 0
O1 O2
NOTE 1 AND UP1! E" " " 0 O2
WIRING TERMINALS
O1
(4-20mA)
ADJUSTABLE I
S I
STOP
9 A AT 125 VAC/VDC
BRN
C1NO
C1 YEL
C1NC
ORN
C1C
SWITCH C1
9 A AT 125/250 VAC
GROUND BLU
C2NO SWITCH C2
C2
SCREW WHT/BLU
C2NC
RED
C2C SWITCH C3
C1N O 9 A AT 125/250 VAC
BRN C3NO
C3 SWITCH C4
C2NO YEL C3NC
ORN C3C ELECTRIC SHA
C3NO 9 A AT 125 VAC/VDC
BLU
C4NO
C4NO C4 WHT/BLU
C4NC
RED C4C HAND AND ACTUATOR
LINKAGE LEVER
ENCLOSURE MOUNTING CONTACT WIRING ENCLOSURE
SCREWS (4) DIAGRAM
NOTES:
1. PRESSURE GAGES ARE AVAILABLE ONLY AS ACCESSORIES AND MUST BE INSTALLED BY THE CUSTOMER.
2. FOR UP1! A, 21-103 KPA (3-15 PSIG); FOR UP1! B, 21-186 KPA (3-27 PSIG); PLUGGED FOR UP1! C, UP1! D AND
UP1! E.
3. THE UNIVERSAL ACTUATOR IS NORMALLY SUPPLIED WITH THE TUBING CONNECTIONS FOR DIRECT LOADING. FOR
REVERSE LOADING APPLICATIONS, REVERSE THE AIR LINES AT THE POSITIONER PORTS O1 AND O2 AND INSTALL
REVERSE ACTING POSITIONER CAM. TP20103B .
Figure 3-1. Type UP1 Actuator with Type AV Positioner, Electric

Shaft Position Transmitter and Alarm/Travel Switches
Types UP3 and UP4 Actuator
The Types UP3 and UP4 actuators have two removable side covers
and a removable top cover.
SIDE COVER
1. Loosen the lock screws at the bottom of the side covers -turn.
2. Release the link lock fasteners that secure the top cover to the
side covers.
3. Release the link lock fasteners that secure the side covers to the
actuator frame.
4. Remove the side covers by pulling down and outward from the
bottom.
ENCLOSURE REMOVAL
3-3
INSTALLATION
POSITIONER INTEGRAL
SHUTOFF AND
EQUALIZING VALVE OUTPUT
POSITION CONNECTION O2
INDICATOR OUTPUT CONNECTION -18 NPT
O1 -18 NPT
-18 NPT O1 AND O2
OUTPUT CONNECTIONS REMOVABLE MANUAL
(NOTE 1) TOP COVER LOCK BOLT
LINK LOCK
FASTENER
O1 O2
O2
CUTOUT FOR
CUSTOMER CONDUIT
O1
CONNECTION FOR
UP2 # [C,D,E]
S I
I INPUT SIGNAL
ADJUSTABLE B CONNECTION I
STOP -18 NPT (NOTE 3)
CUTOUT FOR
O UT F
REMOVABLE I
HEATER A O1
SIDE PANEL OPTION S
O2
CONDUIT
HAND AND ACTUATOR CONNECTION
LINKAGE LEVER AF2 AF1
(VIEW A-A A
B
SIDE PANEL SCREWS

CUTOUT FOR ELECTRIC SHAFT
SUPPLY SIGNAL
POSITION TRANSMITTER/
TERMINAL STRIP FOR TRANSMITTER/ FOR AIR FAILURE
CONTACT OPTION CONDUIT
ALARM CONTACT OPTION. FOUR SPDT
CONNECTION (VIEW B-B) LOCK OPTION
AUXILIARY SWITCHES. -18 NPT
C1NO
C1
C1NC
C1C REMOTE RESET FOR AIR
C2NO FAILURE LOCK OPTION
C2
C2NC -18 NPT (NOTE 2)
C2C
C1 AND C4: C2 AND C3:
125 VAC/VDC M1
M2
125/250 VAC
9 A AT 60C M3 9 A AT 60C NOTES:
(140F) C3NO (140F) 1. THE ROTARY ACTUATOR IS NORMALLY SUPPLIED WITH THE TUBING
C3NC C3
CONNECTIONS FOR DIRECT LOADING. TO CHANGE TO REVERSE LOADING
C3C TERMINAL STRIP FOR
ARRANGEMENT, REVERSE AIR LINE CONNECTIONS AT POSITIONER O1
C4NO CUSTOMER 120/240 VAC
C4 AND O2 PORTS AND INSTALL REVERSE ACTING POSITIONER CAM.
C4NC 500 W HEATER OPTION
C4C 2. THE MANUAL REMOTE RESET BUTTON (SUPPLIED BUT NOT SHOWN) IS
L2 TO BE MOUNTED BY THE CUSTOMER AND PIPED TO THIS CONNECTION.
+ 4-20 mA ELECTRIC
3. FOR UP2! A, 21-103 KPA (3-15 PSIG); FOR UP2! B, 21-186 KPA (3-27 PSIG);
SHAFT POSITION
PLUGGED FOR UP2! C, UP2! D AND UP2! E.
XMTTR CONNECTIONS L1
VIEW B-B VIEW A-A

TP20106B .
Figure 3-2. Type UP2 Actuator with Type AV Positioner
TOP COVER
1. Remove the manual operator ratchet handle and the hand/auto

transfer handle.
2. Unsnap the link lock fasteners holding the top cover to the side
covers.
ENCLOSURE REMOVAL
3-4
INSTALLATION
MANUAL OPERATOR
HAND/AUTO RATCHET HANDLE
TRANSFER TOP COVER
HANDLE
OPERATING LEVER LINK-LOCK FASTENER
MAY BE LOCATED
POSITION ON EITHER SIDE AND
INDICATOR AT 14 INTERVALS
CLAMPING
50
SCREWS (2)
REMOVABLE POSITIONER OR
SIDE COVERS SOLENOID VALVE
POSITIONER A
HAND/AUTO
TRANSFER LEVER A
BB CCD E2
S1 - AIR SUPPLY
CONNECTION AFC - CUTOUT FOR AIR
-18 NPT FAILURE LOCK CONTACT
D CONDUIT CONNECTION
V1 - CUTOUT FOR
E1 - CONTROL LOADING PRESSURE ELECTRIC SHAFT
-18 NPT FOR TYPE UP[3,4] # [A,B] POSITION XMTTR
CUTOUT FOR CONDUIT CONNECTION (OPTIONAL) CONDUIT
FOR ALL OTHER TYPES CONNECTION
PNEUMATIC
SHAFT POSITION
TRANSMITTER
5
PNEUMATIC
SHAFT
POSITION I
O1
TRANSMITTER S SUPPLY
O2
CONNECTION S
-18 NPT
S1 V1 AFC
E1 E2
OUTPUT SIGNAL
CONNECTION O2 -18 NPT
RAISE LOWER 9 A AT 125 VAC/VDC

HAND BRN
C1 C1NO
AV4 +24 V YEL
C1NC
TYPE UP3" E OR UP4" E ORN
- + C1C
9 A AT 125/250 VAC
TYPE UP[3,4]" " 11 BLU
C2NO
C2
HAND/AUTO WHT/BLU
C2NC
TYPE UP[3,4]" [C,D] ONLY 4-20 mA
TRANSFER AUTO RED
C2C
LEVER 120/240 VAC TYPE UP[3,4]" [5,F] OUTPUT 9 A AT 125/250 VAC
BRN
C3NO
115/125 VDC TYPE UP3" 6 OR C3 YEL
VIEW A-A UP4" 6 C3NC
ORN
SOL AV XMTR C3C
9 A AT 125 VAC/VDC
BLU
AF1 AF2 C4NO
C4 WHT/BLU
S2 V2 HTR + - G ND - + - + C4NC
L N RED
C4C
120/240 VAC TYPE UP[3,4]" [8,G] 13 A AT 115/230 VAC
115/125 VDC TYPE UP3" 9 OR 0.5 A AT 110/125 VDC
RED
UP4" 9 NO
SOL SOL BLU
NC AFC
HTR - CUTOUT FOR HEATER A B BLK
C
CONDUIT CONNECTION
+ - G ND + - - + 1,000 W, 120/240 VAC L1
V2 - CUTOUT FOR ALARM/ HTR
L N L N HEATER RATING N
TRAVEL SWITCHES CONDUIT
CONNECTION VIEW B-B VIEW C-C
AF1 - AIR FAILURE LOCK
REMOTE RESET -18 NPT
VIEW D-D TP20181B .
Figure 3-3. Types UP3 and UP4 Actuators
ENCLOSURE REMOVAL
3-5
INSTALLATION
4. Types UP5 and UP6 Actuator Enclosure
Types UP5 and UP6 actuators have removable bottom side covers,
top side covers, and a removable top cover.
BOTTOM SIDE COVER
1. Loosen the bottom side cover bolts.
REMOVABLE DOOR
POSITION FOR ACCESS TO
INDICATOR TOP COVER MANUAL OPERATOR
GROOVE PIN
MANUAL OPERATOR LINK-LOCK FASTENER

RATCHET HANDLE
TOP SIDE
OPERATING LEVER MAY BE
HAND/AUTO COVER
LOCATED ON EITHER SIDE
TRANSFER HANDLE AND AT 11 15' INTERVALS
E
TOP SIDE
E COVER BOLTS CLAMPING SCREWS (2)
ELASTIC STOP NUT
B POSITIONER INTEGRAL
EQUALIZING VALVE FOR BOTTOM SIDE SHUTOFF AND
SOLENOID-EQUIPPED COVER BOLTS EQUALIZING VALVE FOR
AND/OR AIR FAILURE C C POSITIONER-EQUIPPED
A A B UP5 AND UP6 ACTUATORS
LOCK-EQUIPPED UP5
AND UP6 ACTUATORS D D
GROUND CYLINDER SIDE

BOTTOM SIDE COVER SCREW
TYPE UP5" " 11 OR UP6" " 11 9 A AT 125 VAC/VDC

BRN
C1NO S1 - SUPPLY AIR LINE -14 NPT
TYPE UP5" [C,D,E] OR UP6" [C,D,E] 4-20 mA C1 YEL
C1NC
OUTPUT E1 - CONTROL LOADING PRESSURE
120 VAC TYPE UP5" 5 OR UP6" 5 ORN
C1C
9 A AT 125/250 VAC -18 NPT FOR TYPE UP[5,6]" [A,B] OR
240 VAC TYPE UP5" F OR UP6" F BLU
C2NO CUTOUT FOR CONDUIT CONNECTOR
C2
115/125 VDC TYPE UP5" 6 OR
WHT/BLU
C2NC FOR ALL OTHER TYPES
SOL AV XMTR RED
UP6" 6 C2C
9 A AT 125/250 VAC
BRN
S1 E1 S2 E2 AF1
+ - - + - + C3NO
L N C3 YEL
C3NC
120 VAC TYPE UP5" 8 OR UP6" 8 ORN
C3C
240 VAC TYPE UP5" G OR UP6" G 9 A AT 125 VAC/VDC
BLU
C4NO AF1 - AIR FAILURE LOCK
115/125 VDC TYPE UP5" 9 OR SOL SOL C4 WHT/BLU REMOTE RESET -18 NPT
AV XMTR C4NC
UP6" 9 A B RED
C4C E2 - PNEUMATIC XMTTR
13 A AT 115/230 VAC OUTPUT SIGNAL -18 NPT
+ - + - - + - +
0.5 A AT 110/125 VDC
L N L N RED S2 - PNEUMATIC XMTTR
NO
VIEW A-A BLU
NC AFC SUPPLY (OPTIONAL)
BLK
C -18 NPT
S, S3 - SLAVE DRIVE
1,000 W, 120/240 VAC L1
TYPE UP6! 00000 HTR VIEW C-C
HEATER RATING N
NPT
S V1 AFC HTR S3 VIEW B-B

HAND
HTR - CUTOUT FOR HEATER CONDUIT CONNECTION

AFC - CUTOUT FOR AIR FAILURE LOCK CONTACT
CONDUIT CONNECTION HAND/AUTO
TRANSFER AUTO
V1 - CUTOUT FOR ELECTRIC SHAFT POSITION HANDLE
XMTTR AND TRAVEL SWITCHES (OPTIONAL)
CONDUIT CONNECTION VIEW E-E
VIEW D-D TP20107B .
Figure 3-4. Types UP5 and UP6 Actuators
ENCLOSURE REMOVAL
3-6
INSTALLATION
2. Unfasten the link lock fasteners that secure the bottom side cov-
ers to the top side covers.
3. Remove the bottom side covers by pulling down and outward on

the panel.
TOP COVER
1. Unsnap the link lock fasteners that secure the top cover to the top
side covers.
TOP SIDE COVER
1. Remove the bottom side covers and top cover.
2. On the cylinder side of the actuator, loosen the top side cover
bolts and lift the panel outward.
3. On the other side of the actuator, remove the manual operator

ratchet handle and hand/auto transfer handle.
4. Loosen the top side cover bolts and lift the panel outward.
WIRING CONNECTIONS, TUBING CONNECTIONS AND CABLING
These procedures describe wiring, tubing and cabling necessary to

make the actuators operable.
Connecting Tubing
Use suitable fittings and tubing sizes listed in Table 3-1 to make sup-
ply and signal connections. If supply regulation is needed, use the
regulator data shown in Table 3-1. Refer to Figures 3-1 through 3-4
and 3-9 and 3-10 for the size and location of connections.
Refer to Table 3-2 for suggested maximum operating torque values

versus minimum and maximum supply pressure. Refer to Figures 3-5
through 3-8 for data on operating torque and stall torque versus air
supply pressure values. Use these graphs to select the air supply
pressure necessary to get the required output torque. Keeping supply
pressure at plus or minus five percent of the selected pressure
requires no further supply regulation.
NOTE: The primary units in these graphs are Newton meters and
kilopascals. American units are in parentheses.
Installing a regulator with a flow capacity greater than or equal to

those listed in Table 3-1 protects the driven device. It also prevents
exceeding the maximum supply or operative limit of the actuator.

3-7
INSTALLATION
Table 3-1. Tubing Sizes, Air Filters and Air Supply Regulators
Regulator
Actuator Min Supply Signal Line Regulator Supply Air Filter
Capacity Approx
Type Line Size (in.) Size (in.) Part No.1 Part No.2
cm3/sec (scfm)
UP1 and 1951029 _ 5 ( 2,830 (6) 5238563 1
UP2 NPT) or 5238563 2
UP3 through 1951439 1 14,160 (30) 5238563 1
UP6 ( 38 NPT) 5238563 2
NOTES:
1. A high capacity regulator is suggested for applications using Types UP5 and UP6 actuators where stroke speed is important.
2. In-line coalescing filter for removal of solid and liquid contaminants in compressed air. Filter comes with universal mounting bracket and
grade DX filter that is 93% efficient at 0.1 microns. Part No. 5238563 2 has an anodized aluminum bowl guard.
Table 3-2. Suggested Maximum Operating Torque at Minimum and

Maximum Supply Pressure Limits
Min and Max

Max Operating Torque
Actuator Type Supply Pressure
Nm (ft-lbs)
kPa (psig)
UP1 276 (40) 54 (40)
690 (100) 122 (90)
UP2 276 (40) 224 (165)
690 (100) 610 (450)
UP3 276 (40) 441 (325)
690 (100) 1,085 (800)
UP4 276 (40) 746 (550)
690 (100) 1,966 (1,450)
UP5 276 (40) 1,437 (1,060)
690 (100) 3,796 (2,800)
UP6 276 (40) 2,576 (1,900)
690 (100) 6,372 (4,700)
Connecting Wiring
Be sure all wiring and electrical connections comply with the local,
National Electrical Code or Canadian Electrical Code.
Grounding
It is the responsibility of the customers and/or their installation/wiring

contractor to insure that the actuator, other associated control or test
equipment and all exposed conductive materials are properly
grounded in accordance with local, National Electrical Code or Cana-
dian Electrical Code regulations. In addition, insure that they are not a
hazard, including under fault conditions, to operation and service per-
sonnel.

3-8
INSTALLATION
700
(516)
600
(443)
500
(369)
UP2
400
(295)
OPERATING TORQUE
NM (FT-LB)
300
(221)
200
(148)
100 UP1
(74)
0
200 300 400 500 600 700
(29) (44) (58) (73) (87) (102)
SUPPLY PRESSURE
KPA (PSIG) TP20122B .
Figure 3-5. Operating Torque Versus Air Supply

Pressure (Types UP1 and UP2 Actuators)
The actuators have a connection for a grounding conductor. Do not

use it as a common point for other electrical equipment.
NOTES:
1. Because of the prevailing differences in soil conditions through-
out the world and differences in acceptable practices, it is not within
the scope of this instruction to describe grounding electrode sys-
tems. It is the responsibility of the customer to insure that a ground-
ing electrode system that is acceptable to the local building and
wiring codes exists at the facility where the actuator is to be
installed.
2. The NEC, Article 250, Section H, details requirements for

grounding electrode systems acceptable in the United States. The
CEC, Section 10, paragraphs 700 through 712, details the require-
ments for grounding electrode systems acceptable in Canada.
3. The structural metal frame of a building shall not be used as the

required equipment grounding conductor for the actuators.

3-9
INSTALLATION
800
(590)
700
(516)
600
(443)
UP2
500
(369)
STALL TORQUE 400

NM (FT-LB) (295)
300
(221)
200
(148)
100 UP1
(74)
0
100 200 300 400 500 600 700
(15) (29) (44) (58) (73) (87) (102)
SUPPLY PRESSURE
Figure 3-6. Stall Torque Versus Air Supply Pressure

(Types UP1 and UP2 Actuators)
Air Quality
NOTE: Installing a filter in the air supply line prevents entrained

moisture or dirt from entering the positioner. Refer to Table 3-1 for
the air filter part number.
1. Follow the air quality guidelines of ISA S7.3, Quality Standard

for Instrument Air.
2. Keep the oil content of the air as low as possible, with a maxi-
mum of one part per million.
3. Particle size in the air should not exceed three microns.
4. Keep the dew point at line pressure at least 10C (18F) below
minimum ambient temperature.

3 - 10
INSTALLATION
8000
(5900)
7000
(5163)
6000
(4425)
5000
UP6
(3688)
OPERATING TORQUE 4000

NM (FT-LB) (2950)
3000 UP5
(2213)
2000
(1475)
UP4
1000 UP3
(738)
0
100 200 300 400 500 600 700 800
(15) (29) (44) (58) (73) (87) (102) (116)
SUPPLY PRESSURE
Figure 3-7. Operating Torque Versus Air Supply Pressure

(Types UP3, UP4, UP5 and UP6 Actuators)
Characterizable Pneumatic Positioner Tubing
Tubing for the Type AV1 Characterizable Pneumatic Positioner differs

slightly depending on the actuator. If the actuator supplied includes
the air failure lock, refer to Air Failure Lock Tubing.
TYPES UP1 AND UP2 ACTUATORS
NOTE: Refer to Figures 3-1 And 3-2.
1. Connect the supply pressure line directly to the S port on the

positioner.
2. Connect the control loading pressure directly to the I port on the

positioner (pneumatic input only).

3 - 11
INSTALLATION
11000
(8113)
10000 UP6 STALL

(7376) AT MIDSTROKE
9000
(6638)
8000
(5900)
7000
(5163)
UP5 STALL
6000 AT MIDSTROKE
(4425)
STALL TORQUE
NM (FT-LB)
5000
(3688)
4000
(2950)
UP4 STALL
3000 AT MIDSTROKE
(2213)
2000 UP3 STALL

(1475) AT MIDSTROKE
1000
(738)
0
100 200 300 400 500 600 700 800
(15) (29) (44) (58) (73) (87) (102) (116)
SUPPLY PRESSURE
KPA (PSIG)
NOTE: STALL TORQUES AT 0% AND 100%

ARE 70% OF THE VALUES AT MIDSTROKE. TP20120B .
Figure 3-8. Stall Torque at Midstroke Versus Air Supply Pressure

(Types UP3, UP4, UP5 and UP6 Actuators)
1. Connect the supply pressure line directly to the S1 port at the

base of the actuator.
2. Connect the control loading pressure directly to the E1 port at the



3 - 12
INSTALLATION
2. Connect the control loading pressure directly to the E1 port at the

Characterizable I/P Positioner Tubing and Wiring
Tubing for Types AV2 and AV3 Characterizable I/P Positioners differs
slightly depending on the actuator. If the actuator supplied includes
the air failure lock, refer to Air Failure Lock Tubing.
1. Connect the supply pressure line directly to the S port on the

positioner.
2. The I port is plugged.
3. There is a conduit connection on the side of the positioner hous-

ing for signal wiring with a cross-sectional area of 0.32 to 1.30 square
millimeters (22 to 16 AWG). A twisted shielded pair is recommended
for signal wiring. Refer to the Characterizable Positioner Type AV1,
AV2, AV3, AV4 specification for the wiring procedure.

2. A conduit connection, E1, is provided at the actuator base for sig-

nal wiring to the I/P positioner. All power to the positioner is supplied
over the signal wiring. Use shielded or non-shielded wire with a
cross-sectional area of 0.2 to 2.1 square millimeters (24 to 14 AWG)
for the control signal to the positioner.
3. Remove the side cover on the positioner side of the actuator as

described in ENCLOSURE REMOVAL.
4. Feed the wires through the conduit connection and connect them
to the terminal block AV+ and AV- positions.
5. Replace the side cover.

3 - 13
INSTALLATION

2. A conduit connection, E1, is provided at the actuator base for sig-

nal wiring to the I/P positioner. All power to the positioner is supplied
over the signal wiring. Use shielded or non-shielded wire with a
cross-sectional area of 0.2 to 2.1 square millimeters (24 to 14 AWG)
for the control signal to the positioner.
3. Remove the bottom side cover as described in ENCLOSURE

REMOVAL.
to the terminal block AV+ and AV- positions.
5. Replace the bottom side cover.
Solenoid Tubing and Wiring
Solenoid tubing and wiring differs slightly depending on the actuator.

If the actuator supplied includes the air failure lock, refer to Air Fail-
ure Lock Tubing.
1. Types UP1 and UP2 actuators have a conduit connection pro-

vided on the solenoid valve for electrical hookup.
2. The solenoid wires (AC or DC) have no color coding or polarity

markings. Use either wire for positive (+).
3. Connect the supply pressure line directly to the P port on the

solenoid valve.

2. A conduit connection, E1, is provided at the actuator base for

solenoid valve wiring (AC or DC).
3. Remove the side cover on the solenoid side of the actuator as


3 - 14
INSTALLATION
OVERRIDE LEVER MANUAL

(A.F. LOCK) CUSTOMER
LOCK NUT
AIR SUPPLY
POSITION CONNECTION P
INDICATOR CUTOUT FOR CONDUIT
CONNECTION
EQUALIZING
VALVE
B
TRIP PRESSURE A
ADJUSTMENT
138-552 KPA (20-80 PSIG)
ADJUSTABLE
STOP
TRIP VALVE EXHAUST
LATCHING PORT E
SPRING 3/8 NPT
CUSTOMER RETURN
CYLINDER SOLENOID
CONNECTION
6.3 MM (0.25 IN.) VALVE
O.D. TUBING A D
D C
MANUAL REMOTE HAND AND
RESET BUTTON ACTUATOR B
B
(SUPPLIED BUT NOT LINKAGE LEVER
SHOWN) TO BE
MOUNTED BY
CUSTOMER AND PIPED CUSTOMER TRIP VALVE
TO THIS CONNECTION SUPPLY -18 NPT TP20102B .
Figure 3-9. Type UP1 Actuator with Solenoid Valve

and Air Failure Lock
to the terminal block solenoid positions. The solenoid wires are not
color coded or marked for polarity. Either wire can be used for positive
(+).
5. Connect a grounding wire to the termination provided.

2. A conduit connection, E1, is provided at the actuator base for

solenoid valve wiring (AC or DC).
3. Remove the bottom side cover on the solenoid side of the actua-
tor as described in ENCLOSURE REMOVAL.

3 - 15
INSTALLATION
CUSTOMER
POSITION MANUAL
AIR SUPPLY
INDICATOR REMOVABLE LOCK BOLT
CONNECTION P
TOP COVER
LINK-LOCK EXHAUST
B FASTENER PORT 3/8 NPT
A ADJUSTABLE
STOP SOLENOID
VALVE
B
CUTOUT FOR
HEATER OPTION
CONDUIT CUTOUT FOR ELECTRIC
REMOVABLE
CONNECTION A SHAFT POSITION TRANSMITTER/
SIDE PANEL
CONTACT OPTION CONDUIT
HAND AND CONNECTION
ACTUATOR
SIDE PANEL LINKAGE
AF2 AF1
A
SCREWS (6) LEVER
B
TERMINAL STRIP FOR TRANSMITTER/ AIR FAILURE LOCK AIR FAILURE LOCK
ALARM CONTACT OPTION. FOUR SPDT
AUXILIARY SWITCHES.
OPTION -18 NPT OPTION -18 NPT
CONNECTION FOR SUPPLY CONNECTION
9 A AT 125 VAC/VDC REMOTE RESET
BRN
C1NO MANUAL REMOTE
C1 YEL RESET BUTTON
C1NC
ORN (SUPPLIED BUT NOT
C1C
9 A AT 125/250 VAC SHOWN) TO BE
BLU
C2NO MOUNTED BY
C2 WHT/BLU
C2NC CUSTOMER AND PIPED
RED
C2C TO THIS CONNECTION
M1
M2
M3
9 A AT 125/250 VAC
BRN
C3NO
C3 YEL
C3NC
ORN
C3C
9 A AT 125 VAC/VDC
BLU
C4NO
C4 WHT/BLU
C4NC
RED TERMINAL STRIP FOR
C4C CUSTOMER 120/240 VAC
500 W HEATER OPTION
4-20 mA L2
ELECTRIC SHAFT +
POSITION XMTTR
CONNECTIONS L1
VIEW B-B VIEW A-A TP20124B .
Figure 3-10. Type UP2 Actuator with Solenoid Valve

3 - 16
INSTALLATION
to the terminal block solenoid positions. The solenoid wires are not
color coded or marked for polarity. Either wire can be used for positive
(+).
5. Connect a grounding wire to the termination provided.
6. Replace the bottom side cover.
Master/Slave Tubing Connections for Type UP6 Actuators
NOTES:
1. Refer to Figure 3-11 and Table 3-3.
2. This installation requires the use of an installation kit (supplied

as part of the slave drive), kit number 258458 1.
1. To drive a common load, connect the master and slave actuators

in parallel.
LOCK VALVE 2, PORT B

LOCK VALVE 1, PORT B
DRIVEN LOCK VALVE 1, PORT A
SHAFT LOCK VALVE 2, PORT A
SYSTEM SYSTEM
O1 O2
INPUTS O1 O2 INPUTS
3
8 4
8
POSITIONER
S3 S1 S1 S1
5 TOP BOT 5 TOP BOT
2 2
1 1 POSITIONER
SUPPLY
CUSTOMER TUBING CONNECTIONS
UP6 " " " " " " SLAVE UP6" " " " 0 " MASTER UP6 " " " " 1" MASTER
PIPING DIAGRAM PIPING DIAGRAM WITHOUT PIPING DIAGRAM WITH
AIR FAILURE LOCK AIR FAILURE LOCK TP95265C .
Figure 3-11. Master/Slave Tubing Connections
2. Be sure both actuators are properly aligned so they work

together, without binding, throughout the stroke.

3 - 17
INSTALLATION
Table 3-3. Master/Slave Installation Kit (Kit No. 258458 _1)
Item Qty Part No. Description

1 2 1952621_1 bulkhead fitting
2 2 8-8CBI2-B tubing elbow
3 2 3
8 -18 NPT brass female tee
4 2 3
8 -18 NPT brass close nipple
5 2 R9021-0050 152 cm (60 in.) 0.50 OD tubing
8 2 5323705_1 tubing elbow
3. The total volume displacement for both actuators is 41,200 cm3

(2,514 in.3).
4. A supply delivery capacity of 11,800 cm3/sec (25 scfm) or more is

desirable, unless some decrease in stroke speed can be allowed.
5. Connect the supply air line directly to the S1 port at the base of
the master actuator.
6. Refer to ENCLOSURE REMOVAL and remove the top and side

covers of the master actuator.
7. If the master actuator has the air failure lock option, perform
Steps 8 through 11. If the master actuator does not have the air failure
lock option, go to Step 12.
8. Remove the bypass valve air line fittings from the tees in the cyl-
inder air lines.
9. Install a second female tee into the two existing tees using the
close nipples (supplied).
10. Connect the bypass valve air lines to one of the open ports in
each added tee.
11. Go to Step 13.
12. Remove the pipe plugs from the tees in the cylinder air lines.
13. Install two bulkhead fittings in the two available conduit knockouts
at the base of the master. The knockouts have -14 NPT internal
threads.
14. Connect -inch OD nylon tubing between each bulkhead fitting

and the tees in the cylinder air lines using the four elbow tube fittings
supplied.
15. Route and tie down the tubing so it clears all moving parts.
16. Label the bulkhead fittings to identify the one that tees into the top
of the cylinder and the one that tees into the bottom of the cylinder.
The external ends of the bulkhead fittings are female NPT.

3 - 18
INSTALLATION
17. Use -inch minimum air lines to connect the master and slave
actuators.
18. Hook up the two air lines connecting the master and slave actua-
tors so cylinder forces (output torques) aid each other. Polarity of this
connection varies for each installation. It depends on the physical
setup of the actuators and how the linkage connects.
19. On the slave actuator, S1 goes to the top of the cylinder, and S3
goes to the bottom of the cylinder.
Increased pressure on the top of the cylinder causes the output shaft
on the left side (when facing the hand crank end) to rotate counter-
clockwise. Rotation on the master actuator is the same. Increased
pressure on the bottom of the cylinder causes the output on the right
side (when facing the hand crank end) to rotate clockwise. Rotation
on the master actuator is the same.
To change from direct to reverse loading, refer to Control Loading

Arrangements.
INSTALLATION OF OPTIONAL EQUIPMENT
These procedures describe the tubing, wiring and cabling necessary

to make the various options operable.
Reserve Air Tank Tubing and Wiring
NOTE: The reserve air tank option is not available for Type UP1
actuators.
All tubing connections inside the actuator for the optional reserve air
tank are completed before shipment. External tubing consists of con-
necting the air tank to the supply air line and actuator.
TYPE UP2 ACTUATORS
NOTE: Refer to Figures 3-12 and B-11
1. Securely install the reserve air tank as close to the actuator as

possible in a vibration-free location where the reserve air tank and air
lines will not be damaged.
2. Using -inch OD tubing, connect the customer air supply to the

tee fitting at the S port on the positioner or the P port on the solenoid
valve.
3. Using -inch OD tubing, connect the inlet port on the reserve air
tank to the check valve fitting on the positioner or solenoid valve.

3 - 19
INSTALLATION
4. Using -inch OD tubing, connect the outlet port on the reserve

air tank to the C port on either the upper or lower 3-way valve. The
output shaft of the actuator can be rotated to either the 0% or 100%
position with either connection.
NOTE: The unused C port must remain open to vent air.
ROTARY
VANE
ACTUATOR
EQUALIZING
VALVE
FITTINGS ON ENCLOSURE
D D
A C A C
B B
ALARM
PRESSURE
SWITCH
01 02
(A) (B) FACTORY
INSTALLED
POSITIONER
(SOLENOID) TERMINAL
STRIP INSIDE
I S ACTUATOR
(E) (P)
0.250 O.D. CHECK CUSTOMER

VALVE SUPPLIED
TUBING
CUSTOMER
OR
AIR SUPPLY
OUTLET - RESERVE
FLOW FLOW
AIR TO ACTUATOR
(0.250 O.D. TUBING)
INLET - AIR SUPPLY

TO TANK (0.250 O.D.
TUBING) RESERVE
AIR TANK CUSTOMER TUBING
FACTORY TUBING
NOTES:
1. THE UNUSED C PORT ON THE 3-WAY VALVE NOT CONNECTED TO THE
OUTLET PORT OF THE AIR TANK MUST BE LEFT OPEN.
2. THE PLACEMENT OF THE 0% AND 100% LABELS BELOW THE FITTINGS
ON THE ACTUATOR ENCLOSURE DEPENDS ON WHICH 3-WAY VALVE IS
CONNECTED TO THE OUTLET PORT OF THE RESERVE AIR TANK. TP20442A
Figure 3-12. Reserve Air Tank Tubing for

Type UP2 Actuators

3 - 20
INSTALLATION
5. A designation label is supplied with the reserve air tank kit. One
half is marked 0% and the other half is marked 100%. Cut the label in
half and apply the 0% and 100% designations below the bulkhead fit-
tings on the actuator frame that correspond to the 0% and 100% out-
put shaft travel limits.
6. An alarm pressure switch and terminal block are installed inside

the actuator for an external air failure alarm, indicator, etc. Refer to
Type UP2 Actuator and remove the cover necessary to access the
terminal block.
7. Run the wires for the external alarm through one of the holes in
the actuator enclosure and connect them as shown in Figure 3-12.
8. Replace the actuator cover.
TYPES UP3 THROUGH UP6 ACTUATORS
NOTE: Refer to Figures 3-13, B-12 and B-13.
1. Securely install the reserve air tank as close to the actuator as

possible in a vibration-free location where the air tank and air lines will
not be damaged.
2. Using -inch OD tubing, connect the customer air supply directly

to the S1 port on the actuator.
3. Using -inch OD tubing, connect the inlet port on the reserve air
tank to the S2 port on the actuator.
4. Using -inch OD tubing, connect the outlet port on the reserve

air tank to the actuator. Select one of the following:
For the cylinder piston to be driven to the full down position upon
loss of pressure from the supply line, connect to the CYL DN port
on the actuator.
NOTE: The CYL UP connection must remain open to vent air from
the bottom of the cylinder.
- or -
For the cylinder piston to be driven to the full up position upon

loss of pressure from the supply line, connect to the CYL UP port
on the actuator.
NOTE: The CYL DN connection must remain open to vent air from
the top of the cylinder.

3 - 21
INSTALLATION
UP DOWN
VALVE VALVE
D D
A C A C
B B
01 02 ALARM
(A) (B) PRESSURE
POSITIONER SWITCH
(SOLENOID) FACTORY
INSTALLED
I S EQUALIZING
(E) (P) VALVE
TERMINAL
STRIP INSIDE
ACTUATOR
CUSTOMER
SUPPLIED
CHECK
VALVE
FITTINGS AT ACTUATOR BASE FITTINGS AT ACTUATOR BASE

S1 AFC S2 CYL UP CYL DN
0.500 O.D.
TUBING OR
FLOW
CUSTOMER
INLET - AIR SUPPLY OUTLET - RESERVE
AIR SUPPLY
TO TANK (0.250 O.D. AIR TO ACTUATOR
TUBING) FLOW (0.500 O.D. TUBING)
CUSTOMER TUBING
FACTORY TUBING
RESERVE
AIR TANK
TP36330A .
Figure 3-13. Reserve Air Tank Tubing for Types UP3 through UP6 Actuators
5. An alarm pressure switch and terminal block are installed inside

the actuator for an external air failure alarm, indicator, etc. Refer to
Types UP3 and UP4 Actuator or Types UP5 and UP6 Actuator
Enclosure and remove the covers necessary to access the terminal
block.
6. A conduit connection, AFC, is provided at the actuator base for

access to the air failure contacts. Feed the wiring through this con-
nection.
7. Make the connections to the proper points on the terminal strip as

shown in Figure 3-13.
8. Replace the actuator covers.
Air Failure Lock Tubing
There are two possible tubing arrangements for actuators with the
optional air failure lock.

3 - 22
INSTALLATION
Automatic Reset. The air failure lock automatically resets when

the air supply exceeds the trip valve setting.
Remote Reset. The air failure lock remains tripped until deliber-
ately reset via a reset switch as supplied (shown in Fig. 3-14) or a
normally closed solenoid valve (not supplied).
16
0.62
12.7
0.50
16
0.62
32
1.25
16
0.62 PANEL DRILLING
SUPPLY AIR PRESSURE

55 1/8-27 NPT
2.16
43
1.73
PIPE PLUG
1/8-27 NPT
DIMENSIONS
MILLIMETERS
TO ACTUATOR INCHES
AIR FAILURE LOCK
1/8-27 NPT TP20037A .
Figure 3-14. Reset Switch for Air Failure

Lock (Part Number 19515895 1)
TYPE UP1 ACTUATOR
NOTES:
1. Refer to Figures 3-9, 3-14 and 3-15.
2. The reset switch and pipe plug are located in a drawstring bag
attached to the actuator frame.
Automatic Reset
1. Connect the customer air supply directly to port B of the trip

valve.
2. Connect the customer air supply also to port D on the trip valve.

3 - 23
INSTALLATION
Remote Reset
1. Connect the customer air supply directly to port B of the trip

valve.
2. Install the reset switch in a suitable location. Refer to Figure 3-14

for the dimensions.
3. Connect port 1 on the reset switch to port D on the trip valve.
4. Connect the customer air supply also to port 2 on the reset

switch.
5. Install the pipe plug into port 4 of the reset switch.
Alarm Pressure Switch Installation
NOTE: Refer to Figures 3-9 and 3-15.
If desired, connect a pressure switch (part number 1941099 2 or

equivalent) to sound an alarm or for status lights to indicate a loss of
air supply.
1. Connect a tee between port 1 of the reset switch and port D of the
trip valve.
2. Run tubing from the open end of the tee to the pressure switch.
3. Wire the switch to a terminal block or directly to the alarm as

TYPE UP2 ACTUATOR
NOTES:
1. Refer to Figures 3-10, 3-14 and 3-16.
Automatic Reset
1. Connect the customer air supply directly to the AF1 port on the
actuator enclosure.
2. Connect the customer air supply also to the AF2 port on the actu-
ator enclosure.

3 - 24
INSTALLATION
RESTRICTION
TRIP VALVE PLUG
ROTARY
D VANE
A C AUTOMATIC 2 4
MECHANICALLY ACTUATOR
B
ACTUATED
EQUALIZING
VENT 1
VALVE
LATCHING SPRING
RETURN CYLINDER O1 O2
(A) (B)
POSITIONER
(SOLENOID)
I S
(E) (P)
ACCESSORY
CUSTOMER ALARM
AIR CUSTOMER-SUPPLIED
PRESSURE
SUPPLY TERMINAL STRIP
SWITCH
BLK-COM
BLU-NC
2 1
RESET
RED-NO
PUSH-
PLUG 4 BUTTON
BAILEY-FISCHER & PORTER PART NO.
1941099# 2 OR EQUIVALENT
REMOTE RESET
RESTRICTION
TRIP VALVE PLUG
ROTARY
D
AUTOMATIC VANE
A C 2 4
MECHANICALLY ACTUATOR
B
ACTUATED
EQUALIZING
VENT 1
VALVE
LATCHING SPRING
RETURN CYLINDER O1 O2
(A) (B)
POSITIONER
(SOLENOID)
I S
(E) (P)
ACCESSORY
CUSTOMER ALARM
AIR CUSTOMER-SUPPLIED
PRESSURE
SUPPLY TERMINAL STRIP
SWITCH
BLK-COM
BLU-NC
RED-NO
CUSTOMER TUBING BAILEY-FISCHER & PORTER PART NO.

1941099# 2 OR EQUIVALENT
FACTORY TUBING AUTO RESET
TP20245B .
Figure 3-15. Tubing Schematic for Type UP1 Actuator with Air Failure Lock
Remote Reset

for the dimensions.
3. Install a tee into the air supply line.
4. Run tubing from one outlet of the tee to port 2 of the reset switch
and from the other outlet of the tee to the AF1 port on the actuator
frame.

3 - 25
INSTALLATION
5. Run tubing from port 1 of the reset switch to the AF2 port on the
actuator frame.
Alarm Pressure Switch Installation
NOTE: Refer to Figures 3-10 and 3-16. If desired, connect a pres-

sure switch (part number 1941099_2 or equivalent) to sound an
alarm or for status lights to indicate a loss of air supply.
1. Connect a tee between port 1 of the reset switch and the AF2
port on the actuator frame.
2. Run tubing from the open end of the tee to the pressure switch.
3. Wire the switch to a terminal block or directly to the alarm as

NOTES:
1. Refer to Figures 3-3 and 3-17.
Automatic Reset
1. Connect the customer air supply directly to the S1 port on the

actuator enclosure.
2. Connect the customer air supply also to the AF1 port on the actu-
ator enclosure.
Remote Reset

for the dimensions.
and from the other outlet of the tee to the S1 port at the base of the
actuator.
5. Run tubing from port 1 of the reset switch to the AF1 port at the

3 - 26
INSTALLATION
RESTRICTION
TRIP VALVE
PLUG ROTARY
D VENT VANE
A C AUTOMATIC 2 4 ACTUATOR
B MECHANICALLY
ACTUATED
EQUALIZING
VALVE 1
LATCHING SPRING
RETURN CYLINDER
O1 O2
AF1 AF2 (A) (B)
FITTINGS ON
ACTUATOR
ENCLOSURE POSITIONER
(SOLENOID)
I S
(E) (P)
ACCESSORY
CUSTOMER
AIR ALARM
CUSTOMER-SUPPLIED
SUPPLY PRESSURE
TERMINAL STRIP
SWITCH
BLK-COM
BLU-NC
2 1
RESET RED-NO
PUSH-
BUTTON
PLUG 4 BAILEY-FISCHER & PORTER PART NO.
1941099! 2 OR EQUIVALENT
REMOTE RESET
RESTRICTION
TRIP VALVE
PLUG ROTARY
D VENT VANE
A C AUTOMATIC 2 4 ACTUATOR
MECHANICALLY
B ACTUATED
EQUALIZING
VALVE 1
LATCHING SPRING
RETURN CYLINDER
O1 O2
A F1 AF2 (A) (B)
FITTINGS ON
ACTUATOR
CLOSURE POSITIONER
(SOLENOID)
I S
(E) (P)
ACCESSORY
CUSTOMER
AIR ALARM
SUPPLY CUSTOMER-SUPPLIED
PRESSURE
TERMINAL STRIP
SWITCH
BLK-COM
BLU-NC
RED-NO
BAILEY-FISCHER & PORTER PART NO.

1941099! 2 OR EQUIVALENT
CUSTOMER TUBING
AUTO RESET
FACTORY TUBING
TP20044C .
Figure 3-16. Tubing Schematic for Type UP2

Actuator with Air Failure Lock
Alarm Pressure Switch Wiring

3 - 27
INSTALLATION
Types UP3 and UP4 actuators come with the alarm pressure switch
installed. If desired, connect an alarm or status lights to indicate a
loss of air supply.
1. Remove the side covers on both sides of the actuator as


nection.
4-WAY LOCK VALVE
TRIP VALVE
RESTRICTION A B C PLUG
S
D PLUG
A V D E F
C VENT
B
VENT FACTORY-SUPPLIED
O1 O2
(A) (B) CYLINDER ALARM
PRESSURE
POSITIONER SWITCH
(SOLENOID)
I S
(E) (P)
BLU
AIR
FAILURE BLK RED
LOCK
FITTINGS AT FITTINGS AT EQUALIZING
ACTUATOR BASE ACTUATOR BASE VALVE
S1 AFC AF1
TERMINAL
STRIP
INSIDE
AFC-C ACTUATOR
2 1
RESET CUSTOMER-SUPPLIED AFC-NC
CUSTOMER PUSH-
AIR PLUG 4 AFC-NO
BUTTON
SUPPLY
REMOTE RESET
TRIP VALVE 4-WAY LOCK VALVE
RESTRICTION A B C PLUG
S
D
A V D E F PLUG
C VENT
B
VENT FACTORY-SUPPLIED
O1 O2
(A) (B) CYLINDER ALARM
PRESSURE
POSITIONER SWITCH
(SOLENOID)
I S
(E) (P)
BLU
AIR
FAILURE BLK RED
LOCK
FITTINGS AT FITTINGS AT EQUALIZING
ACTUATOR BASE ACTUATOR BASE VALVE
S1 AFC AF1
TERMINAL
STRIP
INSIDE
AFC-C ACTUATOR
CUSTOMER-SUPPLIED AFC-NC
CUSTOMER
AIR
SUPPLY
CUSTOMER TUBING
AUTO RESET
FACTORY TUBING
TP20045A .
Figure 3-17. Tubing Schematic for Types UP3 and UP4

Actuators with Air Failure Lock

3 - 28
INSTALLATION

shown in Figures 3-3 and 3-17.
4. Replace the side covers.
NOTES:
Automatic Reset
1. Connect the customer air supply directly to the S1 port on the

actuator enclosure.
2. Connect the customer air supply line to the AF1 port on the actu-
ator enclosure.
Remote Reset

for the dimensions.
and from the other outlet of the tee to the S1 port at the base of the
actuator.
5. Run tubing from port 1 of the reset switch to the AF1 port at the
Alarm Pressure Switch Wiring
Types UP5 and UP6 actuators come with the alarm pressure switch
installed. If desired, connect an alarm or status lights to indicate a
loss of air supply.
1. Remove both of the bottom side covers as described in ENCLO-

SURE REMOVAL.

nection.

3 - 29
INSTALLATION

shown in Figures 3-4 and 3-18.
4. Replace the bottom side covers.
Pneumatic Shaft Position Transmitter Tubing for Types UP2 through UP6 Actuators
NOTE: A pneumatic shaft position transmitter is not available for the

Type UP1 actuator.
LOCK LOCK
TRIP VALVE VALVE 2 VALVE 1 FACTORY-
SUPPLIED
D D D
A C VENT A C PLUG A C PLUG
B B B
ALARM
PRESSURE
SWITCH
O2 O1
(B) (A)
AIR
POSITIONER FAILURE BLU
(SOLENOID) LOCK
EQUALIZING
AFC VALVE CYLINDER BLK RED
S1 AF1 I S
(E) (P)
FITTINGS AT
ACTUATOR
BASE TERMINAL
2 1
AFC-C STRIP
RESET
PUSH- INSIDE
CUSTOMER CUSTOMER-SUPPLIED AFC-NC ACTUATOR
AIR BUTTON
SUPPLY PLUG 4
AFC-NO
REMOTE RESET
LOCK LOCK
TRIP VALVE VALVE 2 VALVE 1 FACTORY-
SUPPLIED
D D D
A C VENT A C PLUG A C PLUG
B B B
ALARM
PRESSURE
SWITCH
O2 O1
(B) (A)
AIR
POSITIONER FAILURE BLU
(SOLENOID) LOCK
EQUALIZING
AFC VALVE CYLINDER BLK RED
S1 AF1 I S
(E) (P)
FITTINGS AT
ACTUATOR
BASE
TERMINAL
AFC-C
STRIP
CUSTOMER INSIDE
CUSTOMER-SUPPLIED AFC-NC
AIR ACTUATOR
SUPPLY AFC-NO
CUSTOMER TUBING AUTO RESET

FACTORY TUBING
TP20046A .
Figure 3-18. Tubing Schematic for Types UP5 and UP6

Actuators with Air Failure Lock

3 - 30
INSTALLATION
TYPES UP2, UP3 AND UP4 ACTUATORS
These actuators have the pneumatic shaft position transmitter

mounted externally.
1. Connect the required air supply line directly to the S port of the
shaft position transmitter.
2. Using -inch tubing and suitable fittings, connect the output line
to the street tee in the O2 port of the shaft position transmitter.
3. Maintain a supply pressure of at least 35 kPa (5 psig) above the

maximum desired output pressure, but not higher than 345 kPa (50
psig).
These actuators have the pneumatic shaft position transmitter

mounted internally.
1. Connect the required air supply directly to the S2 port at the base
of the actuator.
2. Connect the output line directly to the E2 port at the base of the
actuator.
3. Use -inch tubing and suitable fittings.
4. Maintain a supply pressure of at least 35 kPa (5 psig) above the

maximum desired output pressure, but not higher than 345 kPa (50
psig).
Volume Booster Tubing for Type UP6 Actuators
All tubing connections inside the Type UP6 actuator for the optional
volume booster are completed before shipment. External tubing is the
same as that for Type UP6 actuators described in this chapter, except
the S1, S2 and S3 bulkhead connections on the actuator are -14
NPT. Customer tubing should be one inch OD tubing or -14 NPT
schedule 40 pipe.
Alarm/Travel Switch Contact Wiring for Types UP1 through UP6 Actuators
If the actuator comes with alarm/travel switches, it includes four

SPDT cam-actuated microswitches [two heavy-duty (C1 and C4) for
DC or AC service, and two (C2 and C3) for AC service]. Switches can
be used as alarm contacts or for an external indication.

3 - 31
INSTALLATION
TYPE UP1 ACTUATOR
ELECTRIC SHAFT POSITION TRANSMITTER

BOARD ASSEMBLY MOUNTING BRACKET
ALARM/TRAVEL
SWITCHES C1-C4 PAN HEAD
TB3 ELECTRIC SHAFT
MOUNTING SCREWS
POSITION
TB5 TRANSMITTER
C1NO
C1NC
+ PRINTED CIRCUIT
C1C BOARD ASSEMBLY
C2NO + PART NO. 6633390# 2
C 2 C1
C2NC TB1
DIRECT LOADING
C2C
WHT/GRA
CCW
P2
S WHT/GRN
M1 R11 P3
CW WHT/VIO P1
M2
R11
M3
C3NO C3 C4 FEEDBACK POTENTIOMETER
C3NC LOCKNUT
C3C
COUPLER SET SCREW (2)
C4NO
COUPLER
C4NC
C4C CAM SET SCREW
ALARM UNIT PAN HEAD
MOUNTING MOUNTING MICROSWITCH CAM
BRACKET SCREWS
9 A AT 125 VAC/VDC AT 60C (140F)

BRN
C1NO
YEL
C1
C1NC
ORN
C1C
9 A AT 125/250 VAC AT 60C (140F)
BLU
C2NO
WHT/BLU
C2
C2NC
RED
C2C
9 A AT 125/250 VAC AT 60C (140F)
C3NO BRN
YEL C3
C3NC
ORN
C3C
9 A AT 125 VAC/VDC AT 60C (140F)
BLU
C4NO
C4 NOTE: SWITCH CONTACTS
WHT/BLU MUST BE DERATED 1.5 A
C4NC
FOR EVERY 10C (18F)
RED RISE ABOVE 60C (140F).
C4C
TP20119B .
Figure 3-19. Electric Shaft Position Transmitter and Alarm/Travel

Switches (for nomenclature options 11 in the
sixth and seventh positions)

3 - 32
INSTALLATION
The adjustable travel switches for UP1 actuators are located inside
the cover mounted to actuator frame.
1. Remove the four enclosure mounting screws holding the cover to

the actuator frame.
2. Make the electrical connections from the switches at the terminal

block as shown in Figures 3-1 and 3-19.
3. Run the wires through the conduit connector in the cover and
replace the cover.
TYPE UP2 ACTUATOR
1. Remove the side panel as described in ENCLOSURE

REMOVAL.

3. Run the wires through the conduit connector in the side of the
actuator frame.
4. Replace the side panel and top cover.
1. Remove the side cover on the cylinder side of the actuator as


3. Run the wires through conduit connector V2 at the base of the

actuator.
1. Remove the bottom side cover and top side cover on the cylinder
side of the actuator as described in ENCLOSURE REMOVAL.


3 - 33
INSTALLATION
3. Run the wires through conduit connector V1 at the base of the

actuator.
Electric Shaft Position Transmitter Wiring for Types UP1 through UP6 Actuators
NOTE: Refer to Figures 3-19 through 3-22.
Signal wiring connected in this box must be rated for at least

300 V. Failure to use the proper wire may cause a short circuit
CAUTION
and/or a fire which would damage the equipment and upset the
process.
La capacit nominale du cablage de signaux reli ce botier

doit tre d'au moins 300 V. L'utilisation de cables nadquats
ATTENTION
pourrait provoquer un court-circuit ou un incendie, ce qui
endommagerait le matriel et perturberait le processus.
If the actuator comes with an electric shaft position transmitter (exter-

nal to the characterizable positioner), it has a linkage-driven shaft
position transmitter. It includes the alarm contacts described in
Alarm/Travel Switch Contact Wiring for Types UP1 through UP6
Actuators.
The transmitter, a two-wire, four to 20-milliamp output device, oper-

ates on 12 to 42 VDC. The signal wiring supplies power to the trans-
mitter. Refer to Figure 3-20 for a typical wiring loop diagram. Use wire
with a cross-sectional area of 0.32 to 2.10 square millimeters (22 to
14 AWG) rated at a minimum of 300 volts.
A twisted pair or shielded wire reduces the chance of noise pickup. If

needed, ground the signal wiring at any location in the loop, but not at
more than one point. If there are several transmitters on a single
power supply, make the ground connection at the power supply.
Do not run wiring near high power electrical equipment or in the same
conduit or trays as the power wiring. Although power supply regula-
tion is not vital, ripple should not exceed 0.5 volt peak-to-peak. This
insures a stable output signal. Supply voltages and load changes dur-
ing operation have no effect on accuracy, since the combined load
resistance falls within the operating ranges as shown in Figure 3-21.
Do not exceed the indicated maximum of the combined resistance of
the load and the signal wiring.
If the electric shaft position transmitter is internal to the characteriz-

able positioner, it is a two-wire unit requiring a 12 to 34 VDC supply.
It produces a four to 20-milliamp linear output relative to the actuator
shaft position.

3 - 34
INSTALLATION
NOTES:
1. The procedures for accessing the electric shaft position trans-
mitter on the actuators are the same as those for accessing alarm/
travel switch contacts (described in ENCLOSURE REMOVAL). After
gaining access to the transmitter, continue with the wiring proce-
dures.
2. The wiring procedures in this section describe only the connec-

tions to an electric shaft position transmitter if it is external to the
characterizable positioner. To make the connections to the electric
shaft position transmitter that is internal to the positioner, refer to the
+ POWER
SUPPLY
G
ELECTRIC
SHAFT POSITION +
TRANSMITTER

LOAD
+
4-20 mA
SIGNAL LEADS
TP20043A .
Figure 3-20. Typical Wiring Loop Diagram for the

Electric Shaft Position Transmitter
TYPE UP1 ACTUATOR
NOTE: Refer to Figures 3-1 and 3-19 through 3-22.
1. Make the connections to the transmitter at the terminal block

locations as shown in Figures 3-1 and 3-19.
2. Run the wires through the conduit opening in the cover.
3. Replace the cover.
TYPE UP2 ACTUATOR
1. Make the connections to the transmitter at the terminal block

locations as shown in Figures 3-2 and 3-19.
2. Run the wires through the conduit opening in the actuator frame.
3. Replace the panel and cover.

3 - 35
INSTALLATION
1500
1200
900
LOAD RESISTANCE
( )
600
OPERATING
RANGE
300
0
12 18 24 30 36 42
SUPPLY VOLTAGE
(VDC) TP20038A .
Figure 3-21. Supply Voltage and Load Resistance Limits for the
Electric Shaft Position Transmitter
1. Make the connections to the transmitter at the terminal strip loca-

tions as shown in Figure 3-3.
2. Run the wires through the V1 conduit opening located at the actu-
ator base.
1. Make the connections to the transmitter at the terminal strip loca-

tions as shown in Figure 3-4.
2. Run the wires through the V1 conduit opening located at the base
of the actuator.

3 - 36
INSTALLATION
REVERSE LOADING WIRING FOR ELECTRIC SHAFT POSITION

TRANSMITTERS
1. Remove the cover from the electric shaft position transmitter

assembly.
2. Reverse P1 and P2 on the transmitter circuit board (Fig. 3-22).
3. Refer to Table 3-4 for wire color codes on the transmitter circuit
board, for direct versus reverse loading.
4. Replace the transmitter cover and calibrate as described in

Section 4.
REVISION LEVEL
4-20 mA XMTTR ASSY P2

P3
6633390 # 2
P1
R5 R4
S Z
P E
A R TP1 TP2
TB1
N O
+
TP20089B
Figure 3-22. Electric Shaft Position

Transmitter Circuit Board
Table 3-4. Wire Color Codes for Direct Versus Reverse Loading on
the Electric Shaft Position Transmitter
Control
P1 P2 P3
Loading
Direct WHT/VIO WHT/GRY WHT/GRN
Reverse WHT/GRY WHT/VIO WHT/GRN
Strip Heater Wiring for Types UP2 through UP6 Actuators
NOTE: Strip heaters are not available for Type UP1 actuators.
ABB recommends ordering actuators with heating elements installed

for applications where the ambient temperature remains below zero
degrees Celsius (32 degrees Fahrenheit) for extended periods. A
thermoswitch automatically starts the heaters when the temperature
drops below approximately four degrees Celsius (40 degrees Fahren-
heit).
NOTE: Follow the procedures for gaining access to the terminal

strips for the alarm/travel switches in Alarm/Travel Switch Contact
Wiring for Types UP1 through UP6 Actuators.

3 - 37
INSTALLATION
TYPE UP2 ACTUATOR
1. Make the connections to the terminal strip L1 (hot) and L2 (neu-

tral) as shown in Figure 3-2.
2. Run the wires through the conduit opening in the actuator frame.
1. Make the connections to the terminal strip L1 (hot) and N (neu-

2. Run the wires through the HTR conduit opening in the actuator
frame.
1. Make the connections to the terminal strip L1 (hot) and N (neu-

2. Run the wires through the HTR conduit opening in the actuator
frame.
PRE-OPERATING ADJUSTMENTS
Use these procedures to make any adjustments necessary to make

the actuator operational.
Control Loading Arrangements
The actuator normally comes with the tubing connections made for
direct loading operation. If desired, change to reverse loading opera-
tion.
POSITIONER CONTROL LOADING ARRANGEMENTS
The two types of positioner control loading are direct loading and
reverse loading. Direct loading allows movement from zero to 100
percent (position indicator reading) as the control signal to the posi-
tioner increases. The actuator leaves the factory in this configuration.
3 - 38
INSTALLATION
Reverse loading allows the actuator to move from 100 to zero percent
as the control signal to the positioner increases. To change from
direct loading to reverse loading, remove the actuator covers (if
required) necessary to access the positioner as outlined in ENCLO-
SURE REMOVAL. Follow the instructions for reverse loading in the
SOLENOID VALVE CONTROL LOADING ARRANGEMENTS
The actuator normally comes with the tubing connections made for
direct loading operation. If desired, change to reverse loading opera-
tion.
Direct loading allows movement from zero to 100 percent when the
solenoid is energized. The actuators leave the factory in this configu-
ration.
Reverse loading allows movement from 100 to zero percent when the
solenoid is energized. To switch from direct to reverse loading:
1. Remove the actuator covers (if required) to gain access to the

solenoid valve as described in ENCLOSURE REMOVAL.
2. Loosen the air line connections at the A and B ports of the sole-
noid.
3. Reverse the air line connections and tighten these connections.
NOTE: For dual coil solenoid valves, reverse either the air lines or
the electrical connections to the coils.
3 - 39
INSTALLATION
Operating Lever Adjustment
Failure to tighten the lever assembly bolts to the torque specifi-

WARNING cations may cause the load to shift and bodily injury could
result.
Toute ngligence serrer les boulons du levier conformment

AVERTISSEMENT au couple prescrit pourrait entraner le dplacement de la
charge et par consquent provoquer des blessures.
TYPE UP1 ACTUATOR
NOTE: Refer to the drawings in SPARE PARTS in Appendix A and

DIMENSION DRAWINGS in Appendix B.
1. Loosen the two socket hex-head cap screws in the lever hub
using a 5 16 -inch socket wrench.
2. Determine at what angle to locate the lever for zero percent posi-
tion (normally parallel to the driven lever).
3. Rotate the lever to the correct position.
4. Secure the lever assembly to the shaft by tightening the socket

hex-head cap screws to 71 to 79 Newton meters (52 to 57
foot-pounds).
5. Connect the linkage to the lever in the desired arrangement.
6. Refer to Connecting Linkage for Universal Rotary Actuators

for alternate linkage arrangements.
TYPE UP2 ACTUATOR

1. Loosen the two socket hex-head cap screws in the lever hub
using a -inch hex wrench.
3. Rotate the lever to the correct position.
4. Secure the lever assembly to the shaft by tightening the socket

hex-head cap screws to 85 to 91 Newton meters (63 to 67
foot-pounds).

3 - 40
INSTALLATION
TYPES UP3/4/5/6 ACTUATORS

1. Loosen the clamping screws in the lever hub.
2. Pull the lever off of the splined shaft.
NOTE: The lever may be located on either end of the shaft.
4. Push the lever onto the shaft in the desired position.
5. Secure the lever to the shaft by tightening the clamping screws to

38 to 44 Newton meters (28 to 32 foot-pounds).

Position Indicator
Upon changing the control loading of the actuator, switch the scale for
the position indicator to match the rotation of the actuator.
NOTE: Before mounting the position indicator, clean dust, dirt, oil,
moisture, etc. from the mounting surface.
Types UP1 and UP2 actuators come with two adhesive-backed posi-
tion indicator scales. They are graduated from zero to 100 percent in
ten percent increments. One scale, fixed to the sector plate at the fac-
tory, reads zero to 100 percent from left to right. The second scale,
taped to the rear side of the sector plate, reads zero to 100 percent
from right to left. Install the latter scale on reverse acting actuators to
match the rotation of the driven device. Simply remove the backing,
and place the reverse indicating scale over the scale installed at the
factory.
TYPES UP3/4/5/6 ACTUATORS
Types UP3, UP4, UP5 and UP6 actuators come with a shaft-mounted
position indicator and indicator scales graduated from zero to 100
percent in 25 percent increments. One scale reads zero to 100 per-
cent from right to left. The second scale reads zero to 100 percent
from left to right. These scales come in a separate bag. Choose the
scale that matches the closed versus open position of the driven
device. Two punch marks on the actuator at the output shaft help
position the scale
3 - 41
INSTALLATION
Mechanical Stop Adjustment for Types UP1 and UP2 Actuators
NOTES:
2. The mechanical stop is only available on the types UP1 and

UP2 actuators.
The nominal setting of the stroke is for a rotation of 90 degrees.

Adjustable mechanical stops, located on each end of the actuator,
allow adjustment over a range of 80 to 92 degrees.
1. Loosen the 5 16 -18 hex nut located on the socket head stop-
screw.
2. Hold the hex nut and adjust the stopscrew clockwise to decrease
the rotation, or counterclockwise to increase rotation.
3. Tighten the hex nut.
4. Calibrate the positioner (if supplied) for the new output stroke.
Refer to Zero Adjustment for Positioner-Equipped Types UP1
through UP6 Actuators and Span Adjustment for Posi-
tioner-Equipped Types UP1 through UP6 Actuators in Section 4.
3 - 42
SECTION 4 - CALIBRATION
INTRODUCTION
This section includes the calibration required before placing the actu-
ator into operation. Calibration procedures for optional equipment
appear here.
EQUIPMENT REQUIRED FOR CALIBRATION
A full complement of screwdrivers, hex wrenches and Allen

wrenches.
Instrument pressure gage - part number 5326605_4, or equiva-

lent.
Two output pressure gages - part number 5326605_6, or equiva-

lent.
Milliammeter capable of reading 4 to 20-milliamp output.
CALIBRATION PROCEDURES
The positioner calibration procedures described in this section apply

to the actuator only as a function of the positioner. The procedures for
positioner calibration are printed in the appropriate instruction for the
positioner in use and are not reprinted here.
Positioner Access
Access to the positioner on Types UP1 and UP2 actuators is not

restricted by an enclosure. Refer to the proper enclosure removal
procedure in the installation section to access the positioner on Types
UP3 through UP6 actuators.
Zero Adjustment for Positioner-Equipped Types UP1 through UP6 Actuators
The actuator comes set for full travel proportional to full range input
signal. The positioner range spring assembly applies a proportional
feedback force to the input signal diaphragm assembly. The zero
adjustment nut in the positioner applies initial tension on the range
spring and provides a zero adjustment. Install the actuator as
directed, check the positioner zero and adjust if necessary.
If requiring another relationship between travel and input signal, set

the zero before any other adjustment. This sets the cam zero relative
to the minimum input signal [21 kilopascals (three pounds per square
inch gage) or four milliamps].
INTRODUCTION
4-1
CALIBRATION
For an elevated zero, an initial tension imposed on the range spring

prevents the actuator from moving from its minimum position until the
input signal increases above the elevated zero value. Refer to Table
4-1 for zero elevations.
Table 4-1. Zero Elevation
Actuator
Calibrated Zero Elevated Zero
Type
UP__A 21 kPa (3.0 psig) Any value between 21 and 62 kPa
(3 and 9 psig)
UP__B 21 kPa (3.0 psig) Any value between 21 and 103 kPa
(3 and 15 psig)
UP__C 4 mA Any value between 4 and 12 mA by
adjusting pneumatic zero
UP__D 4 mA Any value between 4 and 12 mA by
adjusting pneumatic zero
Some applications that might use an elevated zero are when two or
more actuators are operated in sequence or when the characteristics
of the device moved by the actuator need to match those of another
regulated device.
1. Gain access to the positioner.
2. Take off the cover to the positioner by removing the two cover
screws.
3. Refer to the appropriate positioner instruction for the step-by-step

zero adjustment procedure.
Span Adjustment for Positioner-Equipped Types UP1 through UP6 Actuators
The span adjustment affords a variation of actuator motion for a given

span of control signal pressure.
With any of the characterized cams, the span adjustment allows full
actuator travel to occur with a signal change as small as 50 percent of
its full span. This is referred to as split ranging. This is valuable when
running two or more actuators in sequence. For example, one actua-
tor could fully open a damper from a 21 to 62 kilopascals (three to
nine pounds per square inch gage) signal, while the next opens fully
from a 62 to 103 kilopascal (nine to 15 pounds per square inch gage)
signal. In this case, the second actuator requires zero elevation.
At the other extreme, the span adjustment can be set to produce as

little as 50 percent of the travel capability of the actuator over the full
input signal span. This is referred to as travel limiting. This is valuable
when the device the actuator regulates is oversized and a full open
CALIBRATION PROCEDURES
4-2
CALIBRATION
position is not desirable. Before starting the procedure, determine the

percentage of travel desired.
2. Refer to the appropriate positioner instruction for the step-by-step

span adjustment procedure.
Speed Adjustment for Positioner-Equipped Types UP1 through UP6 Actuators
When the system involves only a single actuator, a high positioning

speed is usually an advantage. However, in a complex control system
it is generally desirable to operate all power devices at the same
speed. This helps to avoid interaction between units that produce
undesirable process conditions. If it is necessary to reduce the speed
of operation, 1.02 millimeter (0.04 inch) speed control orifices (Part
No. 5327327_1) are available from ABB. If these orifices are too
small, they may be drilled out to obtain the desired speed control. To
reduce the speed even more, blank orifices (Part No. 5327327_2) are
also available.
NOTE: Do not use the speed control orifices to correct an instability

(hunting action). Use the orifices only to vary the stroke time.
2. Refer to the appropriate positioner instruction for the speed

adjustment procedure.
Gain Adjustment for Positioner-Equipped Types UP1 through UP6 Actuators
Gain adjustment on positioner-equipped Types UP1 through UP6

actuators is accomplished by changing the positioner gain hinge
spring. The hinge installed at the factory is suitable for most applica-
tions. However, if the gain is too great for an application, oscillation of
the driven element could result. If this is the case, install a gain hinge
spring that yields a lower gain.
2. Take off the cover to the positioner by removing the two cover
screws.
3. Refer to the appropriate positioner instruction for the gain adjust-

ment procedure.
OPTIONAL EQUIPMENT CALIBRATION
Use the following procedures to calibrate any optional equipments

that may be installed on the actuator.

4-3
CALIBRATION
Electric Shaft Position Transmitter Calibration for Types UP1 through UP6 Actuators
NOTES:
1. Refer to Figure 3-19.
2. This procedure is for an electric shaft position transmitter exter-

nal to the positioner. To calibrate transmitters internal to the posi-
tioner, refer to the appropriate positioner instruction.
1. Refer to the proper enclosure removal procedure in the installa-

tion section to access the electric shaft position transmitter.
2. Connect a milliammeter in series with the positive (+) or negative

(-) leads of the transmitter output, or across the test jacks TP1 (+) and
TP2 (-) (Fig. 3-19).
3. Activate the 12 to 42 VDC power in the transmitter loop.
4. Manually position the actuator to the zero percent travel position

(100 percent for reverse acting) and observe the reading on the mil-
liammeter.
5. Adjust the zero potentiometer (R4 - Fig. 3-19) until the milliamme-
ter reads 4.0 mA.
6. Manually position the actuator to the 100 percent position (zero

percent for reverse acting) and observe the reading on the milliam-
meter.
7. Adjust the span potentiometer (R5 - Fig. 3-19) until the milliam-
meter reads 20.0 mA.
8. Repeat Steps 4 through 7 until the milliammeter indicates the cor-

rect reading at both extremes of travel.
9. Manually position the actuator to the 50% position and verify that
the milliammeter reads 12.0 mA.
Alarm/Travel Switch Calibration
This option consists of four linkage-driven, cam-operated SPDT

microswitches, adjustable over the full stroke of the actuator.
Switches can be used as alarm contacts or for external indicators.
Set the microswitch alarm contacts that make up the alarm/ travel
switch assembly to operate at any desired position. To do so, adjust
the switch cam to make or break a contact at that point.
1. Refer to the proper enclosure removal procedure in the installa-

tion section to access the alarm/travel switches.

4-4
CALIBRATION
2. Manually position the actuator output shaft to the desired actuat-

ing position.
3. Loosen the cam setscrew holding the cam to the switch assembly
shaft.
4. Rotate the microswitch cam to the desired actuating position.
5. Tighten the setscrew to lock the cam on the shaft.
Pneumatic Shaft Position Transmitter Calibration
NOTE: The pneumatic shaft position transmitter option is not avail-

able for Type UP1 actuators.
1. The pneumatic shaft position transmitter mounts on the outside of

the Types UP2, UP3 and UP4 actuators. Refer to the proper enclo-
sure removal procedure in the installation section to access the pneu-
matic shaft position transmitter on Types UP5 and UP6 actuators.
2. Refer to the appropriate positioner instruction to calibrate the

pneumatic shaft position transmitter.
Reserve Air Tank Calibration
No adjustment is required for the trip valves or pressure switch. All

adjustments are made before shipment.
Volume Booster Calibration
The volume booster has a bypass restriction adjustment for stable

actuator performance. Refer to the appropriate volume booster
instruction for the adjustment procedure.
Air Failure Lock Calibration
The trip and lock valves require adjustment based on the required or
available air supply to obtain the required output torque.
Factory personnel set the trip valve at 240 kilopascals (35 pounds per
square inch gage) for Types UP1 and UP2 actuators and 380 kilopas-
cals (55 pounds per square inch gage) for Types UP3, UP4, UP5 and
UP6 actuators. If the application requires a different setting, refer to
Figures 3-5 and 3-7 for the suggested maximum operating torque
versus air supply pressure. The stall torque graphs in Figures 3-6 and
3-8 show the minimum supply pressure needed to hold the actual
load imposed on the actuators. Consider this pressure as the mini-
mum trip valve setting. The maximum trip valve setting is 103 kilopas-
cals (15 pounds per square inch gage) below the available or
required air supply for actuators with positioners and 138 kilopascals
(20 pounds per square inch gage) for actuators with solenoid valves.

4-5
CALIBRATION
The recommended lock valve setting is a minimum of 103 kilopascals

(15 pounds per square inch gage) below the trip valve setting.
Types UP1 and UP2 actuators use a mechanical latch device with a
three-way pneumatic trip valve as the air supply sensor. A cus-
tomer-supplied pressure switch may be added to signal an air failure
alarm or for a status light. Types UP3, UP4, UP5 and UP6 actuators
come with lock valves along with the trip valve. They use a three-way
pneumatic trip valve as the air supply sensor that trips one four-way
(Types UP3 and UP4 actuators) or two three-way (Types UP5 and
UP6 actuators) lock valves to lock the actuator in the last position.
Types UP3 through UP6 actuators include a pressure switch that can
be used to signal an air failure alarm or for a status light.
The trip valve mounts on the outside of the Type UP1 actuator. Refer
to the proper enclosure removal procedure in the installation section
to access the air failure lock on Types UP2 through UP6 actuators.
TRIP VALVE ADJUSTMENT FOR TYPES UP1 THROUGH UP6

ACTUATORS
1. Install a supply pressure gage in the supply pressure line.
NOTE: If the air supply connected according to Figures 3-15

through 3-18 in Section 3 is not adjustable, or if adjustment would
disrupt other processes, disconnect it and connect a 345 kPa (50
psig) up to 689 kPa (100 psig) air supply for Types UP1 and UP2
actuators, or a 482 kPa (70 psig) to 689 kPa (100 psig) air supply
for Types UP3 through UP6 actuators.
2. Loosen the trip valve adjusting screw locknut (Fig. 3-9).
3. On positioner-equipped units, make sure the control loading sig-

nal is connected as described in the installation section.
4. Increase the air supply pressure to the operating value and press
the remote pushbutton, if installed.
5. Decrease the air pressure to the desired trip value.
6. Turn the trip valve adjusting screw clockwise to increase the trip
pressure or counterclockwise to decrease the trip pressure.
7. Repeat Steps 4 through 6 until the trip valve drops out at the
desired trip pressure.
8. Tighten the adjusting screw locknut.

4-6
CALIBRATION
LOCK VALVE ADJUSTMENT FOR TYPES UP3/4/5/6 ACTUATORS
Types UP3 through UP6 actuators have lock valves along with the trip
valve. The trip valve dumps the control pressure to the lock valves,
trapping the air in the cylinder. Factory personnel set the lock valves
at 138 kilopascals (20 pounds per square inch gage). If the trip valve
setting is decreased below 345 kilopascals (50 pounds per square
inch gage), adjust the lock valves to at least 103 kilopascals (15
pounds per square inch gage) below the trip valve setting. An
increase in trip valve setting requires no change in lock valve setting.
1. Install a supply pressure gage in the supply pressure line.
2. Disconnect the tubing from the inlet port of the lock valve (S port
for Types UP3 and UP4 actuators and D port for Types UP5 and UP6
actuators).
3. Connect the adjustable air supply to the inlet port and set the
pressure for 103 to 137 kPa (15 to 20 psig) below the trip valve pres-
sure setting.
4. Reduce the lock valve pressure adjustment until the lock

switches.
5. Disconnect the adjustable air supply and connect the original tub-
ing.

4-7
SECTION 5 - OPERATING PROCEDURES
INTRODUCTION
This section of the manual has procedures for normal operation of the
Type UP Universal Pneumatic Rotary Actuators. Descriptions of the
controls reside here.


AVERTISSEMENT
ment des membres.
NORMAL OPERATING CONSIDERATIONS
All actuators can operate in either an automatic or a manual mode.
Positioner-equipped actuators make use of the integral shutoff and

equalizing valve (Figs. 5-1, 5-2 and 5-3) on the positioner. This allows
either manual or automatic operation of the actuator power unit.
When set for automatic operation, the valve is locked into position by
a safety latch. This safety latch prevents the valve from being
bumped or jarred out of position.
Changing to manual operation cuts off the supply pressure to the

actuator and couples the O1 and O2 ports of the positioner to equal-
ize pressure across the vane (Types UP1 and UP2 actuators) or cyl-
inder (Types UP3, UP4, UP5 and UP6 actuators). This allows manual
positioning of the actuator unit.
Solenoid-equipped actuators have an equalizing valve (Figs. 5-1,

5-2 and 5-3). On the Types UP1 and UP2 actuators, this valve equal-
izes pressure on both sides of the rotary vane paddle. This allows
manual positioning of the vane paddle. On Types UP3, UP4, UP5 and
UP6 actuators, the valve equalizes pressure on both sides of the cyl-
inder. This allows manual positioning of the actuator using the hand
operator ratchet handle.
The remote reset air failure lock (if supplied) locks the actuator in
place on loss of air supply pressure. The pneumatic pushbutton
allows release of the air failure lock from a local or remote location
upon restoration of the air supply pressure.
On Types UP1 and UP2 actuators, the air failure lock consists of a
latching spring return cylinder (nonadjustable) that is triggered from
an adjustable trip valve. This latches a rack gear mechanism. When
INTRODUCTION
5-1
OPERATING PROCEDURES
the air supply fails, the latching spring return cylinder opens the
equalizing valve across the vane power unit. This permits manual
operation of the actuator. A customer-supplied pressure switch (Figs.
3-15 and 3-16) may be used to signal an air failure alarm or a status
light.
On Types UP3, UP4, UP5 and UP6 actuators, the air failure lock is a
pneumatic device that uses a three-way pneumatic trip valve as the
air supply sensor. It trips a four-way lock-up valve on Types UP3 and
UP4 actuators, or two three-way lock-up valves on Types UP5 and
UP6 actuators. The actuators include a pressure switch for use as an
air failure alarm or a status light.
TYPES UP1 AND UP2 ACTUATOR OPERATION
Types UP1 and UP2 actuator operation differs slightly depending on

whether control of the actuator comes from a positioner or a solenoid
valve. The addition of the air failure lock option also varies the opera-
tion. The reserve air tank option (Type UP2 actuator only) has no
effect on normal actuator operation.
from Automatic to Manual Operation
When a Type UP1 or UP2 actuator is supplied with a positioner and is

in the automatic mode, the integral shutoff and equalizing valve on
the positioner is in the AUTO position. When the application calls for
manual operation:
1. Pull the manual lock bolt up tight.
2. Push down on the integral shutoff and equalizing valve on the

positioner and turn it counterclockwise to the MAN position.
3. When not in the automatic mode, pull the manual lock bolt up
tight. If it is necessary to reposition the load while in the manual
mode:
a. Loosen the manual lock bolt.
b. Reposition the load using the extended handle on the link-

age.
c. Tighten the manual lock bolt.
4. Note the position of the rotary vane on the position indicator.

5-2
OVERRIDE LEVER MANUAL OVERRIDE LEVER MANUAL

(A.F. LOCK) LOCK BOLT (A.F. LOCK) LOCK BOLT
POSITIONER INTEGRAL
SHUTOFF AND
EQUALIZING VALVE
HAND AND HAND AND EQUALIZING

ACTUATOR ACTUATOR VALVE
LINKAGE LINKAGE
LEVER LEVER
A A
D D
B B
UP1 WITH POSITIONER UP1 WITH SOLENOID VALVE
POSITION MANUAL POSITION MANUAL

INDICATOR LOCK BOLT INDICATOR LOCK BOLT
B
A
EQUALIZING
HAND AND VALVE HAND AND
ACTUATOR ACTUATOR
LINKAGE LEVER LINKAGE LEVER
UP2 WITH POSITIONER UP2 WITH SOLENOID VALVE

TP20231A .
Figure 5-1. Operating Controls - Types UP1 and UP2 Actuators
5. If the manual lock bolt does not lock the rotary vane unit in posi-
tion, and the actuator must stay in that initial position, adjust the input
signal to correspond with:
a. The actuator position as indicated by the balanced positioner

output pressures,
- or -
b. A plot of the actuator position versus the input signal, devel-

oped from prior knowledge of the unit.

5-3
from Manual to Automatic Operation

in the manual mode, the integral shutoff and equalizing valve on the
positioner is in the MAN position. When the application calls for auto-
matic operation:
1. Before shifting to AUTO, the actuator position must agree, as

close as possible, to the input signal. If not, the hand and actuator
linkage lever jumps when the transfer takes place. Adjust the input
signal to correspond to the actuator position (or vice versa). Estimate
by watching the balanced positioner output pressures. If the setup
needs more precision, use a previously prepared plot of the input sig-
nal versus the actuator position.
2. Turn the integral shutoff and equalizing valve on the positioner to

the AUTO position.
3. Release the manual lock bolt slowly. Let the actuator move
slightly to get a balanced condition.
4. The actuator positions itself automatically.
Solenoid-Equipped Types UP1 and UP2 Actuators without Air Failure Lock Transfer from
Automatic to Manual Operation
When a Type UP1 or UP2 actuator is supplied with a solenoid valve

and is in the automatic mode, the customer air supply shutoff valve is
open and the solenoid equalizing valve is closed. When the applica-
tion calls for manual operation:
1. Tighten the manual lock bolt.
2. Close the customer air supply shutoff valve.
3. Open the solenoid equalizing valve.
4. When the hand and actuator linkage lever is not being operated,
the manual lock bolt is pulled up tight. Temporarily release the manual
lock bolt and position the actuator by manual operation of the hand
and actuator linkage lever.
5. If desired, lock the actuator pointer arm and hand and linkage
lever in position with the manual lock bolt.

5-4
Manual to Automatic Operation

and is in the manual mode, the customer air supply shutoff valve is
closed and the solenoid equalizing valve is open. When the applica-
tion calls for automatic operation:
1. Open the customer air supply shutoff valve.
2. Close the solenoid equalizing valve.
3. Slowly and carefully release the manual lock bolt.
4. Unless the actuator is already at the full end of travel dictated by

the action of the solenoid valve, it will move in that direction.
Remote Reset Air Failure Lock Equipped Types UP1 and UP2 Actuators Transfer from
If the customer air supply fails, the latching spring return cylinder
opens the equalizing valve across the vane power unit. This permits
manual operation of the actuator. If desired, switch to manual opera-
tion even if the customer air supply has not failed.
1. Disengage the lock latch by use of the override lever.
2. Follow the instructions under Positioner-Equipped Types UP1

and UP2 Actuators without Air Failure Lock Transfer from
Automatic to Manual Operation or Solenoid-Equipped Types UP1
Automatic to Manual Operation.
If the actuator is in the manual mode and it is desired to switch to

automatic operation, the customer air supply must be operational.
1. Press the remote release pushbutton (if used) to release the air
failure lock.
2. Engage the lock latch by use of the override lever.

5-5

and UP2 Actuators without Air Failure Lock Transfer from Man-
ual to Automatic Operation or Solenoid-Equipped Types UP1 and
UP2 Actuators without Air Failure Lock Transfer from Manual
to Automatic Operation.

tion. The reserve air tank option has no effect on normal actuator
operation.

in the automatic mode, the positioner integral shutoff and equalizing
valve is in the AUTO position, and the HAND/AUTO transfer handle is
in the AUTO position. When the application calls for manual opera-
tion:
1. Move the HAND/AUTO transfer handle on top of the actuator to

the HAND position.
NOTE: The HAND/AUTO transfer handle may not engage immedi-

ately with the split nut. Turn the hand operator ratchet handle in
either direction until the split nut mechanism snaps in place.
2. Press in the safety latch on the positioner integral shutoff and

equalizing valve. Turn the valve to the HAND position.
3. Move the actuator to the desired position by means of the hand

NOTE: The manual operating mechanism is self-locking and holds

any position to which it is set.

in the manual mode, the positioner integral shutoff and equalizing
valve is in the HAND position, and the HAND/AUTO transfer handle is
in the in the HAND position. When the application calls for automatic
operation:

5-6
Undesirable motion of the drive arm and linkage may occur

WARNING which could cause injury or upset the process if the transfer
instructions are not followed.
Danger d'un mouvement inopportun du bras de commande et

de la tringlerie pouvant causer des blessures ou bouleverser le
AVERTISSEMENT
procede. Suivre attentivement les procedures du transfert de
commande manuelle a automatique.
NOTE: If a HAND/AUTO remote-mounted control station exists, it

should be in the HAND mode before attempting the transfer.

close as possible, to the input signal. If not, the drive arm jumps when
the transfer takes place.
2. Adjust the input signal to correspond to the actuator position (or

vice versa if the system conditions permit). This can be closely
approximated by using a previously prepared plot of the input signal
versus the actuator position.
3. Two methods of transfer exist. Method A is most often used.
METHOD A CHANGING THE INPUT SIGNAL TO MATCH THE

ACTUATOR POSITION
NOTE: Use Method A if it is not possible to move the actuator with-

out endangering the operation of the system.
a. Turn the positioner shutoff and equalizing valve to the AUTO

position.
b. Slowly change the input signal to match the actuator position.
c. Exert moderate force on the HAND/AUTO transfer handle

toward the AUTO position while adjusting the input signal. Do this
until the HAND/AUTO transfer handle moves freely to the AUTO
position.
METHOD B MANUALLY POSITIONING THE ACTUATOR TO

MATCH THE INPUT SIGNAL
NOTE: Use Method B if it is possible to move the actuator position

without endangering the operation of the system.

position.
b. Turn the hand operator ratchet handle to determine the direc-

tion of the least load resistance. Use the selector button at the
hub of the ratchet to change the direction of rotation.

5-7
HAND/AUTO SELECTOR HAND OPERATOR

TRANSFER BUTTON RATCHET HANDLE
HANDLE
POSITION
50 INDICATOR
POSITIONER OR
SOLENOID VALVE
SOLENOID
POSITIONER EQUALIZING
INTEGRAL VALVE OR AIR
SHUTOFF AND FAILURE LOCK
EQUALIZING EQUALIZING
VALVE VALVE
V2 HTR
S2
AF1 AF2
TP20232B .
c. While turning the hand operator ratchet handle in the direc-

tion of least resistance, exert moderate force on the HAND/
AUTO transfer handle toward the AUTO position. Do this until the
HAND/AUTO transfer handle moves freely to the AUTO position.
After completing the transfer via Method A or Method B, the actuator

positions itself automatically.

and is in the automatic mode, the customer air supply valve is open,
the solenoid equalizing valve is closed and the HAND/AUTO transfer
handle is in AUTO. When the application calls for manual operation:
1. Turn the HAND/AUTO transfer handle to HAND.

5-8
3. Close the customer-installed air supply shutoff valve.

ately with the split nut. Turn the hand operator ratchet handle in
either direction until the split nut snaps in.



and is in the manual mode, the customer air supply shutoff valve is
closed, the solenoid equalizing valve is open and the HAND/AUTO
transfer handle is in HAND. When the application calls for automatic
operation:
1. Manually position the actuator to the extreme end of travel corre-

sponding to solenoid demand.
3. Slowly open the customer air supply shutoff valve.
4. Turn the HAND/AUTO transfer handle to AUTO.
After completing the transfer, the actuator is under solenoid control.
If the customer air supply fails, the actuator may be put into manual
operation. It may also be desirable to switch to manual operation
even if the customer air supply has not failed.
1. Open the air failure lock equalizing valve.


5-9

1. Press the remote release pushbutton (if used) to release the air
failure lock.
2. Close the air failure lock equalizing valve.


tion. The reserve air tank option has no effect on actuator operation.
POSITION INDICATOR
HAND OPERATOR
RATCHET HANDLE
50
HAND/AUTO
TRANSFER HANDLE
SELECTOR BUTTON
EQUALIZING VALVE POSITIONER

FOR SOLENOID- INTEGRAL
EQUIPPED AND/OR SHUTOFF AND
AIR FAILURE LOCK- EQUALIZING
EQUIPPED UP5 AND VALVE FOR
UP6 ACTUATORS POSITIONER-
EQUIPPED UP5
AND UP6
ACTUATORS
TP20233B .

5 - 10

in the automatic mode, the positioner integral shutoff and equalizing
valve is in the AUTO position, and the HAND/AUTO transfer handle is
in the AUTO position. When the application calls for manual opera-
tion:
1. Move the HAND/AUTO transfer handle to the HAND position.

ately with the clutch mechanism. Turn the hand operator ratchet
handle in either direction until the clutch mechanism snaps in place.
2. Press in the safety latch on the positioner integral shutoff and

equalizing valve (located on the side of the actuator). Turn the valve
to the HAND position.



in the manual mode, the positioner integral shutoff and equalizing
valve is in the HAND position, and the HAND/AUTO transfer handle is
in the HAND position.
Undesirable motion of the drive arm and linkage may occur

WARNING which could cause injury or upset the process if the transfer
instructions are not followed.
Danger d'un mouvement inopportun du bras de commande et

de la tringlerie pouvant causer des blessures ou bouleverser le
AVERTISSEMENT
procede. Suivre attentivement les procedures du transfert de
commande manuelle a automatique.
NOTE: If a HAND/AUTO remote mounted control station exists, it

should be in the HAND mode before attempting the transfer.
When the application calls for automatic operation:

close as possible, to the input signal. If not, the drive arm jumps when
the transfer takes place.
2. Adjust the input signal to correspond to the actuator position (or

vice versa if the system conditions permit). This can be closely
approximated by using a previously prepared plot of the input signal
versus the actuator position.
3. Two methods of transfer exist. Method A is most often used.

5 - 11
METHOD A CHANGING THE INPUT SIGNAL TO MATCH THE

ACTUATOR POSITION
NOTE: Use Method A if it is not possible to move the actuator with-

out endangering the operation of the system.

position.
b. Slowly change the input signal to match the actuator position.
c. Exert moderate force on the HAND/AUTO transfer handle

toward the AUTO position while adjusting the input signal. Do this
until the HAND/AUTO transfer handle moves freely to the AUTO
position.
METHOD B MANUALLY POSITIONING THE ACTUATOR TO

MATCH THE INPUT SIGNAL
NOTE: Use Method B if it is possible to move the actuator position

without endangering the operation of the system.

position.
b. Turn the hand operator ratchet handle to determine the direc-

tion of the least load resistance. Use the selector button at the
hub of the ratchet to change the direction of rotation.
c. While turning the hand operator ratchet handle in the direc-

tion of least resistance, exert moderate force on the HAND/
AUTO transfer handle toward the AUTO position. Do this until the
HAND/AUTO transfer handle moves freely to the AUTO position.
After completing the transfer via Method A or Method B, the actuator

positions itself automatically.

and is in the automatic mode, the customer air supply valve is open,
the solenoid equalizing valve is closed and the HAND/AUTO transfer
handle is in AUTO. When the application calls for manual operation:
1. Turn the HAND/AUTO transfer handle to HAND.

5 - 12
3. Close the customer-installed air supply shutoff valve.

ately with the clutch mechanism. Turn the hand operator ratchet
handle in either direction until the clutch mechanism snaps into
place.



and is in the manual mode, the customer air supply valve is closed,
the solenoid equalizing valve is open and the HAND/AUTO transfer
handle is in HAND. When the application calls for automatic opera-
tion:
1. Manually position the actuator to the extreme end of travel corre-

sponding to solenoid demand.
3. Slowly open the customer air supply shutoff valve.
4. Turn the HAND/AUTO transfer handle to AUTO.
After completing the transfer, the actuator moves automatically.
If the customer air supply fails, the actuator may be put into manual
operation. It may also be desired to switch to manual operation even
if the customer air supply has not failed.
1. Open the air failure lock equalizing valve.

5 - 13


1. Press the remote release pushbutton to release the air failure

lock.
2. Close the air failure lock equalizing valve.


5 - 14
SECTION 6 - TROUBLESHOOTING
INTRODUCTION
If an obvious fault occurs, check the supply pressure, input and out-
put connections, gage connections, and mechanical linkage adjust-
ments before removing the system from service.
Disconnect the supply signal source or remove the equipment

from the process before servicing. Failure to do so can cause
unexpected movement posing a risk of bodily injury.
WARNING
The covers prevent access to moving components that pose a
Dbranchez le signal ou retirez lquipement du processus

avant de procder lentretien. Toute ngligence cet gard
risque de donner lieu des mouvements inattendus pouvant
provoquer des blessures.
AVERTISSEMENT
ment des membres.
PROBLEM DETERMINATION AND VERIFICATION PROCEDURE
If a fault occurs with the actuator, refer to Table 6-1 and correct any
problems that occur with the actuator, positioner or associated com-
ponents.
Table 6-1. Fault Correction Chart
Fault Probable Cause Corrective Action

Final actuation element at Air lines in wrong ports. Reverse lines connected to positioner O1 and O2
one end of stroke and does ports.
not respond to change. Reversed positioner cam Install proper positioner cam. Refer to the appro-
rotation. priate positioner instruction.
I/P not functioning.1 Monitor the I/P at the I port on the positioner mani-
fold. If output changes from 21 to 103 kPa (3 to 15
psig) with input change of 4 to 20 mA, the I/P is
working. If not, replace I/P as outlined in the appro-
priate positioner instruction.
INTRODUCTION
6-1
TROUBLESHOOTING
Table 6-1. Fault Correction Chart (continued)

Excessive air consumption Leakage at joints of mani- Remove positioner manifold and check O-rings.
(exhaust loud). fold assembly of posi-
tioner.
Positioner pilot valve Remove pilot valve body. Refer to the appropriate
leaking excessively or positioner instruction.
stuck in place.
Check for continuity of Replace solenoid coils or entire solenoid.
solenoid coils.
Oscillation of final actuation Gain too high. Change gain hinge spring to greater thickness.
element. Refer to the appropriate positioner instruction.
Drive arm not securely Tighten or correct linkage as necessary.
attached to final actuation
element.
Slow response. Positioner pilot valve Remove and clean pilot valve. Refer to the appro-
blocked. priate positioner instruction.
Leaky seals in rotary Replace seals.
vane or cylinder.
Supply input drops when Monitor supply input pressure. Correct if
actuator moves. necessary.
Final actuation element at Air lines in wrong ports. Check air line connections.
either travel stop and will Incorrect cam installed Determine application (direct or reverse acting)
not respond to input for application. and check cam.
change.
Signal diaphragm Replace diaphragm. Refer to the appropriate posi-
leaking. tioner instruction.
No output from I/P Verify air supply to the I/P as 138 10 kPa (20 1.5
assembly. psig). If input is correct replace the I/P assembly as
outlined in the appropriate positioner instruction. If
not, check the regulator and replace if necessary.
Uprange zero shift that can- Signal diaphragm Check and replace if necessary. Refer to appropri-
not be adjusted. leakage. ate positioner instruction.
No output from I/P Verify air supply to the I/P as 138 10 kPa (20 1.5
assembly. psig). If input is correct, replace the I/P assembly
as outlined in the appropriate positioner instruc-
tion. If not, check the regulator and replace if nec-
essary.
Full range cannot be Signal diaphragm Check and replace if necessary. Refer to the
obtained with adjustment. leaking. appropriate positioner instruction.
Actuator will not operate Trapped moisture frozen If supplied with heaters, check for continuity
below freezing. in air lines. across heater or thermoswitch leads. If defective,
refer to Section 8. If not supplied with heaters,
check instrument air drying equipment.
Pneumatic shaft position Pneumatic transmitter Repair or replace transmitter. Refer to Section 8.
transmitter will not operate. defective.
Electric shaft position trans- Transmitter board Replace transmitter board assembly. Refer to
mitter will not operate assembly defective. Section 8.
Feedback potentiometer Check potentiometer resistance. If open, replace
defective. feedback potentiometer. Refer to Section 8. If not
defective, check transmitter board.

6-2
TROUBLESHOOTING
Table 6-1. Fault Correction Chart (continued)

Alarm/travel switch unit will Loose microswitch cam. Tighten cam.
not operate. Microswitches defective. Replace microswitches. Refer to Section 8.
Air failure lock will not oper- Trip valve or lock valve Refer to Section 4 and properly adjust the trip or
ate. improperly set. lock valve.
Trip valve or lock valve Replace trip valve or lock valves. Refer to
defective. Section 8.
Latching spring return Replace latching spring return cylinder. Refer to
cylinder defective (Types Section 8.
UP1 and UP2 actuators
only).
Reserve air tank will not Trip valve defective. Replace the trip valve. Refer to Section 8.
operate the actuator.
Check valve to air tank Replace the check valve. Refer to Section 8.
defective.
Air lines from reserve air Clean or replace air lines from the air tank to the
tank to actuator are actuator.
plugged or leaking.
NOTE:
1. Types AV2 and AV3 positioners only.

6-3
SECTION 7 - MAINTENANCE
INTRODUCTION
This section contains maintenance procedures to be performed on a

scheduled and as needed basis.
Stay clear of moving components when performing procedures

that require the equipment to be energized. The equipment can
WARNING
operate automatically. There is a risk of entanglement of body
parts when performing these procedures.
Restez lcart des composantes en mouvement lorsque vous

effectuez des procdures ncessitant que lquipement soit
AVERTISSEMENT sous tension. Lquipement peut se dplacer de faon automa-
tique. Ces procdures prsentent un risque demmlement des
membres.
PERIODIC MAINTENANCE

WARNING from the process before servicing. Failure to do so can cause

AVERTISSEMENT
If the connections require tightening, do not exceed the maxi-

mum torque of 6.8 Nm (60 in.-lbs) for -18 NPT connections, or
1
3.4 Nm (30 in.-lbs) for 8 -27 NPT connections. Do not use teflon
CAUTION tape to seal threaded fittings. Use only liquid or paste pipe
sealant. Use of Loctite sealants, which are polyacrylate or
acrylic diesters based, is not recommended. Water based Loc-
tite sealant, such as Vibra Seal No. 503, is acceptable.
Si les connecteurs exigent us serrage, ne pas depasser le cou-

ple maximal de 6.8 Nm (60 pouces-livres) pour filetage -18
1
NPT ou 3.4 Nm (30 pouces-livres) pour filetage 8 -27 NPT.
Nepas employer du ruban de teflon pour sceller les raccords
ATTENTION
filetes. Employer sculement un scelle-joint liquide ou en pate
pour tuyanterie. L'emploi de scelle-joint Loctite a base de poly-
acrylique ou d'acrylique n'est pas recommande. Le scelle-joint
Loctite base d'eau, tel que Vibra-Seal No. 503 est acceptable.
INTRODUCTION
7-1
MAINTENANCE
1. Check all air connections for leakage. While under pressure, pour
soapsuds solution on the connections. If the solution bubbles, tighten
the connections.
2. Check the linkage for mechanical wear or binding. Lubricate as

often as required as determined by equipment use (refer to Connect-
ing Linkage for Universal Rotary Actuators).
3. Periodically check for loose bolts. If needed, torque the bolts to

the required specifications. Refer to the drawings in Appendix B for
torque specifications.
4. Maintain a clean air supply (free of dirt, oil and moisture) to insure
sound operation of the positioner.
5. If the supply line has the suggested filter, remove and clean it if
needed. Refer to Air Quality in Section 3.
6. Whenever the positioner is out of service (or when needed), per-

form the maintenance procedures outlined in the maintenance sec-
tion of the appropriate positioner instruction.
ANNUAL OR SEMIANNUAL MAINTENANCE
1. Check the adjustment and calibration of the positioner and the

final actuator element. The procedure is outlined in the calibration
section of the appropriate positioner instruction.
2. Verify that the reserve air tank option can drive the cylinder or
rotary vane to the end of its stroke. Drain moisture from air tank if
required, through a drain provided in the bottom of the tank.
3. Check the adjustment of the air failure brake as described in Air

Failure Lock Calibration in Section 4.
4. Every six months, apply a streak of dry, graphite-based lubricant

to the Types UP5 and UP6 actuator shaft bearings, roller chain and
air cylinder. Remove the rear panel and side covers to see the grease
fittings and chain.
5. On Types UP5 and UP6 actuators, check the roller chain for
undue slack. Do not let slack exceed -inch on either side (one inch
total). Refer to ROLLER CHAIN ADJUSTMENT (TYPES UP5 AND
UP6 ACTUATORS) in Section 8.
6. Once a year (or when needed), apply dry, graphite-based lubri-

cant to the drag pins of the Types UP5 and UP6 actuator clutch
assembly.
ANNUAL OR SEMIANNUAL MAINTENANCE

7-2
MAINTENANCE
7. Check the clutch for undue wear. Refer to CLUTCH FORK

INSPECTION AND REPLACEMENT (TYPES UP5 AND UP6 ACTU-
ATORS) in Section 8 for the procedure.
NOTE: Inspect the clutch yearly for an actuator exposed to normal

use, and more often if exposed to harsh conditions.
8. Check that the positioner integral shutoff and equalizing valve

moves easily. If not, refer to the appropriate positioner instruction for
cleaning procedures.
9. Lubricate the grease fittings on the cylinders for Types UP4

through UP6 actuators until the grease comes out the relief. See Fig-
ures 8-3 through 8-5 for the location of these fittings. For Type UP3
actuators, lubricate the inside diameter of the bushing as shown in
Figure 8-2.
MAINTENANCE AS REQUIRED
Use solvents only in well-ventilated areas. Avoid prolonged or

repeated breathing of vapors. Avoid prolonged or repeated
contact with the skin. Solvents can cause nausea, dizziness
WARNING
and skin irritation. In some cases, overexposure to solvents
has caused nerve and brain damage. Solvents are flammable
do not use near extreme heat or open flame.
N'utilisez des solvants que dans des zones bien ares. Evitez
de respirer les vapeurs de facon prolonge ou rpte. Evitez
les contacts prolongs ou rpts avec la peau. Les solvants
peuvent provoquer des nauses, des tourdissements et l'irri-
AVERTISSEMENT
tation cutane. Cans certains cas, une surexposition aux sol-
vants provoque des dommages au systme nerveux ou au
cerveau. Les solvants sont inflammables il ne faut pas les uti-
liser prs d'une source de chaleur ou d'une flamme ouverte.
1. Completely disassemble and clean the positioner. Refer to the

appropriate positioner instruction for cleaning procedures.
2. Completely disassemble and clean the actuator as described in

Section 8.
3. Unless detecting excessive leakage, do not service the air cylin-

der or rotary vane. If needed, refer to ROTARY VANE SEAL REPAIR
AND HOUSING CLEANING or CYLINDER ASSEMBLY REPAIR
AND CLEANING in Section 8.
MAINTENANCE AS REQUIRED
7-3
SECTION 8 - REPAIR AND REPLACEMENT PROCEDURES
INTRODUCTION
Occasionally, the actuator may need to have components replaced.

Use these procedures if a fault is found as determined by the meth-
ods described in the troubleshooting section.

WARNING from the process before servicing. Failure to do so can cause

AVERTISSEMENT
If the connections require tightening, do not exceed the maxi-

mum torque of 6.8 Nm (60.0 in.-lbs) for -18 NPT connections,
1
or 3.4 Nm (30.0 in.-lbs) for 8 -27 NPT connections. Do not use
CAUTION teflon tape to seal threaded fittings. Use only liquid or paste
pipe sealant. Use of Loctite sealants, which are polyacrylate or
acrylic diesters based, is not recommended. Water based Loc-
tite sealant, such as Vibra-Seal No. 503, is acceptable.
Si les connecteurs exigent us serrage, ne pas depasser le cou-

ple maximal de 6.8 Nm (60.0 pouces-livres) pour filetage -18
1
NPT ou 3.4 Nm (30.0 pouces-livres) pour filetage 8 -27 NPT.
Nepas employer du ruban de teflon pour sceller les raccords
ATTENTION
filetes. Employer sculement un scelle-joint liquide ou en pate
pour tuyanterie. L'emploi de scelle-joint Loctite a base de poly-
acrylique ou d'acrylique n'est pas recommande. Le scelle-joint
Loctite base d'eau, tel que Vibra-Seal No. 503 est acceptable.
INTRODUCTION
8-1
REPAIR AND REPLACEMENT PROCEDURES
ENCLOSURE REMOVAL


AVERTISSEMENT
ment des membres.
Refer to the proper enclosure removal procedure in Section 3 to

access the components referred to in this section.
POSITIONER REMOVAL AND REPLACEMENT
NOTE: Refer to the applicable parts drawings in Appendix A.
1. Place the actuator in the manual mode to prevent the load from
shifting.
2. Place the positioner integral shutoff and equalizing valve in the

manual position to shut off the air supply to the positioner.
3. Allow the air pressure to subside completely.
4. Remove the covers (if necessary) to access the positioner.
5. For Type AV1 positioners, disconnect and label the O1, O2, sig-
nal and supply lines from the positioner.
6. For Types AV2, AV3 and AV4 positioners, disconnect and label
the O1, O2 and supply line from the positioner, remove the cover and
disconnect and label the two wires from the input terminal block.
7. For Types UP1 and UP2 actuators, perform Step 7a. For Types
UP3 through UP6 actuators, perform Steps 7b and 7c.
a. Remove the three -inch fasteners that hold the positioner to

the actuator.
b. Remove the linkage from the positioner.
c. Remove the mounting screws securing the positioner to its

mounting bracket.
8. Remove the positioner.
9. To repair the positioner, refer to the appropriate positioner instruc-

tion.
ENCLOSURE REMOVAL
8-2
10. Reverse the procedure to install the positioner. Use the torque
values specified in the drawings in Appendix A to tighten all fasteners
when assembling.
SOLENOID VALVE REMOVAL AND REPLACEMENT
NOTE: Refer to the applicable parts drawings in Appendix A.
shifting.
2. Use the solenoid equalizing valve to shut off the air supply.
4. Remove the covers (if necessary) to access the solenoid valve.
5. For Types UP1 and UP2 actuators, perform Step 5a. For Types
UP3 through UP6 actuators, perform Step 5b.
a. Disconnect and label the solenoid valve leads from the sole-
noid valve.
b. Disconnect and label the solenoid valve leads from the termi-
nal strip inside the actuator (refer to Figures 3-3 and 3-4).
6. Disconnect and label the supply air line from port P and the outlet
air lines from ports A and B.
7. Remove the screws holding the solenoid valve to the mounting

bracket.
8. Remove the solenoid valve.
9. Reverse the procedure to install the new solenoid valve.
shifting.
2. Use the positioner integral shutoff and equalizing valve or the

solenoid equalizing valve to shut off the air supply.
4. Remove the covers (if necessary) to access the rotary vane.
5. Disconnect and label the two air lines from the rotary vane at the
connecting elbows.
SOLENOID VALVE REMOVAL AND REPLACEMENT

8-3
BRAKE ARM
BRAKE ARM MOUNTING BOLTS
ACTUATOR
MOUNTING PLATE
LEVER
MOUNTING
SCREW
ACTUATOR
MOUNTING
SCREWS
MOUNTING
BOLTS POSITIONER
MOUNTING
PLATE
SET SCREWS
HAND AND
ACTUATOR
LINKAGE
LEVER FRAME
ACTUATOR
COVER
PLATE
PADDLE SEAL
ACTUATOR RINGS (2)
HALF
PADDLE
LARGE O-RING
STOP
ADJUSTMENT
ACTUATOR HOUSING TP20091B .
Figure 8-1. Rotary Vane Removal and Seal Replacement
6. Feed the lines through the actuator frame.
7. Refer to POSITIONER REMOVAL AND REPLACEMENT or

SOLENOID VALVE REMOVAL AND REPLACEMENT and remove
the positioner or solenoid valve.
8. Loosen the cap screw holding the hand and actuator linkage
lever to the actuator shaft.
9. Remove the hand and actuator linkage lever.
10. Remove the cap screws holding the brake arm to the bottom of
the actuator shaft.
11. Remove the bolt securing the top of the brake arm to the mount-
ing plate.
8-4
12. Remove the brake arm.
13. Loosen the three large bolts holding the mounting plate to the
actuator frame.
14. Loosen the two smaller bolts securing the mounting plate to the
actuator frame.
15. Loosen the cap screw holding the mounting plate to the actuator
frame.
16. Remove the mounting plate.
17. Remove the five bolts holding the actuator shaft cover plate in
place.
18. Remove the actuator shaft cover plate.
19. Remove the three large bolts holding the actuator to the actuator
frame.
20. Lift the actuator out of the actuator frame.
21. Reverse this procedure to install the rotary vane.
ROTARY VANE SEAL REPAIR AND HOUSING CLEANING
Use solvents only in well ventilated areas. Avoid prolonged or

repeated breathing of vapors or contact with skin. Solvents can
cause nausea, dizziness and skin irritation. In some cases,
WARNING
overexposure to solvents has caused nerve and brain damage.
Solvents are flammable - do not use near extreme heat or open
flame.
Nutilisez des solvants que dans des zones bien ares. Evitez
peuvent provoquer des nauses, des tourdissements et lirri-
AVERTISSEMENT
cerveau. Les solvants sont inflammables - il ne faut pas les uti-
liser prs dune source de chaleur ou dune flamme ouverte.
1. Refer to ROTARY VANE REMOVAL AND REPLACEMENT

(TYPES UP1 AND UP2 ACTUATORS) and remove the rotary vane
from the actuator frame.

8-5
2. Remove the screws holding the housing together.
3. Separate the covers and remove the paddle.
4. Clean the inside surface of the rotary vane housing with a suit-
able grease solvent.
5. Remove the sealant on the joining surfaces of the housing with

lacquer thinner.
6. Lubricate the internal surfaces with lubricant, Part No. 199354_1

(No. 55M Dow Corning Grease).
7. Replace the large O-ring on the paddle assembly.
8. Replace the seal rings on each side of the paddle shaft.
9. Lubricate the O-ring and seal rings with lubricant, Part No.
199354_1.
10. Place the paddle in the housing.
11. Coat the housing joining surfaces with sealant Part No. 199926_1
(GE Silmate RTV 1473 Sealant).
12. Replace the housing.
13. With the paddle turned to the right side, snug down the bolts on
the left side.
14. Rotate the paddle to the left side of the rotary vane and snug
down the screws on the right side.
15. Tighten all screws and bolts securely.
16. Rotate the shaft several times through a full 90 degree rotation to
remove any excess sealant inside the housing.
NOTE: Do not place the rotary vane in service for at least four hours
to allow the sealant to set up completely.
17. Refer to ROTARY VANE REMOVAL AND REPLACEMENT

(TYPES UP1 AND UP2 ACTUATORS) to install the rotary vane in the
actuator housing.

8-6
CYLINDER ASSEMBLY REPLACEMENT (TYPES UP3/4/5/6 ACTUATORS)
NOTE: Refer to the drawings in Appendix A.
shifting.

4. Remove the covers necessary to access the cylinder assembly.
5. Disconnect and label the air lines from the top and bottom of the
cylinder.
6. Remove the pin assembled through the piston rod end and the
crank arm assembly.
7. Remove the pin attaching the cylinder to the actuator stand.
8. Lift the assembly out of the stand.
9. Reverse this procedure to install the cylinder assembly.
CYLINDER ASSEMBLY REPAIR AND CLEANING
NOTE: Refer to Tables 8-1 through 8-4 and Figures 8-3 through 8-5.
1. Refer to CYLINDER ASSEMBLY REPLACEMENT (TYPES

UP3/4/5/6 ACTUATORS) and remove the cylinder from the actuator
frame.
2. Remove the hex full nuts (on Type UP3 actuators), or retaining
rings (on Types UP4 through UP6 actuators).
3. Remove the bottom end flange.
4. To remove the piston assembly, rod and top flange, pull the piston
out of the cylinder.
5. Remove the retaining ring from the top flange assembly.
6. Extract the bushing.
7. Remove the O-rings from the end flanges.
8. Remove the rod seals from the bushing.
9. Remove the rod wiper from the bushing.
10. Inspect the O-rings for signs of wear and replace them if neces-
sary.
CYLINDER ASSEMBLY REPLACEMENT (TYPES UP3/4/5/6 ACTUATORS)

8-7
Table 8-1. Parts List for Type UP3 Actuator Cylinder

Assembly (Part Number 5328775 1)1
Item Qty Part No. Description Item Qty Part No. Description
1 1 5327215_1 Bottom flange 12 1 1951416_218 O-ring
2 2 1951416_256 O-ring 13 1 5327205_1 Bushing
3 1 5328773_1 Piston 14 1 197164_150 Retaining ring
4 2 5328772_1 Back-up plate 15 1 1951401_1 Wiper ring
5 2 5328776_1 Spacer 16 1 5328778_1 Piston rod
6 1 195825_15 O-ring 17 1 199355_1 Lube label not
shown
7 1 5328777_1 Spacer 18 1 197120_22 Elastic stop nut
8 8 19781_6 Stud 19 16 0.375-16 Hex full nut
1
9 1 53406ac1 Cylinder body 21 2 8 -27 Plastic pipe plug
1
10 1 1951399_214 O-ring 22 4 8 -27 Steel Hex head
pipe plug
11 1 5327214_1 Upper flange 23 A/R 199354_1 Lube not shown
NOTE:
1. Order cylinder spare parts kit by Part No. 2582401. Refer to Appendix A for parts list.
8 7 4 2
19
21
13
16 11
14
15
LUBRICATE I.D. 12
OF BUSHING 1
10
(ITEM 13) WITH
22 18
ITEM 23
3 6 5
2 9
TP20451A .
Figure 8-2. Cylinder Assembly for Type UP3

Actuators (Part Number 5328775 1)

8-8

1 2 5311428_41 O-ring 10 1 5316536_1 Stop spacer
2 2 197736_1 Retaining ring 11 1 5328695_1 Top flange
assembly
3 2 5328697_1 Ring lock 12 1 5328692_1 Piston rod
4 1 5328671_1 Bottom flange 13 1 5319921_1 Cylinder body
5 1 197132_7 Locknut 14 2 195148_1 Pipe plug
6 2 5328744_1 Back-up plate 15 4 NIDAC16005 Pan head sems
7 1 5328743_1 Spacer 16 1 NLHAC38000 Hex Jam Nut
8 1 195825_9 O-ring 17 2 pipe thread
protector
9 1 5328768_1 Piston 18 A/R 199354_1 Lube not shown
NOTE:
15
1
10 6
2
17 3
16
12 11
4
4
14
5
2 1 13 9 8 7
GREASE FITTING TP20452A .


8-9

1 2 5311428_41 O-ring 10 1 5316536_1 Stop spacer
2 2 197736_1 Retaining ring 11 1 5328695_1 Top flange
assembly
3 2 5328697_1 Ring lock 12 1 5328943_2 Piston rod
4 1 5328951_1 Bottom flange 13 1 5319921_2 Cylinder body
5 1 197132_7 Locknut 14 3 195148_2 Pipe plug
6 2 5328744_1 Back-up plate 15 4 NIDAC16005 Pan head sems
7 1 5328743_1 Spacer 16 1 NLHAC38000 Hex jam nut
8 1 195825_9 O-ring 17 A/R 199354_1 Lube not shown
9 1 5328768_1 Piston
NOTE:
1
10 6
14 A 15 2
16
12 11
4
A
5
14 2 1 13 9 8 7
GREASE FITTING
SECTION A-A TP20453A .


8 - 10
Table 8-4. Parts List for Type UP6 Actuator

Cylinder Assembly (Part Number 5328945 1)1
1 2 5328697_1 Ring lock 9 1 5328743_1 Spacer
2 1 197132_7 Locknut 10 1 195825_9 O-ring
3 1 5328944_1 Bottom flange 11 1 5328946_1 Top flange
assembly
4 2 197737_1 Retaining ring 12 1 5328943_1 Piston rod
5 2 5311428_39 O-ring 13 2 1951421_2 Pipe plug
6 2 5328942_1 Back-up plate 14 4 0.190-32 Pan head sems
ext
7 1 5317659_1 Cylinder body 15 1 1.000-14 Hex pull nut
8 1 5328941_1 Piston 16 A/R 199354_1 Lube not shown
NOTE:
5
6
14
15
12 11
3
13
GREASE FITTING 2
4 5 7 8 10 9 4
TP20454A .
Figure 8-5. Cylinder Assembly for UP6


8 - 11
11. Inspect the piston seal for signs of wear and replace if necessary.
12. Clean the cylinder and the empty O-ring grooves with a suitable
grease solvent.
Use solvents only in well ventilated areas. Avoid prolonged or

repeated breathing of vapors or contact with skin. Solvents can
cause nausea, dizziness and skin irritation. In some cases,
WARNING
overexposure to solvents has caused nerve and brain damage.
Solvents are flammable - do not use near extreme heat or open
flame.
Nutilisez des solvants que dans des zones bien ares. Evitez
peuvent provoquer des nauses, des tourdissements et lirri-
AVERTISSEMENT
cerveau. Les solvants sont inflammables - il ne faut pas les uti-
liser prs dune source de chaleur ou dune flamme ouverte.
13. Lubricate the piston seal and O-rings with lubricant. Part No.
199354_1 (No. 55M Dow Corning Grease).
14. Place the piston seal and O-rings into the piston rod, end flanges
and bushing.
15. Inspect the insides of the cylinder, piston rod and upper flange for
signs of scoring or wear.
16. Replace the scored or worn parts, as they might damage the
seals.
17. Lubricate the inside of the cylinder, upper flange and bushing with
lubricant, Part No. 1993541.
18. Paying added attention not to damage the O-rings, reassemble

the cylinder assembly.
19. This step applies only to Type UP3 actuators. Tighten the hex full
nuts to 8.1 Nm (72 in.-lbs).
20. This step applies only to Types UP4 through UP6 actuators.
Install the retaining rings and the bottom end flange.
21. Check the assembly for leaks using soapsuds solution by apply-
ing 345 to 690 kPa (50 to 100 psi).
22. Refer to CYLINDER ASSEMBLY REPLACEMENT (TYPES

UP3/4/5/6 ACTUATORS) to install the cylinder assembly.

8 - 12
CLUTCH FORK INSPECTION AND REPLACEMENT (TYPES UP5 AND UP6 ACTUATORS)
CONNECTING
LINK CLUTCH FORK
ASSEMBLY ASSEMBLY CLUTCH FORK
ASSEMBLY CLUTCH
PUSH-ON (SEE NOTE)
RINGS STOP
CLEVIS
PIN
DRAG .0 31 X
PIN DRAG PIN SHIMS
SHOWN HERE
RETAINING
ROTATED 90
RING
RETAINING RING
FORK PIVOT SHAFT
GEAR
NOTE: SHOWN IN HAND POSITION WITH 0.00 IN. CLEARANCE.
CARRIER
WHEN IN AUTOMATIC, CLEARANCE BETWEEN CLUTCH AND
D5328953 .
STOP SHOULD BE 0.040 TO 0.100 IN. TP20099B .
Figure 8-6. Clutch and Clutch Fork Assembly
The clutch assembly disengages the gear from the output shaft dur-
ing manual operation. The clutch has two drag pins, subject to wear.
Excessive wear causes the clutch to approach the stop, resulting in
engagement of the manual operator gears. This engagement pre-
vents normal automatic operation of the control drive, i.e., it locks in
place.
Lubricating extends the life of the drag pins. Lubricate the pins, and
the plate they bear upon, with dry graphite-based lubricant. Inspect
the clutch assembly once a year for a drive subject to normal opera-
tion or more often to one exposed to harsh conditions.
shifting.

3. Allow the air supply to subside completely.
4. Remove the covers to allow access to the clutch fork assembly.
5. Place the clutch assembly in the lock position.
6. Measure the distance between the clutch and stop with feeler
gages, or equivalent.
CLUTCH FORK INSPECTION AND REPLACEMENT (TYPES UP5 AND UP6 ACTUATORS)
8 - 13
7. If the gage shows less than 1.0 mm (0.04 in.), remove the clutch
fork assembly and measure the drag pins directly. Refer to Figure 8-6
for proper inspection of the clutch clearance and the drag pins.
8. Remove the push on rings at each end of the clevis pin at the top
of the clutch fork assembly.
9. Remove the clevis pin.
10. Remove the retaining rings at each end of the fork pivot shaft at
the bottom of the clutch fork assembly.
11. Remove the fork pivot shaft.
12. Remove the clutch fork assembly.
13. Normally, a drag pin measures 7.9 mm (0.31 in.) in diameter. If

the diameter measures less than 6.4 mm (0.25 in.), replace the clutch
fork assembly. The diameter is represented as x in Figure 8-6 and
must be between 6.4 and 7.9 mm (0.25 and 0.31 in.) to pass the
inspection.
14. If the drag pins pass the inspection, lubricate them with Plastilube
NLG-1, Grade 1.
15. Reverse Steps 12 through 8 to install the new clutch fork assem-
bly.
ROLLER CHAIN ADJUSTMENT (TYPES UP5 AND UP6 ACTUATORS)
Turn off the air supply and allow the pressure to bleed off com-
pletely before adjusting the chain. Do not attempt to connect or
WARNING disconnect the chain. Due to the risk of entanglement of body
parts, ABB recommends that replacement of the chain be done
only by ABB personnel.
Interrompez le dbit dair et assurez-vous quil ny a plus

aucune pression avant dajuster la chane. Ne tentez pas de
fixer ou de retirer la chane. Compte tenu des risques
AVERTISSEMENT
demmlement des membres, nous recommandons que seul
un employ de ABB procde au remplacement de la chane
conformment aux directives du fabricant.
The Types UP5 and UP6 actuators come with the roller chain
adjusted for proper operation in the manual mode. Should the slack in
the chain ever exceed -inch movement on either side (one inch
total), the chain needs adjusting.
1. Secure the driven load to prevent sudden movement of the actua-

tor.
ROLLER CHAIN ADJUSTMENT (TYPES UP5 AND UP6 ACTUATORS)

8 - 14
CHAIN ANCHOR SOCKET HEX HEAD

SET SCREW CAP SCREW FOR
CHAIN ADJUSTMENT
TP20090A .
Figure 8-7. Roller Chain Adjustment for

Types UP5 and UP6 Actuators
shifting.

5. Remove the covers to allow access to the roller chain assembly.
6. Loosen the setscrew in the chain anchor.
7. Turn the socket hex head cap screw clockwise to remove undue
chain slack (tighten chain).
NOTE: The suggested chain slack is between -inch and -inch

per side (-inch to one inch total).
8. After removing undue slack, tighten the setscrew in the chain

anchorReplace the actuator cover.
9. Restore the air supply to the actuator.
OPTIONAL EQUIPMENT REPAIR/REPLACEMENT PROCEDURES
NOTE: Refer to the drawings in Appendix A for part numbers and

locations of optional equipment.

8 - 15
Reserve Air Tank Component Removal and Replacement (Types UP2 through UP6
Actuators)
The Types UP2 through UP6 actuators have trip valves and pressure
switch. Use these procedures if it is necessary to remove any of the
reserve air tank kit components.
TRIP VALVE REMOVAL AND REPLACEMENT
shifting.

4. Remove the covers necessary to allow access to the trip valve

(Types UP3 through UP6 actuators only).
5. Label and disconnect the air lines attached to the trip valve.
6. Remove the bolts holding the trip valve to the mounting bracket.
7. Remove the trip valve.
8. Reverse this procedure to install the new trip valve.
PRESSURE SWITCH REMOVAL AND REPLACEMENT
shifting.

4. Remove the covers necessary to allow access to the pressure

switch.
5. Label and disconnect the air lines attached to the pressure

switch.
6. Remove the pressure switch assembly from the mounting plate.
7. Remove the cover plate from the pressure switch housing.

8 - 16
8. Disconnect the red (normally open), black (common), and blue

(normally closed) wires from the microswitch in the pressure switch
housing.
9. Reverse this procedure to install the new pressure switch.
Air Failure Lock Component Removal and Replacement (Types UP1 and UP2 Actuators)
Use these procedures if it is necessary to remove or replace any of

the air failure lock components on Types UP1 and UP2 actuators.
TRIP VALVE REPLACEMENT
shifting.

4. Remove the covers (if necessary) to access the trip valve.
5. Remove and label the air lines from the trip valve.
6. Remove the two screws securing the trip valve to the mounting
bracket.
8. Reverse the procedure to install the new trip valve.
LATCHING SPRING RETURN CYLINDER REPLACEMENT
shifting.

4. Remove the covers (if necessary) to access the latching spring

return cylinder.
5. Remove the air line from the latching spring return cylinder.
6. Loosen the 0.500-20 hex jam nut holding the piston to the
adapter (Type UP1 actuator) or clevis arm (Type UP2 actuator).

8 - 17
7. For Type UP1 actuators, perform Step 7a. For Type UP2 actua-
tors, perform Step 7b.
a. Remove the clevis pin and retaining ring holding the base of
the latching spring return cylinder to the mounting yoke.
b. Remove the retaining ring holding the base of the latching

spring return cylinder to the support stud.
8. Remove the latching spring return cylinder.
9. Reverse the procedure to install the new latching spring return

cylinder.
AUTOMATIC MECHANICALLY ACTUATED EQUALIZING VALVE

REPLACEMENT
shifting.

4. Remove the covers (if necessary) to access the automatic

mechanically actuated equalizing valve.
5. Remove and label the air lines from ports 1 and 4 of the auto-
matic mechanically actuated equalizing valve.
6. Remove the nut and washer holding the automatic mechanically

actuated equalizing valve to the mounting bracket.
7. Remove the automatic mechanically actuated equalizing valve.
8. To install the new automatic mechanically actuated equalizing

valve, reverse the procedure.
NOTE: Be sure the plug is installed in port 2 of the new automatic

mechanically actuated equalizing valve.
Air Failure Lock Component Removal and Replacement (Types UP3 through UP6
Actuators)
The Types UP3 and UP4 actuators have a trip valve and a lock valve.
Types UP5 and UP6 actuators have a trip valve and two lock valves.
Use these procedures if it is necessary to remove any of the air failure
lock components on Types UP3 through UP6 actuators.

8 - 18
LOCK VALVES REMOVAL AND REPLACEMENT
shifting.

4. Remove the covers necessary to allow access to the lock valves.
5. Label and disconnect the air lines attached to the lock valves.
6. Remove the bolts that hold the lock valves to the mounting
bracket.
7. Remove the lock valves.
8. Reverse this procedure to install the new lock valves.
TRIP VALVE REMOVAL AND REPLACEMENT
shifting.

4. Remove the covers necessary to allow access to the trip valve.
5. Label and remove the air lines attached to the trip valve.
6. Remove the bolts holding the trip valve to the mounting bracket.
8. Reverse this procedure to install the new trip valve.
PRESSURE SWITCH REMOVAL AND REPLACEMENT
shifting.

4. Remove the covers necessary to allow access to the pressure

switch.

8 - 19
5. Label and remove the air lines attached to the pressure switch.
6. Remove the pressure switch assembly from the lock and trip
valve mounting plate.
7. Remove the cover plate from the pressure switch housing.
8. Remove the red (normally open), black (common), and blue (nor-
mally closed) wires from the microswitch in the pressure switch hous-
ing.
9. Reverse this procedure to install the new pressure switch.
Electric Shaft Position Transmitter Assembly Removal and Replacement
NOTE: Refer to Figures 3-19, 3-22 and the drawings in Appendix A.
shifting.

4. Remove the covers necessary to allow access to the electric

shaft position transmitter.
5. This step applies only to Types UP3 and UP4 actuators. If the
actuator has the air failure lock option, remove it by:
a. Removing the mounting screws holding the air failure lock

assembly to the actuator mounting frame.
b. Removing the entire assembly, attached to its mounting

bracket.
6. This step applies only to Types UP3 through UP6 actuators:
a. Remove the cotter pins that hold the cylinder to the lever.
b. Remove the dowel pin that holds the cylinder to the lever.
c. Place the dowel pin between the cylinder and the actuator
frame to avoid damage to the supply line and its fitting.
7. Remove the cover from the top of the electric shaft position trans-
mitter assembly.
8. Remove and label the two wires connected to TB5 (+) and
TB5 (-).
9. Remove and label the wires from P1, P2 and P3.

8 - 20
10. Remove the three screws holding the electric shaft position trans-
mitter assembly to its mounting bracket.
11. If defective, replace the electric shaft position transmitter assem-

bly.
12. Adjust as described in OPTIONAL EQUIPMENT CALIBRATION

in Section 4.
13. Reverse this procedure to put the unit back together.
Feedback Potentiometer Removal and Replacement
1. Perform Steps 1 through 5 in Electric Shaft Position Transmit-

ter Assembly Removal and Replacement.
2. Remove the pan head mounting screws (0.1875-32 x 0.250)

holding the electric shaft position transmitter board assembly mount-
ing bracket to the alarm unit mounting bracket.
3. Rotate the transmitter mounting bracket clockwise to expose the

setscrews holding the feedback potentiometer to the coupler.
4. Slide the electric transmitter board assembly, with feedback

potentiometer attached, out of the coupler.
5. Pull the assembly out of the actuator frame.
6. Remove the locknut holding the feedback potentiometer to the

electric transmitter board assembly mounting bracket.
7. Disconnect and label the wire leads from P1, P2 and P3 on the
electric transmitter board.
8. Install the new feedback potentiometer.
9. Reverse this procedure to assemble the unit make sure to cen-

ter the feedback potentiometer, with the actuator at the 50% position,
before tightening the coupling setscrews.
Alarm/Travel Switch Removal and Replacement
shifting.


8 - 21
4. Remove the covers necessary to allow access to the alarm/travel

switches.
5. Remove the electric shaft position transmitter assembly and feed-

back potentiometer assembly, with its mounting bracket, from the
alarm mounting bracket. Refer to Electric Shaft Position Transmit-
ter Assembly Removal and Replacement and Feedback Potenti-
ometer Removal and Replacement.
6. Locate the mounting bracket that is part of the actuator frame.
7. Remove the three mounting screws securing the alarm unit

mounting bracket to the actuator frame mounting bracket.
8. Disconnect the linkage from the alarm unit mounting bracket.
9. Take the alarm unit assembly out of the actuator frame.
10. Remove the pan head screws (0.112-40 x 2.0) holding the
microswitches to the alarm unit mounting bracket.
11. Remove the cover from terminal block TB3.
12. Disconnect the microswitch wiring from the terminal block.
13. Replace the microswitches.
14. Wire the microswitches according to the corresponding markings

on the switches and the terminal block (NO=Normally Open, NC=Nor-
mally Closed, and C=Common).
15. With the spacer blocks arranged so that the switch rollers align
with the cam, mount the microswitch assemblies to the alarm unit
mounting bracket.
16. Adjust the microswitches as outlined in Alarm/Travel Switch

Calibration in Section 4.
17. Reverse this procedure to assemble the rest of the unit.
Pneumatic Shaft Position Transmitter Replacement (Types UP2 through UP6 Actuators)
NOTES:
1. The Pneumatic Shaft Position Transmitter is not available for
Type UP1 actuators.
2. Refer to the drawings in Appendix A.
1. To prevent the load from shifting, place the actuator in the manual
mode.
2. Shut off the air supply to the pneumatic shaft position transmitter.

8 - 22
4. Remove the covers (if necessary) to allow access to the pneu-

matic shaft position transmitter.
5. Disconnect the S supply line from the pneumatic shaft position

transmitter.
6. Disconnect the O1 output line from the pneumatic shaft position

transmitter.
7. Disconnect the linkage from the pneumatic shaft position trans-

mitter.
8. Remove the mounting bolts.
9. Reverse this procedure to install the new pneumatic position

shaft transmitter.
Strip Heater Replacement (Types UP2 through UP6 Actuators)
NOTES:
1. Strip heaters are not available for the Type UP1 actuator.
shifting.

4. Remove the covers necessary to allow access to the strip heat-

ers.
5. Remove the mounting screws holding the heaters in place.
6. Remove the mounting screws holding the harness to the actuator

frame.
7. Pull the heater assembly away from the actuator frame.
8. Remove the cover from the heater terminal block.
9. Disconnect the wiring harness.
10. Install the new heaters.
11. Reverse this procedure to put the unit back together.

8 - 23
Thermoswitch Replacement (Types UP2 through UP6 Actuators)
NOTES:
1. Strip heaters are not available for the Type UP1 actuator.
shifting.

4. Remove the covers necessary to access the thermoswitch.
5. Slide the thermoswitch out of its mounting bracket.
6. Label the thermoswitch wires.
7. The new thermoswitch comes with a length of wire attached. Cut

the old thermoswitch wires at a point that leaves a length of wire
attached to the old thermoswitch that is shorter than that attached to
the new thermoswitch.
8. Splice the wires from the new thermoswitch to the wires cut in
Step 7.
9. Slide the new thermoswitch into the mounting bracket.
Volume Booster Replacement (Type UP6 Actuators)
NOTE: Refer to the drawings in Appendix A.
shifting.

4. Remove the covers necessary to access the volume booster.
5. Label and disconnect the air lines connected to the volume

booster.
6. Remove the three bolts that secure the volume booster to its
mounting bracket. Do not remove the mounting bracket from the actu-
ator.

8 - 24
7. Mount the new volume booster onto the mounting bracket with
the three bolts removed in Step 6.
8. Connect the air lines to the volume booster.

8 - 25
SECTION 9 - SUPPORT SERVICES
INTRODUCTION
ABB is ready to help in the use, application and repair of its products.
Contact your nearest sales office to make requests for sales, applica-
tions, installation, repair, overhaul and maintenance contract ser-
vices.
The parts drawings in Appendix A cover the actuators. These draw-

ings normally apply to the units furnished. However, there may be
individual differences in specific assemblies due to:
1. Design changes made since the printing of this product instruc-

tion.
2. Special design of equipment furnished to make it suitable for a

special application.
Therefore, when ordering individual parts, insure correct replacement

by specifying the complete nomenclature and series number of equip-
ment for which parts are desired, and the title and number of the parts
drawing on which each part is illustrated.
REPLACEMENT PARTS
Recommended spare parts for each actuator assembly are listed in

the tables in Appendix A.
TRAINING
ABB has a modern training facility available for training your person-
nel. On-site training is also available. Contact a ABB sales office for
specific information and scheduling.
TECHNICAL DOCUMENTATION
Additional copies of this instruction as well as copies of other ABB

documents are available at the nearest sales office at a reasonable
charge.
INTRODUCTION
9-1
APPENDIX A - SPARE PARTS
INTRODUCTION
This appendix has spare parts information as it relates to the various

actuators. There are tables as well as figures illustrating the part num-
bers, descriptions and locations of these parts. It includes complete
spare parts kits and option kits.
Each figure has the corresponding ABB engineering drawing number

printed in its lower right-hand corner. Use this number if requesting a
full-size copy of that drawing. The engineering drawings include the
NEMA 4X versions of the actuators as well as the standard versions
included in this appendix.
TYPE UP1 ACTUATORS
Refer to Tables A-1 through A-8, A-48, and A-49; and Figures A-1
through A-5 and A-30 for spare parts information for Type UP1 actua-
tors.
Table A-1. UP1 with Positioner, Figure A-1 (Drawing No. 5328573)

1 1 5328574_1 Lever
2 1 5328575_1 Vane actuator
3 4 4-4CBI2-B Elbow
4 1 5328576_3 Brake arm
5 1 Refer to Table A-2 Positioner
6 1 5328577_3 Mounting plate
7 1 5328578_3 Frame
8 1 1963353__01 Label, universal, CSA
10 1 197452_3 Long-lok set screw
12 1 1963302_1 Scale
13 1 5328585_1 Insert
14 1 Plain Zn plated steel washer (0.500 x 1.250 x 0.083)
15 1 1963302_2 Scale
17 3 Hex head Zn plated steel cap screw (0.250-20 x 0.750)
18 3 Ext lockwasher Zn plated steel hex keps (0.250-20)
20 61 cm (24 in.) R1021-0022 0.250 OD x 0.040 wall Al tubing with polyethylene jacket
22 7 Zn plated steel reg spring lockwasher (0.375)
24 1 1963318__ Nameplate
25 1 1962207_1 Styleplate
INTRODUCTION
A-1
SPARE PARTS
Table A-1. UP1 with Positioner, Figure A-1 (Drawing No. 5328573) (continued)

28 3 NLJHA21000 Hex full nut (0.250-20)
29 3 452219_8 Seal screw
30 1 NTCHA11000 Flat washer (0.250)
31 1 NBJAU21010 0.250-20 hex washer head screw (whiz lock)
Figure A-1. UP1 with Positioner, Tables A-1 and A-2 (Sheet 1 of 3)
TYPE UP1 ACTUATORS

A-2
SPARE PARTS
Table A-2. UP1 Positioners, Figure A-1
Type Item 5 Type Item 5 Type Item 5

UP1$A AV1121$3 UP1$C AV2321$3 UP1$E AV442103
UP1$B AV1221$3 UP1$D AV3321$3
TYPE UP1 ACTUATORS A-3

SPARE PARTS
TYPE UP1 ACTUATORS

A-4
SPARE PARTS
Table A-3. UP1 with Solenoid Valve, Figure A-2 (Drawing No. 5328581)

1 1 5328574_1 Lever
3 1 4-4FBI2-B Straight fitting
4 1 Refer to Table A-4 Solenoid valve
6 2 4-4CBI2-B Elbow
7 1 5328578_3 Frame
8 1 5328576_3 Brake arm
9 1 5328580_1 Plate
10 1 4-4DBI2-B Elbow
11 1 195161_ Needle valve
12 1 197452_3 Long-lok set screw
13 1 1963302_1 Scale
14 1 5328585_1 Insert
23 1 4-4-4RBI2-B Male run tee
24 1 RRS-B Male tee
26 84 cm (33 in.) R1021-0022 0.25 OD Al tubing polyethylene jacket
27 1 1963318__ Nameplate
28 1 1962207_1 Styleplate
30 1 1963302_2 Scale
Table A-4. UP1 Solenoid Valves, Figure A-2
Type Item 5 Type Item 5

UP1$5 5322137$8 (120 VAC), single coil UP1$9 1951672$2 (115/125 VDC), dual coil
UP1$6 5322137$9 (115/125 VDC), single coil UP1$F 5322137$10 (220VAC at 50 Hz/240
VAC at 60 Hz), single coil
UP1$8 1951672$1 (120 VAC), dual coil UP1$G 1951672$3 (220VAC at 50 Hz/240
VAC at 60 Hz), dual coil

SPARE PARTS
Figure A-2. UP1 with Solenoid Valve, Tables A-3 and A-4 (Sheet 1 of 2)
TYPE UP1 ACTUATORS

A-6
SPARE PARTS

SPARE PARTS
Table A-5. UP1 Alarm/Travel Switch Kit, Figure A-3 (Kit No. 5328745 _1)

1 12 1943825_1 Terminal lug
2 1 194956_12 Terminal block
3 1 1947282_1 Desig plate assembly
4 4 6614403_1 Cam
5 1 5312449_13 Connecting link
6 1 5328742_1 Link arm
7 1 5328596_1 Arm
8 1 5328801_1 Support bracket
9 1 5328701_1 Bracket
10 1 5328589_1 Switch mounting bracket
11 4 1942989_1 Microswitch
12 2 1947261_1 Shield
14 1 5328700_1 Shaft
15 2 5328703_1 Spacer block
16 2 197164_37 Retaining ring
17 1 5328741_1 Cover
18 81 cm (32 in.) 5327724_3H Sealing strip
19 1 197676_1 Ground screw
20 1 197675_1 Washer
21 1 1963318__ Nameplate
25 4 Pan head Zn plated steel screw (0.138-32 x 0.750)
26 2 Hex socket head Zn plated steel cap screw (0.112-40 x 0.625)
27 6 1204-00 Zn plated steel shakeproof lockwasher
29 2 Pan head Zn plated steel sems int (0.190-32 x 0.312)
33 4 Pan head stainless steel machine screw (0.112-40 x 2.000)
35 18 cm (7 in.) R2041-0070 18 AWG brown leadwire
36 18 cm (7 in.) R2041-0035 18 AWG red leadwire
37 18 cm (7 in.) R2041-0050 18 AWG orange leadwire
38 18 cm (7 in.) R2041-0075 18 AWG yellow leadwire
39 18 cm (7 in.) R2041-0055 18 AWG blue leadwire
40 18 cm (7 in.) R2041-1712 18 AWG white/blue leadwire
41 1 5328745 Print
42 1 No. 10 Carton
TYPE UP1 ACTUATORS

A-8
SPARE PARTS
Figure A-3. UP1 Alarm/Travel Switch Kit, Table A-5 (Sheet 1 of 2)

SPARE PARTS
Figure A-3. UP1 Alarm/Travel Switch Kit, Table A-5 (Sheet 2 of 2)
Table A-6. UP1 Electric Shaft Position Transmitter Kit,

Figure A-4 (Kit No. 5328748 _1)

1 1 5328745_1 Alarm unit kit
2 1 5328702_1 Coupler
3 2 197723_1 Set screw, brass tip
4 1 5328704_1 Transmitter bracket
5 1 5839B01P0001 Feedback potentiometer
6 3 197727_6 Support
TYPE UP1 ACTUATORS

A - 10
SPARE PARTS
Table A-6. UP1 Electric Shaft Position Transmitter Kit,

Figure A-4 (Kit No. 5328748 _1) (continued)

7 1 6633390_2 4 to 20-mA transmitter board assembly
8 3 1946162_1 Pin receptacle
9 1 5328594_1 Cover
10 3 197688_3 Threaded spacer
11 1 1963318__ Nameplate
13 11.0 cm (4.5 in.) R2041-1664 22 AWG wht/grn leadwire
14 11.0 cm (4.5 in.) R2041-1666 22 AWG wht/vio leadwire
15 11.0 cm (4.5 in.) R2041-1667 22 AWG wht/gra leadwire
16 3 Pan head Zn plated steel sems ext (0.138-32 x 0.250)
19 4.0 cm (1.5 in.) R9023-0175 Insulation tubing
22 1 5328748 Print
Figure A-4. UP1 Electric Shaft Position Transmitter Kit, Table A-6 (Sheet 1 of 2)
TYPE UP1 ACTUATORS A - 11

SPARE PARTS
Figure A-4. UP1 Electric Shaft Position Transmitter Kit, Table A-6 (Sheet 2 of 2)
Table A-7. UP1 Air Failure Lock Kit, Figure A-5 (Kit No. 5328826 _1)

1 1 5329023_1 Rack gear assembly
2 1 5329022_1 Saddle
3 1 5328811_1 Toggle assembly
4 1 5328810_1 Toggle link assembly
5 1 5328753_1 Spacer
6 1 5328816_1 Center pivot
7 1 5328818_1 Adapter
8 1 5328726_1 Drive link
9 1 5328725_1 Eccentric assembly
10 1 Semi-fin stainless steel reg hex (0.375-16) full nut
11 1 Hex socket head steel cap screw (0.375-16 x 0.875)
12 1 5328751_1 Hand lever
13 1 5328763_1 Hand lock clamp
14 1 5328721_1 Clevis pin
15 2 5327327_3 Adapter
16 1 5328766_1 Rack cover
TYPE UP1 ACTUATORS

A - 12
SPARE PARTS
Table A-7. UP1 Air Failure Lock Kit, Figure A-5 (Kit No. 5328826 _1) (continued)

17 1 5328728_1 Locking rack
18 1 5328730_1 Rack plate
19 1 5328729_1 Mounting yoke
21 1 1951589_2 Air valve
22 1 1951589_1 Air valve
23 1 1951610_1 Air cylinder
24 3 197120_8 Elastic stop nut
25 1 197259_1 Hex lock nut
26 1 1951606_1 3-way valve
27 1 5328788_1 Mounting bracket
28 1 4-4CB12-B Male elbow
29 2 4-4FB12-B Male connector
30 3 4-4-4RB12-B Male run tee
31 1 NPT brass tee
32 1 NPT brass close nipple
33 1 5328825_1 Felt washer
34 1 197745_1 Extension spring
35 1.2 m (4.0 ft) R1021-0022 0.250 OD x 0.040 Wall Al tubing
1
36 1 1951041_2 8 NPT socket head pipe plug
37 2 Pan head stainless steel machine screw (0.164-32 x 0.188)
38 2 Pan head ph Zn plated steel rolok (0.190-32 x 0.625)
41 3 Hex socket head Zn plated steel cap screw (.0250-20 x 0.750)
44 1 Steel milled stud (0.375-16 x 1.500)
48 1 Semi-fin Zn plated steel reg hex jam nut (0.500-20)
50 2 Pan head Zn plated steel threaded ctg type 1 screw (0.190-32 x
1.500)
51 1 3 x 5 cotton draw string bag
52 1 5328826 Print
53 1 No. 24 Carton
54 1 Hex socket head stainless steel cap screw (0.250-20 x 1.250)
55 2 4CBI2-B Male elbow

SPARE PARTS
Table A-7. UP1 Air Failure Lock Kit, Figure A-5 (Kit No. 5328826 _1) (continued)

57 1 1963318__ Nameplate
1
59 1 8 NPT brass pipe plug
60 1 3053306 Print
Figure A-5. UP1 Air Failure Lock Kit, Table A-7 (Sheet 1 of 2)
TYPE UP1 ACTUATORS

A - 14
SPARE PARTS
Figure A-5. UP1 Air Failure Lock Kit, Table A-7 (Sheet 2 of 2)
Table A-8. UP1 Rotary Vane Seal Repair

Kit, Figure 8-1 (Kit No. 285244 _1)

1 2 341816_212 O-ring (shaft)
2 1 1951631_425 O-ring (vane)
A/R 199354_1 Lubricant
A/R 199926_1 Sealant
TYPE UP2 ACTUATORS
Refer to Tables A-9 through A-18, A-48 and A-49, and Figures A-6
through A-11 and A-30 for spare parts information for Type UP2 actu-
ators.

SPARE PARTS
Table A-9. UP2 Actuator with Positioner, Figure A-6 (Drawing No. 5328874)

11 1 5329141_1 Side cover
2 1 5328642_3 Case assembly
4 2 5328862_1 Spacer
5 2 5328863_1 Spacer
6 1 5328860_2 Brake plate
7 1 5328871_1 Cover plate
8 1 5328864_1 Drive plate
9 1 197452_4 Set screw, locking
11 1 5328868_2 Shaft assembly
12 2 4-4CBI2-B Male elbow
131 1 5329157_2 Top cover
14 4 6613970_1 Link lock fastener
15 1 5328869_2 Shaft extension
16 1 5328872_1 Cover plate
17 1 5328841_1 Drive lever
18 7 19981_30 Plug button
20 1 1963485_1 Scale
21 1 5328873_1 Pointer
22 1 5328845_1 Brake arm
23 1 1963318__ Nameplate
24 2 67125_15 Rubber grommet
27 3 5328862_2 Spacer
28 1 1951611_2 Shaft seal
29 1 1951611_1 Shaft seal
30 2 1943785_4 Cable tie
31 2 1951569_9 Plug button
33 5 Hex head Zn plated steel cap screw (.0250-20 x 0.375)
34 8 NIDAC09005 Pan head sems ext (0.112)
37 2 Hex socket head stainless steel cap screw (.0250-20 x 1.250)
40 1 1963485_2 Scale
41 2 Ext lockwasher Zn plated steel hex keps nut (0.250-20)
42 1 Semi-fin Zn plated steel heavy hex full nut (0.500-13)
TYPE UP2 ACTUATORS

A - 16
SPARE PARTS
Table A-9. UP2 Actuator with Positioner, Figure A-6 (Drawing No. 5328874) (continued)

45 1 Round head Zn plated steel threaded frmg screw type U
(0.060 x 0.188)
46 132 cm (52 in.) R1021-0022 0.250 OD x 0.040 wall Al tubing with polyethylene jacket
48 9 Zn plated steel hex nut (0.138-32)
49 1 5328865_1 Retainer
50 1 Hex socket head Zn plated steel cap screw (0.250-20 x
1.500)
52 3 Semi-fin Zn plated steel reg hex full nut (0.250-20)
54 1 Stainless steel reg spring lockwasher (0.112)
55 1 5328914_1 Transfer shaft bushing
56 2 4-4FBI2-B Male connector
57 1 1963353__ Label, universal, CSA
58 3 NTMHA21000 Int sems lockwasher (0.250)
59 3 NBAHA21016 Hex socket head screw (0.250-20)
61 3 NNBHA21000 Hex keps nut (0.250-20)
64 1 MF274-593 Warning label
65 1 1964034_1 Ground label
66 1 NNBAC16000 Hex keps nut (0.190)
NOTE:
1. Older models have plastic covers. To order a plastic side cover, use part no. 5328660_1. To order a plastic top cover, use part no.
5328670_1.
Table A-10. UP2 Positioners,

Figure A-6
Type Item 5
UP2$A AV1121$3
UP2$B AV1221$3
UP2$C AV2321$3
UP2$D AV3321$3
UP2$E AV442103

SPARE PARTS
TYPE UP2 ACTUATORS

A - 18
SPARE PARTS

SPARE PARTS
Table A-11. UP2 with Solenoid Valve,

Figure A-7 (Drawing No. 5328891)

11 1 5329141_1 Side cover
4 2 5328862_1 Spacer
5 2 5328863_1 Spacer
6 1 5328860_1 Brake plate
7 1 5328871_1 Cover plate
8 1 5328864_1 Drive plate
10 1 5328868_2 Shaft assembly
121 1 5329157_2 Top cover
13 4 6613970_1 Link lock fastener
15 1 5328872_1 Cover plate
16 1 1951611_1 Shaft seal
17 1 5328841_1 Drive lever
TYPE UP2 ACTUATORS

A - 20
SPARE PARTS

Figure A-7 (Drawing No. 5328891) (continued)

20 1 5328865_1 Retainer
21 1 1963485_1 Scale
22 1 5328873_1 Pointer
23 1 5328845_1 Brake arm
24 1 1963318__ Nameplate
25 1 1951611_2 Shaft seal
29 3 5328862_2 Spacer
31 1 195161_ Needle valve
32 1 RRS-B Male pipe tee
33 1 4-4DBI2-B Female elbow
35 1 1963485_2 Scale
36 2.1 m (7.0 ft) R1021-0022 0.250 OD x 0.040 Wall Al tubing
37 8 NIDAC09005 Pan head sems ext (0.112)
39 3 Hex head Zn plated steel cap screw (.0250-20 x 1.250)
44 2 1951569_9 Plug button
49 1 Round head Zn plated steel threaded frmg screw type U (0.060
x 0.188)
52 9 Zn plated steel hex nut (0.138-32)
54 1 Stainless steel reg spring lockwasher (0.112)

SPARE PARTS


57 3 Semi-fin Zn plated steel Reg hex full nut (0.250-20)
58 1 5328914_1 Transfer shaft bearing
60 1 197452_4 Set screw
64 1 MF274-593 Warning label
65 1 1964034_1 Ground label
66 1 NNBAC16000 Hex keps nut (0.190)
NOTE:
1. Older models have plastic covers. To order a plastic side cover, use part no. 5328660_1. To order a plastic top cover, use part no.
5328670_1.
TYPE UP2 ACTUATORS

A - 22
SPARE PARTS
Table A-12. UP2 Solenoid Valves, Figure A-7
Type Item 5
UP2$5 5322137$8 (120 VAC), single coil
UP2$6 5322137$9 (115/125 VDC), single coil
UP2$8 1951672$1 (120 VAC), dual coil
UP2$9 1951672$2 (115/125 VDC), dual coil
UP2$F 5322137$10 (220 VAC at 50 Hz /240 VAC at
60 Hz), single coil
UP2$G 1951672$3 (220VAC at 50 Hz/240 VAC at 60
Hz), dual coil

SPARE PARTS
Table A-13. UP2 Alarm/Travel Switch Kit, Figures

A-8 and A-30 (Kit No. 5328932 _1)

1 1 5328596_1 Arm
2 1 5328931_1 Linkage assembly
3 3 19934_198 Spacer
4 1 5328698_1 Alarm unit
5 1 1963318__ Nameplate
11 1 Pan head screw (0.190-32)
12 3 NBZHA16028 Hex keps nut (0.190-32)
13 3 NNBHA16000 Zn plated steel hex nut (0.190-32)
14 1 No. 20 Carton
15 1 5328932 Print
Table A-14. UP2 Electric Shaft Position Transmitter Kit, Figures

A-8 and A-30 (Kit No. 5328932 _2)

1 1 5328596_1 Arm
2 1 5328931_1 Linkage assembly
3 3 19934_198 Spacer
4 1 5328698_2 Electric shaft position transmitter
5 1 1963318_ Nameplate
12 3 NBZHA16028 Pan head screw (0.190-32)
15 1 5328932 Print
Table A-15. UP2 Pneumatic Shaft Position Transmitter Kit,

Figure A-9 (Kit No. 5328936 _2/3)

1 1 AV112000 Pneumatic shaft position transmitter for Type UP2_AC___ (kit
no. 5328936_2)
AV122000 Pneumatic shaft position transmitter for Type UP2_BD___ (kit
no. 5328936_3)
3 1 5328846_2 Positioner mounting bracket
4 1 19934_110 Spacer
6 1 1963318__ Nameplate
7 1 1951041_1 NPT socket head pipe plug
8 1 4-4-4RBI2-B male run tee
TYPE UP2 ACTUATORS

A - 24
SPARE PARTS
Figure A-8. UP2 with Electric Shaft Position Transmitter and/or Alarm/Travel
Switches, Tables A-13, A-14, A-48 and A-49 (Sheet 1 of 2)

SPARE PARTS
Figure A-8. UP2 with Electric Shaft Position Transmitter and/or Alarm/Travel
Switches, Tables A-13, A-14, A-48 and A-49 (Sheet 2 of 2)
TYPE UP2 ACTUATORS

A - 26
SPARE PARTS
Figure A-9. UP2 with Pneumatic Shaft Position Transmitter, Table A-15 (Sheet 1 of 2)

SPARE PARTS
Figure A-9. UP2 with Pneumatic Shaft Position Transmitter, Table A-15 (Sheet 2 of 2)

Figure A-9 (Kit No. 5328936 _2/3) (continued)

15 15 cm (6 in.) R1021-0022 0.250 OD x 0.040 wall Al tubing w/polyethylene jacket
16 1 FORM MP290 Warning tag
17 1 5328936 Print
18 1 No. 24 Carton
19 1 5329040_1 Link mounting bracket
20 1 Stainless steel roll pin (0.094 dia x 0.438)
23 4 19934_107 Spacer
TYPE UP2 ACTUATORS

A - 28
SPARE PARTS

Figure A-9 (Kit No. 5328936 _2/3) (continued)

25 3 NTMHA21000 Int sems lockwasher (0.250)
Table A-16. UP2 Air Failure Lock Kit,

Figure A-10 (Kit No. 5328925 _1)

1 2 1951609_1 Bulkhead fitting
2 1 5328917_1 Manual lock
3 1 5328863_2 Spacer
4 1 5328938_1 Transfer shaft assembly
5 1 5328909_1 Pin
7 1 5328915_1 Lever
8 2 1941718_1 Conduit gasket
9 2 5328918_1 Pin
13 1 5328912_1 Link
14 1 5328861_1 Rack cover
15 1 5328921_1 Rack
16 1 5328910_1 Rack gear
17 1 5328922_1 Sector plate
19 1 1951589_2 Air valve
21 1 1951606_1 3-way valve
22 1 5328911_1 Support stud
23 1 1951610_1 Air cylinder
24 1 5328919_1 Clevis arm
25 2 5327327_3 Adapter
26 1 197745_1 Extension spring
28 2 4CB12-B Male elbow
30 1 street elbow
31 1 1951589_1 Air valve

SPARE PARTS
Table A-16. UP2 Air Failure Lock Kit,

Figure A-10 (Kit No. 5328925 _1) (continued)

33 1 1963487_1 Label
35 1.8 m (6.0 ft) R1021-0022 0.250 OD x 0.040 wall Al tubing
36 1 close brass nipple
37 1 195273_ Tee
1
38 1 8 brass pipe plug
39 2 Pan head stainless steel cap screw (0.164-32 x 0.188)
40 2 NAUHA21006 Hex head cap screw (0.250-20)
41 2 NAUHA21032 Hex head cap screw (0.250-20)
43 7 Pan head Zn plated steel machine screw (0.190-32 x 0.875)
45 1 6618445_2 Nylon washer
47 3 Plain Zn plated steel flat washer (0.250 x 0.562 x 0.065)
49 2 Rolled split spacer cem
51 1 1963318__ Nameplate
52 2 NTJHA15030 Spring lockwasher (0.500)
53 1 NLHHA29000 Hex jam nut (0.500-13)
55 1 Cotton draw string bag 7.6 x 12.7 cm (3.0 x 5.0 in.)
56 1 5328925 Print
57 4 NTMHA21000 Int lockwasher (0.250)
58 1 Semi-fin Zn plated steel reg hex jam nut (0.500-20)
1
59 1 8 brass pipe plug
60 1 3053306 Print
62 1 NLJHA21000 Hex nut (0.250-20)
TYPE UP2 ACTUATORS

A - 30
SPARE PARTS
Figure A-10. UP2 with Air Failure Lock, Table A-16 (Sheet 1 of 2)

SPARE PARTS
Figure A-10. UP2 with Air Failure Lock, Table A-16 (Sheet 2 of 2)
TYPE UP2 ACTUATORS

A - 32
SPARE PARTS
Table A-17. UP2 Reserve Air Tank Kit, Figure A-11 (Kit No. 5328925 _2)

3 2 1951606_1 3-way pneumatic valve
4 1 1941099_2 Pressure switch
5 1 1941147_1 molded bushing
6 1 5328782_1 Air failure lock harness
8 1 5329189_1 Terminal designation assembly
9 1 5329190_1 Switch mounting plate
11 4 4-4-4SBI2-B Male branch tee
15 1 1951712_1 Check valve
16 1 1963318__ Universal nameplate
17 1 1963489_4 Designation plate
18 1 1951785_5 20.8 liter (5.5 gallon) air tank assembly (Fig. B-11)
20 1 1951608_1 Shutoff valve
21 1 1963478_1 Instruction plate
23 2 NIDAC13008 Pan head ext sems (0.138)
24 2 NIDAC13012 Pan head ext sems (0.138)
25 2 NBJAC16010 Hex washer head screw (0.190)
26 4 NTMAC19000 Int lockwasher (0.190)
27 4 NBZAC17014 Pan head screw (0.190-24)
28 2 NAUAC21006 Hex cap screw (0.250)
29 2 NTLAC25000 Ext lockwasher (0.250)
30 4 NBJAC21008 Hex whiz lock (0.250)
31 1 NTLAC50000 Ext lockwasher (0.500)
32 1 NPT brass street elbow
33 2 NPT brass tee
34 1 NPT x 1.250 long brass nipple
36 3 m (10 ft) R1021-0022 0.250 OD x 0.040 wall Al tubing with black poly jacket
38 1 C3053544 - sh3 Print

SPARE PARTS
6.50
Figure A-11. UP2 Reserve Air Tank Kit, Table A-17 (Sheet 1 of 2)
TYPE UP2 ACTUATORS

A - 34
SPARE PARTS
Figure A-11. UP2 Reserve Air Tank Kit, Table A-17 (Sheet 2 of 2)

SPARE PARTS
Table A-18. UP2 Rotary Vane Seal Repair Kit,

Figure 8-1 (Kit No. 258244 _2)

1 2 341816_218 O-ring (shaft)
2 1 1951631_443 O-ring (vane)
A/R 199354_1 Lubricant
A/R 199926_1 Sealant
Table A-19. UP2 Heater Kits, Figure A-12 (Kit Nos. 5328935 _1/2)

4 2 19934_87 Spacer
5 1 1943002_1 Strip heater (500 W) for 120 VAC operation
1943002_2 Strip heater (500 W) for 240 VAC operation
6 1 662460_1 Thermoswitch
7 1 195105_10 Tube clamp
8 2 1941401_2 Solderless terminal
11 1 197118_2 Conduit connector
12 3 NBZHA13012 Pan head stainless steel screw (0.138)
13 5 NNBAC13000 Hex keps nut (0.138-32)
14 36 cm (14 in.) 5318366_1U Fiberglass insulation
15 1 NBZHA16010 Pan head stainless steel screw (0.190)
16 4 NNBHA16000 Stainless steel hex keps (0.190)
17 2 NBZHA16020 Pan head stainless steel machine screw (0.190-32)
18 1 5328935 Print
19 1 No. 84 Mailer
20 1.2 m (4.0 ft) R2049-0100 14 AWG natural leadwire
21 2 NTCHA09000 Plain stainless steel washer (0.190)
22 1 195105_6 Tube clamp
23 2 1943825_11 Terminal lug
24 2 NBZHA13016 Pan head stainless steel sems ext (0.138)
25 1 1963318__ Nameplate
26 5 197496 _6 Sealing washer
27 3 197496 _10 Sealing washer
TYPE UP2 ACTUATORS

A - 36
SPARE PARTS
Figure A-12. UP2 with Heater, Table A-19 (Sheet 1 of 2)

SPARE PARTS
Figure A-12. UP2 with Heater, Table A-19 (Sheet 2 of 2)
TYPE UP2 ACTUATORS

A - 38
SPARE PARTS
Refer to Tables A-20 through A-31, A-48 and A-49; Figures A-13
through A-21, and A-30 for spare parts information for Types UP3 and
UP4 actuators.
Table A-20. UP3 and UP4 with Positioner, Figure A-13

(Drawing No. 5328749)

Refer to sheets 1 and 2 of Figure A-13.
1 1 5328740_3 Frame assembly

2 4 197730_1 Cotter pin
5 1 1947271_2 Desig plate
6 8 197743_3 Ty-wrap
7 1 Refer to Tables A-21, 8-1, 8-2 and Cylinder assembly
Figures 8-2 and 8-3
8 1 5328779_1 Arm and shaft assembly

9 1 Zn plated roll pin (0.500 dia x 3.500)
10 1 5328735_1 Drive pin
11 2 5328774_1 Roller bearing
13 2 5328737_1 Retainer plate
14 1 5328789_1 Spring plunger
15 1 5328732_1 Spring keeper
16 1 5328785_1 Spring
17 1 5328733_1 Spring guide
18 1 5328734_1 Cam
19 2 5328754_3 Support panel
20 1 5328747_1 Split nut
21 1 5328736_1 Operator rod
22 1 5328738_1 H wheel shaft
24 1 Refer to Table A-21 Desig plate
26 2 5328770_1 Clevis pin
27 Refer to Table A-21 1951407_1 Male connector
28 1 5328718_1 Bearing support
29 1 5328771_1 Clevis
30 1 5328765_2 Gasket
31 6 5313297_1 Washer
32 2 5313299_1 Thrust bearing
33 2 5311759_1 Ball joint
TYPES UP3 AND UP4 ACTUATORS A - 39

SPARE PARTS

(Drawing No. 5328749) (continued)

34 1 5400311_1 Connecting link (AV)
35 Refer to Table A-21 1951609_1 Bulkhead fitting
36 Refer to Table A-21 19981_31 Plug button
38 1 197675_1 Washer
39 Refer to Table A-21 4-4CBI2-B Male elbow
40 Refer to Table A-21 4CBI2-B Male elbow
41 Refer to Table A-21 4-4FBI2-B Male connector
42 1 5328793_1 Sleeve
43 1 1963318_ _ Nameplate
45 2 Hex head Zn plated steel cap screw
(0.500-13 x 0.625)
(0.250-20 x 3.000)
47 Refer to Table A-21 NPT brass street elbow
48 Refer to Table A-21 NPT x 1.250 long brass nipple
(0.250-20 x 0.500)
50 4 Hex head Zn plated steel machine screw
(0.250-20 x 0.750)
51 2 Semi-fin Zn plated steel heavy hex full nut
(0.500-13)
(0.500-13 x 1.500)
54 Refer to Table A-21 1943825_1 Terminal lug
55 1 Hex jam nut (1.000-14)
56 1 Hex nut (0.750-16)
57 Refer to Table A-21 R1021-0022 0.250 OD x 0.040 wall Al tubing with polyeth-
ylene jacket
59 8 SSP-68 Zn plated steel rivet
60 4 Pan head Zn plated steel machine screw
(0.138-32 x 1.000)
(0.138-32 x 0.625)
62 1 5329067_1 Stop plate
64 10 1214-00 Zn plated steel shakeproof int lockwasher
65 1 5320156_1 Spring

A - 40
SPARE PARTS


66 1 5329065_1 Shaft seal
67 1 NPT brass tee
68 1 NPT brass pipe plug
69 3 MDP spiral pin (0.188 dia x 1.000)
70 1 1963503_1 Designation label
74 8 Ext lockwasher Zn plated steel hex keps
(0.250-20)
75 Refer to Table A-21 R2041-0030 18 AWG white leadwire
76 Refer to Table A-21 R2041-0010 18 AWG black leadwire
77 A/R 6634752_1 Shim
79 4 Indented hex washer Zn plated steel
(0.250-20 x 0.500)
80 Refer to Table A-21 4VBI2-B 45 male elbow
81 Refer to Table A-21 NPT brass elbow
84 2 19734_45 Small washer
85 1 5311459_1 Handle valve
86 1 Zn plated steel roll pin (0.125 x 0.750)
87 1 4808-09-01-4102 Stainless steel shakeproof lockwasher
88 1 Plain Zn plated steel washer (0.188 x 0.438 x
0.049)
(0.164-32 x 0.625)
92 A/R 1963353__ 01 Label, universal, CSA
93 Refer to Table A-21 1951408_1 Male elbow
94 Refer to Table A-21 R9021-0050 0.500 OD x 0.062 wall nylon tubing
98 Refer to Table A-21 1941147_1 Bushing
101 2 NTLAC19000 Ext shakeproof lockwasher (0.250)
107 76.2 cm (30.0 in.) R2041-1577 22 AWG brown leadwire
108 76.2 cm (30.0 in.) R2041-1578 22 AWG red leadwire
109 76.2 cm (30.0 in.) R2041-1580 22 AWG yellow leadwire

SPARE PARTS


110 76.2 cm (30.0 in.) R2041-1581 22 AWG blue leadwire
111 76.2 cm (30.0 in.) R2041-1700 22 AWG green leadwire
Refer to sheet 3 of Figure A-13.
1 1 5328792_1 Handle
2 1 198517_2 Handle and ratchet assembly
61 1 5328759_8 Side cover
7 1 1963339_1 Scale
8 1 5328609_2 Pointer
91 1 5328759_7 Side cover
1
10 1 5329164_2 Top cover assembly
12 1 1962207_1 Style plate
13 1 5328797_1 Operating lever
14 1 5324259_1 Hand/auto nameplate
15 1 198531_1 Woodruff key
16 1 1963339_2 Scale
24 1 NRNHA19016 Spiral pin (0.188)
29 4.3 m (14.0 ft) 1951480_1U Sealing strip
31 1 NAUHA21008 Hex cap screw (0.250-20)
34 6.3 cm (2.5 in.) R9410-0025 Vinyl tape (0.250 X 0.375)
NOTE:
1. Older models have plastic covers. To order a plastic side cover, user part nos. 5328759_2 (Item 9). To order a plastic top cover, use
part no. 5328795_1 (Item 10).
Table A-21. UP3 and UP4 Positioners and Unique Items, Figure A-13
Type Item 7 Item 23 Item 24 Item 27 Item 35 Item 36 Item 39 Items 40,80
UP3_A0 5328775_1 AV112100 1947271_8 Omit 2 4 4 1
UP3_A11 5328775_1 AV112100 1947271_8 Omit 2 4 4 1
UP3_AA 5328775_1 AV112110 1947271_8 Omit 2 4 4 1
UP3_AB 5328775_1 AV112120 1947271_8 Omit 2 4 4 1
UP3_AC 5328775_1 AV112100 1947271_8 Omit 2 4 4 1
UP3_B0 5328775_1 AV122100 1947271_8 Omit 2 4 4 1
UP3_B11 5328775_1 AV122100 1947271_8 Omit 2 4 4 1
UP3_BA 5328775_1 AV122110 1947271_8 Omit 2 4 4 1
UP3_BB 5328775_1 AV122120 1947271_8 Omit 2 4 4 1
UP3_BD 5328775_1 AV122100 1947271_8 Omit 2 4 4 1
UP3_C0 5328775_1 AV232100 1947271_8 Omit 1 5 3 1
UP3_C11 5328775_1 AV232100 1947271_8 Omit 1 5 3 1
UP3_CA 5328775_1 AV232110 1947271_8 Omit 1 5 3 1
UP3_CB 5328775_1 AV232120 1947271_8 Omit 1 5 3 1
UP3_D0 5328775_1 AV332100 1947271_8 Omit 1 5 3 1

A - 42
SPARE PARTS
Table A-21. UP3 and UP4 Positioners and Unique Items, Figure A-13 (continued)
Type Item 7 Item 23 Item 24 Item 27 Item 35 Item 36 Item 39 Items 40,80
UP3_D11 5328775_1 AV332100 1947271_8 Omit 1 5 3 1
UP3_DA 5328775_1 AV332110 1947271_8 Omit 1 5 3 1
UP3_DB 5328775_1 AV332120 1947271_8 Omit 1 5 3 1
UP3_E0 5328775_1 AV442100 1947271_9 Omit 1 5 3 1
UP3_E11 5328775_1 AV442100 1947271_9 Omit 1 5 3 1
UP4_A0 5328769_1 AV112100 1947271_8 2 2 4 1 Omit
UP4_A11 5328769_1 AV112100 1947271_8 2 2 4 1 Omit
UP4_AA 5328769_1 AV112110 1947271_8 2 2 4 1 Omit
UP4_AB 5328769_1 AV112120 1947271_8 2 2 4 1 Omit
UP4_AC 5328769_1 AV112100 1947271_8 2 2 4 1 Omit
UP4_B0 5328769_1 AV122100 1947271_8 2 2 4 1 Omit
UP4_B11 5328769_1 AV122100 1947271_8 2 2 4 1 Omit
UP4_BA 5328769_1 AV122110 1947271_8 2 2 4 1 Omit
UP4_BB 5328769_1 AV122120 1947271_8 2 2 4 1 Omit
UP4_BD 5328769_1 AV122100 1947271_8 2 2 4 1 Omit
UP4_C0 5328769_1 AV232100 1947271_8 2 1 5 Omit Omit
UP4_C11 5328769_1 AV232100 1947271_8 2 1 5 Omit Omit
UP4_CA 5328769_1 AV232110 1947271_8 2 1 5 Omit Omit
UP4_CB 5328769_1 AV232120 1947271_8 2 1 5 Omit Omit
UP4_D0 5328769_1 AV332100 1947271_8 2 1 5 Omit Omit
UP4_D11 5328769_1 AV332100 1947271_8 2 1 5 Omit Omit
UP4_DA 5328769_1 AV332110 1947271_8 2 1 5 Omit Omit
UP4_DB 5328769_1 AV332120 1947271_8 2 1 5 Omit Omit
UP4_E0 5328769_1 AV442100 1947271_9 2 1 5 Omit Omit
UP4_E11 5328769_1 AV442100 1947271_9 2 1 5 Omit Omit
Type Item 41 Items 47, 81 Item 48 Item 54 Item 57 Items 75, 76 Items 91, 98 Item 93
UP3_A0 2 Omit 1 0 2.4 m (8.0 ft) Omit Omit Omit
UP3_A11 2 Omit 1 0 2.4 m (8.0 ft) Omit Omit Omit
UP3_AA 2 Omit 1 7 2.4 m (8.0 ft) Omit 1 Omit
UP3_AB 2 Omit 1 5 2.4 m (8.0 ft) Omit 1 Omit
UP3_AC 2 Omit 1 0 2.4 m (8.0 ft) Omit Omit Omit
UP3_B0 2 Omit 1 0 2.4 m (8.0 ft) Omit Omit Omit
UP3_B11 2 Omit 1 0 2.4 m (8.0 ft) Omit Omit Omit
UP3_BA 2 Omit 1 7 2.4 m (8.0 ft) Omit 1 Omit
UP3_BB 2 Omit 1 5 2.4 m (8.0 ft) Omit 1 Omit
UP3_BD 2 Omit 1 0 2.4 m (8.0 ft) Omit Omit Omit
UP3_C0 1 Omit 1 5 2.1 m (7.0 ft) 0.6 m (2.0 ft) 1 Omit
UP3_C11 1 Omit 1 5 2.1 m (7.0 ft) 0.6 m (2.0 ft) 1 Omit

SPARE PARTS
Type Item 41 Items 47, 81 Item 48 Item 54 Item 57 Items 75, 76 Items 91, 98 Item 93
UP3_CA 1 Omit 1 11 2.1 m (7.0 ft) 0.6 m (2.0 ft) 1 Omit
UP3_CB 1 Omit 1 9 2.1 m (7.0 ft) 0.6 m (2.0 ft) 1 Omit
UP3_D0 1 Omit 1 5 2.1 m (7.0 ft) 0.6 m (2.0 ft) 1 Omit
UP3_D11 1 Omit 1 5 2.1 m (7.0 ft) 0.6 m (2.0 ft) 1 Omit
UP3_DA 1 Omit 1 11 2.1 m (7.0 ft) 0.6 m (2.0 ft) 1 Omit
UP3_DB 1 Omit 1 9 2.1 m (7.0 ft) 0.6 m (2.0 ft) 1 Omit
UP3_E0 1 Omit 1 11 2.1 m (7.0 ft) 1.8 m (6.0 ft) 1 Omit
UP3_E11 1 Omit 1 11 2.1 m (7.0 ft) 1.8 m (6.0 ft) 1 Omit
UP4_A0 1 1 2 0 0.3 m (1.0 ft) Omit Omit 4
UP4_A11 1 1 2 0 0.3 m (1.0 ft) Omit Omit 4
UP4_AA 1 1 2 7 0.3 m (1.0 ft) Omit 1 4
UP4_AB 1 1 2 5 0.3 m (1.0 ft) Omit 1 4
UP4_AC 1 1 2 0 0.3 m (1.0 ft) Omit Omit 4
UP4_B0 1 1 2 0 0.3 m (1.0 ft) Omit Omit 4
UP4_B11 1 1 2 0 0.3 m (1.0 ft) Omit Omit 4
UP4_BA 1 1 2 7 0.3 m (1.0 ft) Omit 1 4
UP4_BB 1 1 2 5 0.3 m (1.0 ft) Omit 1 4
UP4_BD 1 1 2 0 0.3 m (1.0 ft) Omit Omit 4
UP4_C0 Omit 1 2 5 Omit 0.6 m (2.0 ft) 1 4
UP4_C11 Omit 1 2 5 Omit 0.6 m (2.0 ft) 1 4
UP4_CA Omit 1 2 11 Omit 0.6 m (2.0 ft) 1 4
UP4_CB Omit 1 2 9 Omit 0.6 m (2.0 ft) 1 4
UP4_D0 Omit 1 2 5 Omit 0.6 m (2.0 ft) 1 4
UP4_D11 Omit 1 2 5 Omit 0.6 m (2.0 ft) 1 4
UP4_DA Omit 1 2 11 Omit 0.6 m (2.0 ft) 1 4
UP4_DB Omit 1 2 9 Omit 0.6 m (2.0 ft) 1 4
UP4_E0 Omit 1 2 11 Omit 1.8 m (6.0 ft) 1 4
UP4_E11 Omit 1 2 11 Omit 1.8 m (6.0 ft) 1 4
Table 21. UP3 and UP4 Positioners and Unique Items, Figure A-13 (continued)
Type Item 94 Item 99 Item 107 Item 108 Item 109 Item 110 Item 111
UP3_A0 Omit Omit Omit Omit Omit Omit Omit
UP3_A11 Omit Omit Omit Omit Omit Omit Omit
UP3_AA Omit Omit 0.8 m (2.5 ft) Omit 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.5 m (1.7 ft)
UP3_AB Omit Omit 0.8 m (2.5 ft) Omit 0.8 m (2.5 ft) Omit 0.5 m (1.7 ft)
UP3_AC Omit Omit Omit Omit Omit Omit Omit
UP3_B0 Omit Omit Omit Omit Omit Omit Omit
UP3_B11 Omit Omit Omit Omit Omit Omit Omit
UP3_BA Omit Omit 0.8 m (2.5 ft) Omit 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.5 m (1.7 ft)
UP3_BB Omit Omit 0.8 m (2.5 ft) Omit 0.8 m (2.5 ft) Omit 0.5 m (1.7 ft)

A - 44
SPARE PARTS
Table 21. UP3 and UP4 Positioners and Unique Items, Figure A-13 (continued)
Type Item 94 Item 99 Item 107 Item 108 Item 109 Item 110 Item 111
UP3_BD Omit Omit Omit Omit Omit Omit Omit
UP3_C0 Omit 0.8 m (2.5 ft) Omit 0.8 m (2.5 ft) Omit Omit 0.5 m (1.7 ft)
UP3_C11 Omit 0.8 m (2.5 ft) Omit 0.8 m (2.5 ft) Omit Omit 0.5 m (1.7 ft)
UP3_CA Omit 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.5 m (1.7 ft)
UP3_CB Omit 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) Omit 0.5 m (1.7 ft)
UP3_D0 Omit 0.8 m (2.5 ft) Omit 0.8 m (2.5 ft) Omit Omit 0.5 m (1.7 ft)
UP3_D11 Omit 0.8 m (2.5 ft) Omit 0.8 m (2.5 ft) Omit Omit 0.5 m (1.7 ft)
UP3_DA Omit 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.5 m (1.7 ft)
UP3_DB Omit 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) Omit 0.5 m (1.7 ft)
UP3_E0 Omit 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.5 m (1.7 ft)
UP3_E11 Omit 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.5 m (1.7 ft)
UP4_A0 2.1 m (7.0 ft) Omit Omit Omit Omit Omit Omit
UP4_A11 2.1 m (7.0 ft) Omit Omit Omit Omit Omit Omit
UP4_AA 2.1 m (7.0 ft) Omit 0.8 m (2.5 ft) Omit 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.5 m (1.7 ft)
UP4_AB 2.1 m (7.0 ft) Omit 0.8 m (2.5 ft) Omit 0.8 m (2.5 ft) Omit 0.5 m (1.7 ft)
UP4_AC 2.1 m (7.0 ft) Omit Omit Omit Omit Omit Omit
UP4_B0 2.1 m (7.0 ft) Omit Omit Omit Omit Omit Omit
UP4_B11 2.1 m (7.0 ft) Omit Omit Omit Omit Omit Omit
UP4_BA 2.1 m (7.0 ft) Omit 0.8 m (2.5 ft) Omit 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.5 m (1.7 ft)
UP4_BB 2.1 m (7.0 ft) Omit 0.8 m (2.5 ft) Omit 0.8 m (2.5 ft) Omit 0.5 m (1.7 ft)
UP4_BD 2.1 m (7.0 ft) Omit Omit Omit Omit Omit Omit
UP4_C0 2.1 m (7.0 ft) 0.8 m (2.5 ft) Omit 0.8 m (2.5 ft) Omit Omit 0.5 m (1.7 ft)
UP4_C11 2.1 m (7.0 ft) 0.8 m (2.5 ft) Omit 0.8 m (2.5 ft) Omit Omit 0.5 m (1.7 ft)
UP4_CA 2.1 m (7.0 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.5 m (1.7 ft)
UP4_CB 2.1 m (7.0 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) Omit 0.5 m (1.7 ft)
UP4_D0 2.1 m (7.0 ft) 0.8 m (2.5 ft) Omit 0.8 m (2.5 ft) Omit Omit 0.5 m (1.7 ft)
UP4_D11 2.1 m (7.0 ft) 0.8 m (2.5 ft) Omit 0.8 m (2.5 ft) Omit Omit 0.5 m (1.7 ft)
UP4_DA 2.1 m (7.0 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.5 m (1.7 ft)
UP4_DB 2.1 m (7.0 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) Omit 0.5 m (1.7 ft)
UP4_E0 2.1 m (7.0 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.5 m (1.7 ft)
UP4_E11 2.1 m (7.0 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.8 m (2.5 ft) 0.5 m (1.7 ft)

A - 46
SPARE PARTS
Figure A-13. UP3 and UP4 with Positioner, Tables A-20 and A-21 (Sheet 1 of 3)
SPARE PARTS

A - 48
SPARE PARTS
SPARE PARTS
Table A-22. UP3 and UP4 with Solenoid Valve,


1 1 5328740_3 Frame assembly
2 4 197730_1 Cotter pin
5 1 1947271_2 Desig plate
6 8 197743_3 Ty-wrap
7 1 Refer to Tables Cylinder assembly
A-23, 8-1, 8-2 and
8-3
8 1 5328779_1 Arm and shaft assembly
9 1 Zn plated roll pin (0.500 dia x 3.500)
10 1 5328735_1 Drive pin
11 2 5328774_1 Roller bearing
13 2 5328737_1 Retainer plate
14 1 5328789_1 Spring plunger
15 1 5328732_1 Spring keeper
16 1 5328785_1 Spring
17 1 5328733_1 Spring guide
18 1 5328734_1 Cam
20 1 5328747_1 Split nut
21 1 5328736_1 Operator rod
22 1 5328738_1 H wheel shaft
26 2 5328770 _1 Clevis pin
28 1 5328718 _1 Bearing support
29 1 5328771_1 Clevis
30 1 5328800 _1 Cover plate
31 6 5313297_1 Washer
32 2 5313299_1 Thrust bearing
34 1 1951608_1 Shut off valve
38 1 197675_1 Washer

SPARE PARTS


39 Refer to Table A-23 4CBI2-B Male elbow
40 Refer to Table A-23 4-4CBI2-B Male elbow
41 Refer to Table A-23 4FBI2-B Male connector
47 Refer to Table A-23 NPT x 1.250 brass nipple
48 Refer to Table A-23 NPT brass street elbow
50 2 NBJAC21012 Hex washer head screw (0.250-20)
54 A/R 6634752_1 Shim, as required
55 1 Hex jam nut (1.000-14)
56 1 Hex nut (0.750-16)
58 Refer to Table A-23 NPT brass elbow
59 Refer to Table A-23 R1021-0022 0.250 OD x 0.040 wall Al tubing with polyethylene jacket
60 1 1963318__ Nameplate
61 1 5328793_1 Sleeve
62 1 5328765_2 Cover gasket
64 1 195273_ NPT brass tee
66 Refer to Table A-23 1941401_2 Solderless terminal
67 1 194879- Insulating bushing
69 1 NPT brass pipe plug
70 3 MDP spiral pin (0.188 DIA x 1.000)
75 10 1114-00 Shakeproof int lockwasher
77 91 cm (36 in.) R9090-0030 Spiral wrap

A - 50
SPARE PARTS


78 Refer to Table A-23 4VBI2-B 45 male elbow
79 Refer to Table A-23 1951408_1 Male elbow
81 4 Indented hex washer Zn plated steel (0.250-20 x 0.500)
84 Refer to Table A-23 R9021-0050 0.500 OD x 0.062 wall nylon with polyester tubing
85 Refer to Table A-23 ( 8 x ) brass reducing bushing
3

1 1 5328792_1 Handle
2 1 198517_2 Handle and ratchet assembly
61 1 5328759_8 Side cover
7 1 1963339_1 Scale
8 1 5328609_2 Pointer
91 1 5328759_7 Side cover
12 1 1962207_1 Style plate
14 1 5324259_1 Hand/auto nameplate
16 1 1963339_2 Scale
24 1 NRNHA19016 MDP spiral pin (0.188)
31 1 NAUHA21008 Hex cap screw (0.250-20)
32 1 20 x 33 cm (8 x 13 in.) poly bag
34 6.3 cm (2.5 in.) R9410-0025 Vinyl tape
NOTE:
1. Older models have plastic covers. To order a plastic side cover, user part nos. 5328759_2 (Item 9). To order a plastic top cover, use part
no. 5328795_1 (Item 10).

A - 52
SPARE PARTS
Figure A-14. UP3 and UP4 with Solenoid Valve, Tables A-22 and A-23 (Sheet 1 of 2)
SPARE PARTS
A - 53
SPARE PARTS
Table A-23. UP3 and UP4 Solenoid Valves and Unique Items, Figure A-14
Items 27, Item Items 40, 47, Items

Type Item 7 Item 23 Rating Item 24
48, 79 39 58, 85 41, 48
UP3_5 5328775_1 5322137_3 120 VAC 1947271_1 1 req 2 req Omit 1 req
UP3_6 5328775_1 5322137_2 115/125 VDC 1947271_1 1 req 2 req Omit 1 req
UP3_8 5328775_1 1951433_1 120 VAC 1947271_6 1 req 2 req Omit 1 req
UP3_9 5328775_1 1951433_2 115/125 VDC 1947271_6 1 req 2 req Omit 1 req
UP3_F 5328775_1 5322137_6 220/240 VAC 1947271_1 1 req 2 req Omit 1 req
UP3_G 5328775_1 1951433_5 220/240 VAC 1947271_6 1 req 2 req Omit 1 req
UP4_5 5328769_1 1951013_1 120 VAC 1947271_1 2 req Omit 1 req Omit
UP4_6 5328769_1 1951013_3 115/125 VDC 1947271_1 2 req Omit 1 req Omit
UP4_8 5328769_1 1951135_1 120 VAC 1947271_6 2 req Omit 1 req Omit
UP4_9 5328769_1 1951135_2 115/125 VDC 1947271_6 2 req Omit 1 req Omit
UP4_F 5328769_1 1951013_2 220/240 VAC 1947271_1 2 req Omit 1 req Omit
UP4_G 5328769_1 1951135_4 220/240 VAC 1947271_6 2 req Omit 1 req Omit
Items 65, Item

Type Item 42 Item 59 Item 63 Item 78 Item 84
66 80
UP3_5 2 req 2.4 m (8.0 ft) 183 cm (72 in.) 2 req 1 req Omit Omit
UP3_F 2 req 2.4 m (8.0 ft) 183 cm (72 in.) 2 req 1 req Omit Omit
UP3_G 2 req 2.4 m (8.0 ft) 366 cm (144 in.) 4 req 1 req Omit Omit
UP4_5 1 req 0.9 m (3.0 ft) 183 cm (72 in.) 2 req Omit 2 req 1.5 m (5.0 ft)
UP4_F 1 req 0.9 m (3.0 ft) 183 cm (72 in.) 2 req Omit 2 req 1.5 m (5.0 ft)
UP4_G 1 req 0.9 m (3.0 ft) 366 cm (144 in.) 4 req Omit 2 req 1.5 m (5.0 ft)
Table A-24. UP3 and UP4 Alarm/Travel Switch Kit,

Figures A-15 and A-30 (Kit No. 5328787 _1)

1 1 5328786_1 Wiring harness
2 1 5328698_1 Alarm unit
4 1 1942978_2 Spacer
6 1 5328596_2 Arm
7 1 1963318__ Nameplate
8 3 Hex head Zn plated steel sems ext (0.190-32 x 0.500)
12 2 Hex head Zn plated steel machine screw (0.190-32 x 0.750)

A - 54
SPARE PARTS
Figure A-15. UP3 and UP4 with Electric Shaft Position Transmitter and/or
Alarm/Travel Switches, Tables A-24, A-25, A-48 and A-49
Table A-25. UP3 and UP4 Electric Shaft Position Transmitter Kit,
Figures A-15 and A-30 (Kit No. 5328787 _2)

3 6 1943785_3 Cable tie
4 1 1942978_2 Spacer
6 1 5328596_2 Arm
7 1 1963318__ Nameplate
9 93 cm (37 in.) R2041-1582 22 AWG white/violet leadwire
10 93 cm (37 in.) R2041-1583 22 AWG white/gray leadwire

SPARE PARTS
Figures A-15 and A-30 (Kit No. 5328787 _2) (continued)

12 2 Hex head Zn plated steel machine screw (0.190-32 x 0.750)
17 122 cm (48 in.) R9090-0030 Spiral wrapping
Table A-26. UP3 and UP4 Pneumatic Shaft Position Transmitter Kits,
Figure A-16 (Kit Nos. 5328798 _315/327)

1 1 5329089_1 Clevis pin
3 1 5329090_1 Drive lever
5 1 AV112000 Shaft position transmitter for kit no. 5328798_315
AV122000 Shaft position transmitter for kit no. 5328798_327
10 2 Zn plated steel cotter pin (0.063 dia x 0.375)
13 1 1963318__ Nameplate
14 1 Brass hex head pipe plug (-18 NPT)
22 1 5329091_1 Pointer
24 1 1945750_1 Pull plug
25 1 5400307_1 Airline connector assembly
26 1 195167_4 -18 male connector
27 1 195171_3 -18 male run tee
28 3 NTMHA21000 Int shakeproof lockwasher (0.250)
30 3 NBJAU21010 Hex wshr head screw (0.250-20)
32 1 NBPAC16014 Slotted hex head screw (0.190-32)

A - 56
SPARE PARTS
Figure A-16. UP3 and UP4 with Pneumatic Shaft Position Transmitter, Table A-26
Table A-27. UP3 Air Failure Lock Kits,

Figure A-17 (Kit Nos. 5328781 _1/2)

1 1 1951607_1 Trip valve
3 1 1951606_1 3-way valve
5 1 1951608_1 Shutoff valve for UP3 with positioner (kit no. 5328781_1)
Omit Omit for UP3 with solenoid valve (kit no. 5328781_2)
7 1 1951589_1 Air valve
12 1 Brass tee ( NPT)

SPARE PARTS
Table A-27. UP3 Air Failure Lock Kits,

Figure A-17 (Kit Nos. 5328781 _1/2) (continued)

13 6 4CBI2-B Male elbow
15 1 5328674_1 Valve mounting bracket
16 1 1963318__ Nameplate
17 4 m (13 ft) R1021-0022 0.250 OD x 0.040 wall tubing
18 1 Brass street elbow ( NPT)
19 1 5327327_3 Adaptor
25 2 Brass pipe plug ( NPT)
26 1 Close brass nipple ( NPT)
27 1 I-P81-20 Instruction
28 1 Cotton drawstring bag
29 1 5328781 Print
30 1 No. 100 Carton
1
31 2 Brass reducing bushing ( x 8 )
1
32 1 Brass pipe plug ( 8 NPT)
33 1 3053306 Print

A - 58
SPARE PARTS
Figure A-17. UP3 with Air Failure Lock, Table A-27

SPARE PARTS
Table A-28. UP4 Air Failure Lock Kits, Figure A-18 (Kit Nos. 5328781 _3/4)

1 1 1951607_1 Trip valve
3 1 1951606_1 3-way valve
5 1 5328781_3 Shutoff valve for UP4 with positioner (kit no. 5328781_3)
7 1 1951589_1 Air valve
12 1 Brass tee ( NPT)
13 4 1951408_1 Male elbow
16 1 1963318__ Nameplate
17 0.9 m (3 ft) R1021-0022 0.250 OD x 0.040 wall tubing
18 4 1951407_1 Male connector
19 1 5327327_3 Adaptor
25 2 Brass pipe plug ( NPT)
26 2 Close brass nipple ( NPT)
27 1 I-P81-20 Instruction
28 1 Cotton drawstring bag
29 1 5328781 Print
30 1 No. 100 Carton
1
32 1 Brass pipe plug ( 8 NPT)
33 1 3053306 Print
34 3 NPT brass elbow
36 2.9 m (9.5 ft) R9021-0050 0.500 OD x 0.062 wall polyester reinforced nylon tubing

A - 60
SPARE PARTS
Figure A-18. UP4 with Air Failure Lock, Table A-28

SPARE PARTS
Table A-29. UP3 Reserve Air Tank Kits, Figure A-19 (Kit Nos. 5328781 _31/32)

1 1 1951712_1 Check valve
5 1 1951608_1 Shut-off valve for UP3 with positioner (kit no. 5328787_31)
11 2 4-4-4SB12-B Male branch tee
12 2 NPT brass tee
13 4 4CB12-B Male elbow
17 4 m (13 ft) R1021-0022 0.250 OD x 0.040 wall Al tubing with black poly jacket
21 10 NAUAC21016 Hex cap screw (0.250-20)
22 10 NTCAC11000 Flat washer (0.250)
24 4 NTMAC19000 Int sems lockwasher (0.190)
33 1 C3053544-Sh 1 Print
Refer to Tables A-34 through A-49, and Figures A-22 through A-30 for
spare parts information for Types UP5 and UP6 actuators.

A - 62
SPARE PARTS
Figure A-19. UP3 with Reserve Air Tank, Table A-29
Table A-30. UP4 Reserve Air Tank Kits, Figure A-20 (Kit Nos. 5328781 _41/42)

1 1 1951712_1 Check valve
12 2 NPT brass tee
13 7 1951408_1 Male elbow

SPARE PARTS
Table A-30. UP4 Reserve Air Tank Kits, Figure A-20 (Kit Nos. 5328781 _41/42) (continued)

17 0.9 m (3.0 ft) R1021-0022 0.250 OD X 0.040 wall Al tubing with black poly jacket
24 4 NTMAC19000 Int sems lockwasher (0.190)
33 1 C3053544-Sh 1 Print
35 2 NPT X 1.250L brass nipple
36 3.1 m (10.0 ft) R9021-0050 0.500 OD X 0.062 wall poly reinforced black nylon tubing
38 1 NPT X 1.500L brass nipple

A - 64
SPARE PARTS
Figure A-20. UP4 with Reserve Air Tank, Table A-30
Table A-31. UP3 and UP4 Heater Kits, Figure A-21

(Kit Nos. 5328784 _1/2)

1 6 1943825_11 Stud terminal
3 3 195586_1 Plastic clamp
5 10 1943785_3 Cable tie
8 1 195105_10 Tube clamp
9 2.9 m (9.5 ft) 5318366_1U Fiberglass insulation
11 4 19934_87 Spacer
12 2 1943002_1 Strip heater for 120 VAC operation
1943002_2 Strip heater for 240 VAC operation
13 1 1963318_ Nameplate
16 4.6 m (15.0 ft) R2049-0100 14 AWG natural leadwire

SPARE PARTS
Table A-31. UP3 and UP4 Heater Kits, Figure A-21

(Kit Nos. 5328784 _1/2) (continued)

18 4 NTKAC19000 Shakeproof lockwasher (0.190)
21 4 NBZAC16016 0.190-32 pan head screw
22 2.1 m (7.0 ft) R9090-0030 Spiral wrapping
24 1 5328784 Print
25 1 No. 17 Carton
Figure A-21. UP3 and UP4 with Heater, Table A-31

A - 66
SPARE PARTS
Table A-32. UP3 Cylinder Spare Parts Kit, Figure 8-2 (Kit No. 258240 _1)
Qty Part No. Description Qty Part No. Description

2 1951416_256 O-ring 1 1951401_1 Wiper ring
1 5328773_1 Piston A/R 199354_1 Lubricant
1 195825_15 O-ring 1 No. 62A Carton
1 1951399_214 O-ring 1 258240 Print
1 1951416_218 O-ring
Table A-33. UP4 Cylinder Spare Parts Kit, Figure 8-3 (Part No. 258241 _1)

2 5311428_41 O-ring 1 195852_1 Wiper ring
1 195825_9 O-ring 1 5311428_24 O-ring
1 1951359_220 O-ring 1 No. 39 Carton
2 195851_1 Back up ring 1 258241 Print
Table A-34. UP5 and UP6 Positioner, Figure A-22 (Drawing No. 5328960)

2 1 5328953_2 Gear carrier
3 1 1963318__ Nameplate
4 Refer to Table A-35 19981_31 Plug button
5 1 5328877_1 Frame
8 2 1951408_1 Elbow
10 Refer to Table A-35 1947578_3 Desig plate
11 1 5328905_2 Bottom side cover
12 8 197743_3 Ty-wrap
14 1 1951611_4 Shaft seal
16 1 198517_2 Ratchet assembly
17 1 5325349_1 Clutch lever
18 1 1951611_3 Shaft seal
20 1 5328930_1 Pointer
21 1 5328934_2 Drive shaft
22 1 5328967_2 Top side cover
23 Refer to Table A-35 R2041-0030 18 AWG white leadwire
1
25 1 5329067_1 Stop plate
26 1 5329010_1 Roller chain

SPARE PARTS
Table A-34. UP5 and UP6 Positioner, Figure A-22 (Drawing No. 5328960) (continued)

28 1 5324693_2 Bushing
29 1 5328956_2 Chain sector
32 2 193221_1 Bearing
33 2 197105_4 Alemite fitting
34 1 198512_2 Key
35 1 1963488_1 Scale
36 1 5329008_1 Chain anchor
37 4 197730_1 Cotter pin
38 1 5311459_1 Valve handle
42 1 Refer to Tables Cylinder
A-35, 8-3, 8-4 and
Figures 8-4 and
8-5
43 1 1947271_2 Desig plate
46 1 197675_1 Washer
47 4 5328949_1 Bolt plate
48 3 1951569_5 Button plug
49 2 5328889_1 Clevis pin
50 1 1963489_2 Desig plate
51 1 1963489_1 Desig plate
52 1 1951569_4 Button plug
55 2 5328436_1 Cap screw
58 1 5328765_2 Gasket
59 2 19934_135 Spacer
62 4 Semi-fin steel reg hex full nut (0.625-11)
65 20 Indented hex washer, Zn plated steel threaded cutting screw
(0.250-20 x 0.500)

A - 68
SPARE PARTS
Table A-34. UP5 and UP6 Positioner, Figure A-22 (Drawing No. 5328960) (continued)

68 1 Zn plated steel roll pin (0.125 x 0.750)
70 1 Zn plated steel type 1 groove pin (0.250 dia x 1.250)
73 2 8 -18 NPT pipe plug
3

75 1 Soc hex hdls Zn plated steel set screw (0.190-32 x 0.312)
76 1 4808-09-01-4102 Stainless steel shakeproof lockwasher
77 1 Zn plated steel washer (0.188 x 0.433 x 0.049)
78 2 8OBI2-B Female branch tee
79 Refer to Table A-35 8-8CBI2-B Elbow
80 Refer to Table A-35 5323705_1 Elbow

SPARE PARTS

A - 70
SPARE PARTS

SPARE PARTS
Table A-34. UP5 and UP6 Positioner, Figure A-22


82 Refer to Table A-35 1951609_1 Bulkhead fitting
83 Refer to Table A-35 4CBI2-B Elbow
86 1 5328957_1 Positioner drive rod
87 2 5311759_1 Ball joint
88 1 5328968_1 Stud
89 Refer to Table A-35 Brass coupling ( 8 )
3
90 Refer to Table A-35 Brass close nipple ( 8 )

3

93 183 cm (72 in.) R9021-0050 0.500 OD nylon tubing
94 Refer to Table A-35 R1021-0022 0.250 OD x 0.040 wall Al tubing
96 4 Zn plated steel spring lockwasher (0.750)
97 1 5328902_1 Crank arm
98 1 1963488_2 Scale
99 1 Poly bag
102 Refer to Table A-35 1947578_4 Desig plate
104 10.4 m (34.0 ft) 1951480 _1U Sealing strip
109 1 1963353__ Label, universal, CSA
NOTE:
1. Older models have plastic top covers. To order a plastic top cover, use Part No. 5329053_1.
Type Item 4 Item 10 Item 23 Item 42 Item 60 Item 79 Item 80 Item 81

UP5_A 7 req 1 req Omit 5328952_1 AV1121_0 1 req 2 req 1 req
UP5_B 7 req 1 req Omit 5328952_1 AV1221_0 1 req 2 req 1 req
UP5_C 8 req 1 req 46 cm (18 in.) 5328952_1 AV2321_0 1 req 2 req Omit
UP5_D 8 req 1 req 46 cm (18 in.) 5328952_1 AV3321_0 1 req 2 req Omit
UP5_E 8 req Omit 91 cm (36 in.) 5328952_1 AV442100 1 req 2 req Omit
UP6_A 7 req 1 req Omit 5328945_1 AV1121_0 3 req Omit 1 req
UP6_B 7 req 1 req Omit 5328945_1 AV1221_0 3 req Omit 1 req
UP6_C 8 req 1 req 46 cm (18 in.) 5328945_1 AV2321_0 3 req Omit Omit
UP6_D 8 req 1 req 46 cm (18 in.) 5328945_1 AV3321_0 3 req Omit Omit
UP6_E 8 req Omit 91 cm (36 in.) 5328945_1 AV442100 3 req Omit Omit

A - 72
SPARE PARTS
Item Item
Type Item 82 Item 83 Items 89,90 Item 91 Item 92 Item 94
100 102
UP5_A 1 req 1 req 1 req Omit Omit 38 cm (15 in.) Omit Omit
UP5_B 1 req 1 req 1 req Omit Omit 38 cm (15 in.) Omit Omit
UP5_C Omit Omit 1 req 4 req 46 cm (18 in.) Omit Omit Omit
UP5_D Omit Omit 1 req 4 req 46 cm (18 in.) Omit Omit Omit
UP5_E Omit Omit 1 req 5 req 137 cm (54 in.) Omit 5 req 1 req
UP6_A 1 req 1 req Omit Omit Omit 38 cm (15 in.) Omit Omit
UP6_B 1 req 1 req Omit Omit Omit 38 cm (15 in.) Omit Omit
UP6_C Omit Omit Omit 4 req 46 cm (18 in.) Omit Omit Omit
UP6_D Omit Omit Omit 4 req 46 cm (18 in.) Omit Omit Omit
UP6_E Omit Omit Omit 5 req 137 cm (54 in.) Omit 5 req 1 req


2 1 5328953_2 Gear carrier
3 1 1963318__ Nameplate
5 1 5328877_1 Frame
8 Refer to Table A-37 8-8CBI2-B Elbow
12 8 197743_3 Ty-wrap
14 1 1951611_4 Shaft seal
16 1 198517_2 Ratchet assembly
17 1 5325349_1 Clutch lever
18 1 1951611_3 Shaft seal
20 1 5328930_1 Pointer
21 1 5328934_2 Drive shaft
26 1 5329010_1 Roller chain
28 1 5324693_2 Bushing
29 1 5328956_2 Chain sector

SPARE PARTS


32 2 193221_1 Bearing
33 2 197105_4 Alemite fitting
34 1 198512_2 Key
35 1 1963488_1 Scale
36 1 5329008_1 Chain anchor
37 4 197730_1 Cotter pin
42 1 Refer to Tables Cylinder
A-37, 8-3, 8-4 and
Figures 8-4 and
8-5
43 1 1947271_2 Desig plate
46 1 197675_1 Washer
47 4 5328949_1 Bolt plate
48 2 1951569_5 Button plug
49 2 5328889_1 Clevis pin
50 1 1963489_2 Desig plate
51 1 1963489_1 Desig plate
52 1 1951608_1 Shut off valve
54 1941401_2 Solderless terminal
55 2 5328436_1 Cap screw
57 1 Refer to Table Solenoid valve
A-37
58 Refer to Table A-37 5323705_1 Elbow
60 140 cm (55 in.) R9021-0050 0.500 OD nylon tubing
62 4 Semi-fin steel reg hex full nut (0.625-11)
65 20 Indented hex washer, Zn plated steel threaded cutting screw
(0.250-20 x 0.500)
68 152 cm (60 in.) R1021-0022 0.250 OD Al tubing

A - 74
SPARE PARTS


70 1 Zn plated steel type 1 groove pin (0.250 dia x 1.250)
73 Refer to Table A-37 3
8 NPT brass coupling
75 1 Soc hex hdls Zn plated steel set screw (0.190-32 x 0.312)
76 91 cm (36 in.) R2041-1594 14 AWG black leadwire
79 Refer to Table A-37 488907_9 Grommet
81 Refer to Table A-37 Brass close nipple ( 3 8 )
82 2 8-4OBI2-B Female branch tee
83 1 5328902_1 Crank arm
84 1 1963488_2 Scale
85 1 8 x 13 poly bag
NOTE:
1. Older models have plastic top covers. To order a plastic top cover, use Part No. 5329053_1.
Table A-37. UP5 and UP6 Solenoid Valves and Unique Items, Figure A-23
Items Item Item Item Item

Type Voltage Item 8 Item 10 Item 42 Item 57
53, 54 58 73 79 81
UP5_5 120 VAC 1 req 1947578_1 5328952_1 2 req 1951013_1 5 req 1 req 1 req 1 req
UP5_6 115/125 VDC 1 req 1947578_1 5328952_1 2 req 1951013_3 5 req 1 req 1 req 1 req
UP5_8 120 VAC 1 req 1947711_1 5328952_1 4 req 1951135_1 5 req 1 req 2 req 1 req
UP5_9 115/125 VDC 1 req 1947711_1 5328952_1 4 req 1951135_2 5 req 1 req 2 req 1 req
UP5_F 220/240 VAC 1 req 1947578_1 5328952_1 2 req 1951013_2 5 req 1 req 1 req 1 req
UP5_G 220/240 VAC 1 req 1947711_1 5328952_1 4 req 1951135_4 5 req 1 req 2 req 1 req
UP6_5 120 VAC 3 req 1947578_1 5328945_1 2 req 1951013_1 3 req Omit 1 req Omit
UP6_6 115/125 VDC 3 req 1947578_1 5328945_1 2 req 1951013_3 3 req Omit 1 req Omit
UP6_8 120 VAC 3 req 1947711_1 5328945_1 4 req 1951135_1 3 req Omit 2 req Omit
UP6_9 115/125 VDC 3 req 1947711_1 5328945_1 4 req 1951135_2 3 req Omit 2 req Omit
UP6_F 220/240 VAC 3 req 1947578_1 5328945_1 2 req 1951013_2 3 req Omit 1 req Omit
UP6_G 220/240 VAC 3 req 1947711_1 5328945_1 4 req 1951135_4 3 req Omit 2 req Omit

SPARE PARTS

A - 76
SPARE PARTS

SPARE PARTS
Table A-38. UP5 and UP6 Alarm/Travel Switch Kit, Figure A-24 (Kit No. 5328962 _1)

1 1 19934_208 Spacer
3 1 5328596_2 Arm
6 1 5328698_1 Alarm unit
7 1 Steel dowel pin (0.375 x 1.500)
8 1 5328924_1 Coupler
13 2 Hex socket hdls Zn plated steel cup pt set screw
(0.190-32 x 0.312)
17 1 1963318__ Nameplate
18 1 No. 20 Carton
19 1 5328962 Print
Figure A-24 (Kit No. 5328962 _2)

1 1 19934_208 Spacer
3 1 5328596_2 Arm
7 1 Steel dowel pin (0.375 x 1.500)
8 1 5328924_1 Coupler
10 1.5 m (5.0 ft) R2041-1583 22 AWG white/gray leadwire
11 1.5 m (5.0 ft) R2041-1582 22 AWG white/violet leadwire
13 2 Hex socket hdls Zn plated steel cup pt set screw
(0.190-32 x 0.312)
17 1 1963318__ Nameplate
18 1 No. 20 Carton
19 1 5328962 Print

A - 78
SPARE PARTS
Figure A-24. UP5 and UP6 with Electric Shaft Position Transmitter and/or Alarm/Travel Switches, Tables A-38,
A-39, A-48 and A-49 (Sheet 1 of 2)

SPARE PARTS
Figure A-24. UP5 and UP6 with Electric Shaft Position Transmitter
and/or Alarm/Travel Switches, Tables A-38,
A-39, A-48 and A-49 (Sheet 2 of 2)

A - 80
SPARE PARTS
Table A-40. UP5 and UP6 Pneumatic Shaft Position

Transmitter Kit, Figure A-25(Kit No. 5328963 _1)

2 2 5311759_1 Ball joint
3 1 5328958_1 Transmitter drive rod
5 4 Pan head Zn plated steel cap screw (0.250-20 x 0.500)
9 122 cm (4 ft) R1021-0022 0.250 OD x 0.040 wall Al tubing
11 1 -18 NPT brass pipe plug
13 1 AV1_2000 Positioner assembly
14 1 1963318__ Nameplate
16 1 No. 24 Carton
17 1 5328963 Print

SPARE PARTS
Figure A-25. UP5 and UP6 with Pneumatic Shaft Position Transmitter, Table A-40 (Sheet 1 of 2)

A - 82
SPARE PARTS
Figure 25. UP5 and UP6 with Pneumatic Shaft Position Transmitter, Table A-40 (Sheet 2 of 2)

SPARE PARTS
Table A-41. UP5 and UP6 with Positioner Air Failure

Lock Kit, Figure A-26 (Kit No. 5328964 _1)

3 1 1951608_1 Shutoff valve
9 1 1951589_1 Air valve
10 1 1963318__ Nameplate
11 1 NPT brass tee
12 1 Brass reducing bushing ( x )
18 2 Brass reducing bushing ( 8
3
x )
20 4.3 m (14.0 ft) R9021-0050 OD nylon tubing
24 3 std brass pipe plug
25 1 Cotton draw string bag
26 1 No. 100 Carton
27 1 5328964 Print
29 1
1
8 brass pipe plug
30 1 3053306 Print

A - 84
SPARE PARTS
Table A-42. UP5 and UP6 with Solenoid Valve Air

Failure Lock Kit, Figure A-26
(Kit No. 5328964 _2)

9 1 1951589_1 Air valve
10 1 1963318__ Nameplate
11 1 NPT brass tee
12 1 Brass reducing bushing ( x )
18 2 Brass reducing bushing ( 3 8 x )

20 4.3 m (14.0 ft) R9021-0050 OD nylon tubing
24 3 std brass pipe plug
25 1 Cotton draw string bag
26 1 No. 100 Carton
27 1 5328964 Print
29 1
1
8 brass pipe plug
30 1 3053306 Print

SPARE PARTS
Figure A-26. UP5 and UP6 with Air Failure Lock, Tables A-41 and A-42 (Sheet 1 of 2)

A - 86
SPARE PARTS
Figure A-26. UP5 and UP6 with Air Failure Lock, Tables A-41 and A-42 (Sheet 2 of 2)

SPARE PARTS
Table A-43. UP5 and UP6 Reserve Air Tank Kits,

Figure A-27 (Kit Nos. 5328964 ___)

1 1 1941099 _2 Pressure switch
2 1 1941147 _1 molded bushing
3 1 1951608 _1 Shut-off valve for UP5 and UP6 with positioner (kit no.
5328964__1). Omit for UP5 and UP6 with solenoid valve (kit
no. 5328964__2).
4 1 5328959 _1 Valve mounting bracket
5 2 5318451 _2 3-way pneumatic valve
6 1 1963478 _1 Instruction plate
7 1 1951609 _1 Bulkhead fitting
8 1 5328782 _1 Air failure lock harness
9 1 1951712 _1 Check valve
10 1 1963318 __ Universal nameplate
11 1 NPT brass tee
12 1 ( x ) brass reducing bushing
14 4 1951407 _1 Male connector
( 8 x ) brass reducing bushing for UP5 and UP6 with posi-
3
18 2
tioner (kit no. 5328964__1). Omit for UP5 and UP6 with sole-
noid valve (kit no. 5328964__2).
19 2 4-4FB12-B Male connector for UP5 and UP6 with positioner (kit no.
5328964__1). Omit for UP5 and UP6 with solenoid valve (kit
no. 5328964__2).
20 4.3 m (14 ft) R9021-0050 0.500 OD nylon tubing
21 4.3 m (14 ft) R1021-0022 0.250 OD x 0.040 wall tubing
24 1 NPT brass tee
27 1 1951408 _1 Male elbow
29 1 1941817 _1 Conduit gasket
30 2 1941817 _3 Conduit gasket
31 2 1951612 _1 Bulkhead fitting
32 1 1963489 _4 Designation plate
33 1 1951785 _8 30.3 liter (8.0 gallon) air tank assembly for UP5
(kit no. 5328964 _ 5 _) (Fig. B-11).
1951785 _17 64.4 liter (17.0 gallon) air tank assembly for UP6
(kit no. 5328964 _ 6 _ ) (Fig. B-12)
34 1 C3053544-Sh2 Print

A - 88
SPARE PARTS
Figure A-27. UP5 and UP6 with Reserve Air Tank, Table A-43 (Sheet 1 of 2)

SPARE PARTS
Figure A-27. UP5 and UP6 with Reserve Air Tank, Table A-43 (Sheet 2 of 2)

A - 90
SPARE PARTS

2 5311428_41 O-ring 1 195852_1 Wiper ring
1 195825_9 O-ring 1 5311428_24 O-ring
1 1951359_220 O-ring 1 No. 39 Carton
2 195851_1 Back up ring 1 258241 Print

2 5311428_39 O-ring 1 5311428_24 O-ring
1 5328941_1 Piston 1 195852_1 Wiper ring
1 195825_9 O-ring A/R 199354_1 Lubricant
2 195851_1 Back up ring 1 No. 18 Carton
1 1951359_220 O-ring 1 258242 Print
Table A-46. UP5 and UP6 Heater Kits, Figure A-28 (Kit Nos. 5328965 _1/3)

3 1 195105_10 Tube clamp
7 2 1943002_1 Strip heater for 120 VAC operation (kit no. 5328965_1)
1943002_2 Strip heater for 240 VAC operation (kit no. 5328965_3)
8 4 19934_87 Spacer
9 2.6 m2 (28.0 ft2) 5318366_1U Fiberglass insulation
10 1 1963318__ Nameplate
12 3 m (10 ft) R2049-0100 14 AWG natural leadwire
14 4 NBZAC21016 slotted pan head screw (0.250-20)
15 4 NTKAC25000 Shakeproof lockwasher (0.250)
16 1 5328965 Print
17 1 No. 17 Carton

SPARE PARTS
Figure A-28. UP5 and UP6 Actuators with Heater, Table A-46 (Sheet 1 of 2)

A - 92
SPARE PARTS
Table A-47. UP6 Volume Boosters Kit, Figure A-29 (Kit No. 5329155)

3 2 5328021_2 Volume booster
4 1 5328018_1 Supply manifold
5 2 5328018_2 Supply manifold
6 1 5329016_1 Bottom flange
7 1 5329017_1 Top flange
8 2 1951772_1 Hose fitting (male)
9 8 1951773_1 Hose fitting (female)
11 5 5328013_1 SAE/NPT male elbow
12 3 5328014_1 SAE/NPT male connector
13 1 5323705_1 Elbow
15 4 195426_1 brass close nipple
17 3 195153_ brass tee
18 2 1951408_1 Male elbow
19 4 195137_ 90_ street elbow
20 1 1963318__ Nameplate
21 A/R 197743_3 Ty-wrap
23 2 -14 NPT brass pipe plug
24 6.1 m (20.0 ft) R9025-0033 0.750 ID black synthetic rubber hose with textile braid
reinforcement
25 2.4 m (8.0 ft) R9021-0050 0.062 wall x 0.500 OD polyester reinforced nylon tubing
26 A/R NPTAC18032 Cherry N rivet
27 6 NIEAC16008 Hex sems ext (0.190-32)
30 12 NTAAC11000 Flat washer (0.250)
32 1 3053268 Sh 2 Print

SPARE PARTS
Figure A-28. UP5 and UP6 Actuators with Heater, Table A-46 (Sheet 2 of 2)

A - 94
SPARE PARTS
Figure A-29. UP6 Actuators with Volume Boosters, Table A-47
A - 95
SPARE PARTS
PARTS KITS FOR ALL ACTUATORS
Tables A-48 and A-49 and Figure A-30 apply to all types of actuators.
Table A-48. Parts List for Alarm/Travel Switch Kit, Figure A-30 (Part No. 5328698 _1)

2 1 197675_1 Washer
6 4 6614403_1 Switch cam
8 1 5328700_1 Shaft
11 2 1947261_1 Shield
12 1 5328701_1 Bracket
21 2 5328703_1 Spacer block
25 1.1 cm (4.5 in.) R2041-0070 18 AWG brown leadwire
26 1.1 cm (4.5 in.) R2041-0075 18 AWG yellow leadwire
27 1.1 cm (4.5 in.) R2041-0050 18 AWG orange leadwire
28 1.1 cm (4.5 in.) R2041-0055 18 AWG blue leadwire
29 1.1 cm (4.5 in.) R2041-1712 18 AWG white/blue leadwire
30 1.1 cm (4.5 in.) R2041-0035 18 AWG red leadwire
45 1 No. 62 Carton

A - 96
SPARE PARTS
Table A-49. Parts List for Electric Shaft Position Transmitter

Kit, Figure A-30 (Part No. 5328698 _2)1

14 1 5328702_1 Coupler
15 2 197723_1 Brass tip set screw
16 1 5839B01P0001 Feedback potentiometer
17 1 5328704_1 Transmitter bracket
18 3 197688_3 Threaded spacer
19 1 6633390_2 Transmitter board assembly
23 3 1946162_1 Pin receptacle
24 3 197688_6 Hex standoff
31 10 cm (4 in.) R2041-1664 22 AWG white/green leadwire
32 10 cm (4 in.) R2041-1666 22 AWG white/violet leadwire
33 10 cm (4 in.) R2041-1667 22 AWG white/gray leadwire
34 3 Pan head Zn plated steel sems ext
(0.138-32 x 0.250)
41 2 Pan head Zn plated steel sems int
(0.190-32 x 0.250)
43 2.5 cm (1.0 in.) R9023-0165 Insulation tubing
46 1 67125_3 Grommet
47 1 6637721_1 EMI bottom cover
48 1 6637740_1 EMI top cover
49 3 NTMAC13000 Lockwasher
50 3 NLMAC13000 Hex nut
NOTE:
1. Use alarm/travel switch kit part no. 5328698 _1 (refer to Table A-48) as a base and add the parts listed in this
table to complete the electric shaft position transmitter kit.
PARTS KITS FOR ALL ACTUATORS A - 97

SPARE PARTS
Figure A-30. Alarm/Travel Switches and Electric Shaft

Position Transmitter, Tables A-48 and A-49

A - 98
APPENDIX B - DIMENSION DRAWINGS
DIMENSION DRAWINGS
HAND AND ACTUATOR LINKAGE

LEVER MAY BE MOUNTED AT
ANY ANGLE (SEE NOTE 2) C
L
296.2 609.6
11.66 24.00
(SEE NOTE 1)
14.2
0.56
127.0
90 TRAVEL 152.4 5.00
177.8 6.00
RAD
7.00 RAD
546.1 RAD
21.50
12.7 DIA
0.50 304.8
(3 HOLES) 393.7
12.00 15.50
RAD
203.2
8.00 13.5 WIDE 16.5 LONG
(SEE NOTE 1) 0.53 WIDE 0.65 LONG
MIN. MOUNTING 4 SLOTS FOR 0.5 BOLTS
BOLT EXTENSION 22.4 SAE GR. 5 CARBON STEEL.
0.88
ABOVE FLOOR TORQUE TO 54.2 6.8 NM
C
L ROTARY (40 5 FT-LB).
153.9 ACTUATOR
6.06 SHAFT 127.0 52.3 124.0
330.2
13.00 5.00 2.06 4.88
368.3 (SEE NOTE 1)
14.50
DIMENSIONS
NOTES:
1. MINIMUM CLEARANCE FOR ADJUSTMENT, INSPECTION, MAINTENANCE AND OPERATION REQUIRED. MILLIMETERS
INCHES
2. AFTER POSITIONING ACTUATOR LEVER, TORQUE TWO 0.375 IN. SOCKET HEAD CAP SCREWS TO 74.6 2.7 NM (55 2 FT-LB).
3. MAXIMUM AMBIENT TEMPERATURE LIMIT = 82C (180F). SOME ACTUATOR/POSITIONER COMBINATIONS MAY HAVE A SLIGHTLY
LOWER MAXIMUM AMBIENT TEMPERATURE LIMIT. REFER TO THE APPROPIATE POSITIONER SPECIFICATION. TP20114B .
Figure B-1. Type UP1 Actuator with Type AV Positioner
DIMENSION DRAWINGS
B-1
DIMENSION DRAWINGS
HAND AND ACTUATOR

LINKAGE LEVER MAY BE CL
MOUNTED AT ANY ANGLE
99.6 296.2 609.6
3.92
(SEE NOTE 2) 11.66 24.00
(SEE NOTE 1)
14.2
0.56
90
TRAVEL
127.0
152.4 5.00
177.8 6.00 RAD
7.00 RAD
12.7 DIA RAD
546.1
0.50 21.50
(3 HOLES)
304.8
393.7
12.00
15.50
RAD 13.5 WIDE 16.5 LONG
0.53 WIDE 0.65 LONG
203.2 4 SLOTS FOR 0.5 BOLTS,
8.00 SAE GR. 5 CARBON STEEL.
(SEE NOTE 1) TORQUE TO 54.2 6.8 NM
APPROX
(40 5 FT-LB).
76.2 153.9
3.00 6.06
CL ACTUATOR
MIN. MOUNTING 330.2 SHA FT
22.4 127.0 52.3 124.0
BOLT EXTENSION 0.88 13.00 368.3 5.00 2.06 4.88
ABOVE FLOOR 14.50 (SEE NOTE 1)
DIMENSIONS
NOTES: MILLIMETERS
INCHES
1. MINIMUM CLEARANCE FOR ADJUSTMENT, INSPECTION, MAINTENANCE AND OPERATION REQUIRED.
3. MAXIMUM AMBIENT TEMPERATURE LIMIT = 82C (180F). SOME ACTUATOR/POSITIONER COMBINATIONS MAY HAVE A SLIGHTLY LOWER
MAXIMUM AMBIENT TEMPERATURE LIMIT. REFER TO THE APPROPRIATE POSITIONER SPECIFICATION. TP20115B .
Figure B-2. Type UP1 Actuator with Type AV Positioner and Air Failure Lock
HAND AND ACTUATOR

LINKAGE LEVER MAY HAND AND ACTUATOR
BE MOUNTED AT ANY CL LINKAGE LEVER
ANGLE (NOTE 2) 343.7 609.6
13.53 24.00
(NOTE 1)
14.2
90 0.56
TRAVEL
127.0
152.4
177.8 6.00 5.00
7.00 RAD RAD
546.1 RAD
21.50
304.8
12.00
RAD 393.7
12.7 DIA 13.5 WIDE 16.5 LONG
15.50
0.50 0.53 WIDE 0.65 LONG
203.2 (3 HOLES) 4 SLOTS FOR 0.5 BOLTS,
FOR 0.50 IN. 22.2 (NOTE 1) TORQUE TO 54.2 6.8 NM
CONDUIT 0.88 DIA (40 5 FT-LB)
CONNECTOR 81.8
3.22 DIMENSIONS
47.2
MINIMUM 1.86 MILLIMETERS
153.9 127.0 124.0 INCHES
MOUNTING
22.4 6.06 CL ACTUATOR 5.00 52.3 4.88
BOLT 330.2 SHAFT
0.88 (NOTE 1) 2.06
EXTENSION 13.00 368.3
ABOVE FLOOR
14.50
NOTES:
2. AFTER POSITIONING ACTUATOR LEVER, TORQUE TWO 0.375 in. SOCKET HEAD CAP SCREWS TO 67.8 6.8 NM
(50 5 FT-LB).
3. MAXIMUM AMBIENT TEMPERATURE LIMIT = 82C (180F). SOME ACTUATOR/POSITIONER COMBINATIONS MAY
HAVE A SLIGHTLY LOWER MAXIMUM AMBIENT TEMPERATURE LIMIT. REFER TO THE APPROPRIATE
POSITIONER SPECIFICATION.
TP20113B .
Figure B-3. Type UP1 Actuator with Type AV Positioner, Electric

Shaft Positioner and/or Alarm/Travel Switches
DIMENSION DRAWINGS
B-2
DIMENSION DRAWINGS
POSITION HAND AND ACTUATOR

INDICATOR HAND AND ACTUATOR
LINKAGE LEVER MAY BE CL
LINKAGE LEVER
MOUNTED AT ANY ANGLE 321.6 457.2
(NOTE 2) 12.66 18.00
(NOTE 1)
14.2
90 0.56
TRAVEL
B
A
127.0
152.4
177.8 6.00 5.00
7.00 RAD RAD
543.1 RAD
21.38
304.8
12.00
RAD 393.7
15.50
13.5 WIDE 16.5 LONG
12.7 DIA 0.53 WIDE 0.65 LONG
(3 HOLES) SAE GR. 5 CARBON STEEL.
153.9 TORQUE TO 54.2 6.8 NM
6.06 (40 5 FT-LB)
CL ACTUATOR
MINIMUM 330.2 SHAFT 127.0 124.0
MOUNTING BOLT 22.4 13.00 368.3 127.0 5.00 4.88
52.3
EXTENSION 0.88 376.9
14.50 5.00 (NOTE 1) 2.06
ABOVE FLOOR (NOTE 1)
14.84
DIMENSIONS
NOTES: MILLIMETERS
1. MINIMUM CLEARANCE FOR ADJUSTMENT, INSPECTION, MAINTENANCE AND OPERATION REQUIRED. INCHES
2. AFTER POSITIONING ACTUATOR LEVER, TORQUE TWO 0.375 IN. SOCKET HEAD CAP SCREWS TO
74.5 2.7 NM (55 2 FT-LB).
3. MAXIMUM AMBIENT TEMPERATURE LIMIT = 82C (180F).
TP20110B .
Figure B-4. Type UP1 Actuator with Solenoid Valve
HAND AND
ACTUATOR LINKAGE HAND AND ACTUATOR
CL
LEVER MAY BE LINKAGE LEVER
MOUNTED AT ANY 94.0
321.5 457.2
ANGLE (NOTE 2) 12.66 18.00
3.70
(NOTE 1)
14.2
0.56
90
TRAVEL
B
A
127.0
177.8 152.4 5.00
7.00 6.00 RAD
12.7 DIA 543.1 RAD RAD
0.50 21.38
(3 HOLES)
304.8
12.00 393.7
RAD 15.50
13.5 WIDE 16.5 LONG

0.53 WIDE 0.65 LONG
TORQUE TO 54.2 6.8 NM
CL ACTUATOR
MINIMUM (40 5 FT-LB)
330.2 SHAFT 127.0 127.0
MOUNTING 13.00
124.0
22.4 368.3 5.00 5.00 4.88
BOLT 52.3
0.88 376.9 14.50 (NOTE 1) (NOTE 1)
EXTENSION 2.06
14.84
ABOVE FLOOR DIMENSIONS
MILLIMETERS
INCHES
NOTES:
3. MAXIMUM AMBIENT TEMPERATURE LIMIT = 82C (180F).
TP20112B .
Figure B-5. Type UP1 Actuator with Solenoid Valve and Air Failure Lock
DIMENSION DRAWINGS B-3

DIMENSION DRAWINGS
POSITION
INDICATOR
POSITION NPT CONDUIT CONNECTION NPT CUSTOMER
INDICATOR ONE FOR UP1 # [5,6,F]# # # 0 MANUAL AIR SUPPLY
TWO FOR UP1 # [8,9,G]# # # 0 ACTUATOR LOCK BOLT CONNECTION P
689 KPA (100 PSIG)
ADJUSTABLE STOP
5/16 HEX HEAD

CAP SCREWS (2)
B 9 A AT 125 VAC/VDC
BRN
A C1NO
C1 YEL
C1NC
ORN
C1C 3/8 NPT
15 A AT 125/250 VAC
C2
BLU C2NO PORT E
WHT/BLU
C2NC
RED
15 A AT 125/250 VAC
C2C SOLENOID
BRN
C3NO VALVE
C3 YEL
SWITCH C1
C3NC
ORN C3C
9 A AT 125 VAC/VDC SWITCH C2
BLU
C4
C4NO ELECTRIC
WHT/BLU
C4NC TRANSMITTER
RED
SWITCH C3
C4C
SWITCH C4 (4-20 mA)
CONTACT WIRING DIAGRAM
(NOTE 1)
ENCLOSURE
HAND AND ACTUATOR
ENCLOSURE MOUNTING GROUND
LINKAGE LEVER
SCREWS (4) SCREW
NOTES:
1. CONTACTS MUST BE DERATED 1.5 A FOR EVERY 10C (18F) RISE ABOVE 60C (140F).
TP20101B .
Figure B-6. Type UP1 Actuator with Solenoid Valve, Electric Shaft
Position Transmitter and/or Alarm/Travel Switches
609.6
SEE NOTE 1
24.00
HAND AND ACTUATOR

LIINKAGE (NOTE 3) 294.6
11.60
127.0
5.00
RAD 196.9 392.4
7.75 254.0 15.45
25.4 DIA RAD 10.00 RAD
1.00
14.3 MM (3 HOLES) RAD
381.0
(0.56 IN.) DIA. 15.00
4 HOLES FOR RAD
0.50 BOLTS, SAE
GR. 5 CARBON
STEEL. TORQUE
TO 47.5 NM
(35 FT-LB).
25.4 139.7
31.8 90 TRAVEL
1.00 5.50
1.25 355.6
165.1 69.1 127.0 14.00
6.50 2.72 5.00 66.0 393.7
609.6 457.2 (SEE NOTE 1) 2.60 15.50
24.00 18.00
CL HAND AND ACTUATOR
(NOTE 1) DIMENSIONS
LINKAGE LEVER
MILLIMETERS
NOTES: INCHES
2. MAXIMUM AMBIENT TEMPERATURE LIMIT = 82C (180F). SOME ACTUATOR/POSITIONER COMBINATIONS MAY HAVE A SLIGHTLY
LOWER MAXIMUM AMBIENT TEMPERATURE LIMIT. REFER TO THE APPROPRIATE POSITIONER SPECIFICATION.
3. AFTER POSITIONING ACTUATOR LEVER, TORQUE TWO 0.50 SOCKET HEAD CAP SCREWS TO 88.13 NM (65 FT-LB). TP20116A .
Figure B-7. Type UP2 Actuator with Type AV

Positioner or Solenoid Valve
DIMENSION DRAWINGS
B-4
DIMENSION DRAWINGS
254.0
SEE NOTE 1
10.00
660.4 254.0 495.3

322.1 26.00 10.00 19.50 345.5
190.2 12.68 (SEE NOTE 1) 13.64
173.2
7.49 6.82
21.8
25.4 DIA
0.86
1.00
90 TRAVEL (3 HOLES)
127.0
279.4 RAD 50
5.00
11.00 197.1 ACTUATOR
7.76 1177.3
LEVER MAY
254.0 46.35
BE ON EITHER
10.00
SIDE AND AT
14 INTERVALS
25.4
1.00
778.8
30.66
38.1
1.50
V1 AFC
MINIMUM S1
E1 E2
MOUNTING 77.7
BOLT EXTENSION 3.06
31.8 288.8 ABOVE FLOOR 63.0 33.5
1.25 11.37 577.9 83.8 2.48 1.32
22.75 3.30
609.6 641.4 457.2 89.2 266.7
24.00 25.25 18.00 3.51 10.50
(SEE NOTE 1) (SEE NOTE 1) DIMENSIONS
MILLIMETERS
NOTES: INCHES
1. MINIMUM CLEARANCE FOR ADJUSTMENTS, INSPECTION, MAINTENANCE AND OPERATION REQUIRED.
2 MAXIMUM AMBIENT TEMPERATURE LIMIT = 82 C (180 F). SOME ACTUATOR/POSITIONER COMBINATIONS MAY HAVE A SLIGHTLY LOWER MAXIMUM
AMBIENT TEMPERATURE LIMIT. REFER TO THE APPROPRIATE POSITIONER SPECIFICATION.
3. NO OTHER WIRES SHALL BE IN CONDUIT USED FOR TYPE UP[3,4]! [C,D,E] SIGNAL.
4. IF SHIELDED CABLE IS USED, SHIELD GROUNDING SHOULD BE CONSISTENT WITH SYSTEM REQUIREMENTS.
5. AFTER MOUNTING ACTUATOR IN PLACE, BUT BEFORE TIGHTENING MOUNTING BOLTS, SHIM SO THAT MOUNTING BOLTS, WHEN TIGHTENED, WILL
NOT WARP FRAME. TEST BY NOTING FREEDOM OF ACTUATOR LEVER SHAFT WITH PISTON ROD CLEVIS PIN REMOVED SO THAT
TP20127B .
PISTON IS DISCONNECTED.
Figure B-8. Types UP3 and UP4 Actuators (Page 1 of 2)

DIMENSION DRAWINGS
DIMENSIONS
MILLIMETERS
INCHES
5
PNEUMATIC
SHAFT POSITION
TRANSMITTER
PNEUMATIC I
O1 SUPPLY
SHAFT POSITION S CONNECTION S
TRANSMITTER O2
NPT 345 KPA
(50 PSIG) MAX
OUTPUT SIGNAL
S1 V1 A FC CONNECTION O2
E1 E2 NPT
540.8 609.6
21.29 24.0
TP20261B .
Figure B-9. Types UP3 and UP4 Actuators (Page 2 of 2)
446.0 RAD
17.56 406.4 RAD
16.00 304.8 RAD 254.0 827.0 254.0
10.00 32.56 10.00
12.00 (SEE NOTE 1) (SEE NOTE 1)
33.5
1.32
ACTUATOR LEVER
50 MAY BE LOCATED
31.8 DIA ON EITHER SIDE
1.25
AND AT 1115'
1365.0
90 TRAVEL INTERVALS
53.74
31.8
987.6 44.5 MM (1.75 IN.) 1.25
38.88 MIN TO 60.2 MM
(2.37 IN.) MAX
MOUNTING BOLT
28.4 MM (1.12 IN.) DIA. EXTENSION
ABOVE FLOOR
4 HOLES FOR 1.00 BOLTS,
ASTM 354 GR. BD, TORQUE
TO 542.3 27.1 NM
(400 20 FT-LB). 119.6
379.5 520.7
14.94 759.0 19.1 20.50 39.6 4.71
419.1 29.88 0.75 599.9 1.56
609.6 16.50 838.2 609.6 23.62
24.00 33.00 24.00 DIMENSIONS
(SEE NOTE 1) (SEE NOTE 1)
MILLIMETERS
INCHES
NOTES:
1. MINIMUM CLEARANCE FOR ADJUSTMENTS, INSPECTION, MAINTENANCE AND OPERATION REQUIRED.
2. MAXIMUM AMBIENT TEMPERATURE LIMIT = 82C (180F). SOME ACTUATOR/POSITIONER COMBINATIONS MAY HAVE A SLIGHTLY LOWER MAXIMUM
AMBIENT TEMPERATURE LIMIT. REFER TO THE APPROPRIATE POSITIONER SPECIFICATION.
3. NO OTHER WIRES SHALL BE IN CONDUIT USED FOR TYPE UP[5,6]! [C,D,E] SIGNAL.
4. IF SHIELDED CABLE IS USED, SHIELD GROUNDING SHOULD BE CONSISTENT WITH SYSTEM REQUIREMENTS.
5. AFTER MOUNTING ACTUATOR IN PLACE, BUT BEFORE TIGHTENING MOUNTING BOLTS, SHIM SO THAT MOUNTING BOLTS, WHEN TIGHTENED, WILL NOT
WARP FRAME. TEST BY NOTING FREEDOM OF ACTUATOR LEVER SHAFT WITH PISTON ROD CLEVIS PIN REMOVED SO THAT PISTON IS DISCONNECTED.
TP20117B .
Figure B-10. Types UP5 and UP6 Actuators
DIMENSION DRAWINGS
B-6
DIMENSION DRAWINGS
DIMENSIONS
MILLIMETERS
INCHES
254.0
10.00
101.6 -14 NPT
4.00 2 PLACES
254.0
10.00
45
158.8
6.25
6.35
0.25
25.4
38.1 228.6 1.00
30
1.50 9.00
206.4
457.2 8.13
18.00 TP20411A .
Figure B-11. 20.8 LIter (5.5 Gallon) Reserve Air Tank

Option for Type UP2 Actuators
203.2
8.00 15.9 33.3 4 SLOTS
0.63 1.31
152.4 304.8 DIA

6.00 12.00
DIMENSIONS
MILLIMETERS
INCHES
247.7
9.75
MALE ELBOW
228.6
9.00
MALE
ELBOW
482.6 203.2
19.00 8.00
TP36331A .
Figure B-12. 30.3 Liter (8.0 Gallon) Reserve Air Tank Option
for Types UP3, UP4 and UP5 Actuators

DIMENSION DRAWINGS
508.0
20.00
254.0 16.0 33.3 4 SLOTS
10.00 0.63 1.31
152.4 304.80
6.00 12.00
276.4
10.88 552.5
21.75 DIMENSIONS
MILLIMETERS
INCHES
939.8
37.00 381.0
15.00 1-11 NPT 30
190.5 1 - 11 NPT
3 PLACES
7.50 2 PLACES
30
228.6 -18 NPT

9.00 1 PLACE
4.8 TYP -14 NPT

0.19 3 PLACES
203.2
8.00
TP20428A .
Figure B-13. 64.4 Liter (17.0 Gallon) Reserve Air Tank for Type UP6 Actuators
DIMENSION DRAWINGS
B-8
Index
A Operating pressure ...............................................1-6

Pneumatic shaft position transmitter ...................3-31
AC safety ground........................................................ 3-8 Regulation .............................................................3-7
Air failure lock Regulators .............................................................3-8
Automatic operation with UP1 .............................. 5-5 UP1 ...................................................... 3-8, 3-9, 3-10
Automatic operation with UP2 .............................. 5-5 UP2 ...................................................... 3-8, 3-9, 3-10
Automatic operation with UP3 .............................. 5-9 UP3 ..............................................................3-8, 3-11
Automatic operation with UP4 .............................. 5-9 UP4 ..............................................................3-8, 3-11
Automatic operation with UP5 ............................ 5-14 UP5 ..............................................................3-8, 3-11
Automatic operation with UP6 ............................ 5-14 UP6 ..............................................................3-8, 3-11
Description.............................................. 1-8, 4-5, 5-1 Versus operating torque........................................3-8
Lock valve adjustment .......................................... 4-7 Alarm pressure switch
Manual operation .................................................. 5-1 Contact ratings ......................................................1-8
Manual operation with UP1................................... 5-5 Alarm/travel switches
Manual operation with UP2................................... 5-5 Adjustment procedure ...........................................4-4
Manual operation with UP3................................... 5-9 Calibration .............................................................4-4
Manual operation with UP4................................... 5-9 Description ............................................................1-8
Manual operation with UP5................................. 5-13 Illustration............................................................3-32
Manual operation with UP6................................. 5-13 Removal and replacement ..................................8-21
Remote reset ...................................................... 3-23 Shipping weight...................................................1-10
Replacement for UP1 ......................................... 8-17 Troubleshooting ....................................................6-3
Replacement for UP2 ......................................... 8-17 Wiring ..................................................................3-31
Replacement for UP3 ......................................... 8-18 Wiring for UP1 .....................................................3-32
Shipping weight .................................................. 1-10 Wiring for UP5 .....................................................3-33
Trip valve adjustment............................................ 4-6 Wiring for UP6 .....................................................3-33
Troubleshooting .................................................... 6-3 Annual or semiannual maintenance............................7-2
Tubing................................................................. 3-22 As required maintenance ............................................7-3
Tubing for UP1.................................................... 3-23 Automatic operation
Tubing for UP2.................................................... 3-24 Air failure lock........................................................5-1
Tubing for UP3.................................................... 3-26 Positioner ..............................................................5-1
Tubing for UP4.................................................... 3-26 Solenoid valve .......................................................5-1
Tubing for UP5.................................................... 3-29 UP1 with air failure lock.........................................5-5
Tubing for UP6.................................................... 3-29 UP1 with positioner ...............................................5-4
Tubing schematic for UP1 .................................. 3-25 UP1 with solenoid valve ........................................5-5
Tubing schematic for UP2 .................................. 3-27 UP2 with air failure lock.........................................5-5
Tubing schematic for UP3 .................................. 3-28 UP2 with positioner ...............................................5-4
Tubing schematic for UP4 .................................. 3-28 UP2 with solenoid valve ........................................5-5
Tubing schematic for UP5 .................................. 3-30 UP3 with air failure lock.........................................5-9
Tubing schematic for UP6 .................................. 3-30 UP3 with positioner ...............................................5-6
UP1....................................................................... 1-8 UP3 with solenoid valve ........................................5-9
UP2....................................................................... 1-8 UP4 with air failure lock.........................................5-9
UP3....................................................................... 1-8 UP4 with positioner ...............................................5-6
UP4....................................................................... 1-8 UP4 with solenoid valve ........................................5-9
UP5....................................................................... 1-8 UP5 with air failure lock.......................................5-14
UP6....................................................................... 1-8 UP5 with positioner .............................................5-11
Air filters ..................................................................... 1-9 UP5 with solenoid valve ......................................5-13
Air quality.................................................................. 3-10 UP6 with air failure lock.......................................5-14
Air supply UP6 with positioner .............................................5-11
Maintenance ......................................................... 7-2 UP6 with solenoid valve ......................................5-13
Index - 1
Index (continued)
C Troubleshooting .................................................... 6-2

UP1..................................................................... 8-20
Calibration UP2..................................................................... 8-20
Air failure lock........................................................4-5 UP3..................................................................... 8-20
Lock valve adjustment .....................................4-7 UP4..................................................................... 8-20
Trip valve adjustment ......................................4-6 UP5..................................................................... 8-20
Alarm/travel switches ............................................4-4 UP6..................................................................... 8-20
Electric shaft position transmitter ..........................4-4 Wiring.................................................................. 3-34
Equipment required ...............................................4-1 Wiring for reverse loading ................................... 3-37
Pneumatic shaft position transmitter .....................4-5 Wiring for UP1 .................................................... 3-35
Positioner gain adjustment ....................................4-3 Wiring for UP2 .................................................... 3-35
Positioner span adjustment ...................................4-2 Wiring for UP3 .................................................... 3-36
Positioner speed adjustment .................................4-3 Wiring for UP4 .................................................... 3-36
Positioner zero adjustment....................................4-1 Wiring for UP5 .................................................... 3-36
Reserve air tank ....................................................4-5 Wiring for UP6 .................................................... 3-36
Clutch Wiring loop diagram ............................................ 3-35
Clutch fork removal, inspection and replacement for Enclosure removal
UP5 .....................................................................8-13 Installation............................................................. 3-2
Illustration ......................................................8-13 UP1....................................................................... 3-2
Clutch fork removal, inspection and replacement for UP2....................................................................... 3-2
UP6 .....................................................................8-13 UP3....................................................................... 3-3
Illustration ......................................................8-13 UP4....................................................................... 3-3
Maintenance..........................................................7-2 UP5....................................................................... 3-6
Control loading UP6....................................................................... 3-6
Direct loading .............................................3-38, 3-39 Equipment application ................................................ 1-2
Electric shaft position transmitter ........................3-37 Equipment description ................................................ 1-1
Positioner ............................................................3-38 Equipment required for calibration.............................. 4-1
Reverse loading ..................................................3-39
Solenoid valve .....................................................3-39
F
Cylinder
Cleaning ................................................................8-7 Features ..................................................................... 1-2
Maintenance..........................................................7-3 Feedback potentiometer
Parts list for UP3 ...................................................8-8 Removal and replacement .................................. 8-21
Parts list for UP4 ...................................................8-9 Fucntional operation
Parts list for UP5 .................................................8-10 UP5....................................................................... 2-1
Parts list for UP6 .................................................8-11 Functional operation
Removal and replacement for UP3 .......................8-7 Master/slave ......................................................... 2-3
Removal and replacement for UP4 .......................8-7 Positioner .............................................................. 2-1
Removal and replacement for UP5 .......................8-7 Solenoid valve ...................................................... 2-1
Removal and replacement for UP6 .......................8-7 UP1....................................................................... 2-1
Repair....................................................................8-7 UP2....................................................................... 2-1
UP3....................................................................... 2-1
E UP4....................................................................... 2-1
UP6....................................................................... 2-1
Electric shaft position transmitter
Adjustment procedure ...........................................4-4
G
Calibration .............................................................4-4
Circuit board illustration.......................................3-37 Gain adjustment
Description ............................................................1-8 Positioner .............................................................. 4-3
Illustration ............................................................3-32 Grounding electrode system....................................... 3-9
Removal and replacement ..................................8-20
Shipping weight ...................................................1-10
Supply voltage and load resistance limits ...........3-36
Index - 2
Index (continued)
I UP4 with positioner ...............................................5-6

UP4 with solenoid valve ........................................5-8
Input ranges UP5 with air failure lock.......................................5-13
Positioner.............................................................. 1-6 UP5 with positioner .............................................5-10
Input ranges, positioner ....................................... 1-1, 1-4 UP5 with solenoid valve ......................................5-12
Installation UP6 with air failure lock.......................................5-13
Enclosure removal ................................................ 3-2 UP6 with positioner .............................................5-10
Grounding ............................................................. 3-8 UP6 with solenoid valve ......................................5-12
Location considerations ........................................ 3-1 Master/slave
UP1 enclosure removal ........................................ 3-2 Illustration............................................................3-17
UP2 enclosure removal ........................................ 3-2 Mechanical stop
UP3 enclosure removal ........................................ 3-3 Adjustment for UP1 .............................................3-42
UP4 enclosure removal ........................................ 3-3 Adjustment for UP2 .............................................3-42
UP5 enclosure removal ........................................ 3-6
UP6 enclosure removal ........................................ 3-6
N
Instruction content ...................................................... 1-2
Intended user ............................................................. 1-1 Nomenclature..............................................................1-4
Intended users............................................................ 1-1
ISA S7.3 ................................................................... 3-10 O
L Operating lever
Adjustment ..........................................................3-40
Linkage Maintenance ................................................. 7-2 UP1 .....................................................................3-40
Location considerations.............................................. 3-1 UP2 .....................................................................3-40
UP3 .....................................................................3-41
M UP4 .....................................................................3-41
UP5 .....................................................................3-41
Maintenance UP6 .....................................................................3-41
Air supply .............................................................. 7-2 Operation
Annual or semiannual ........................................... 7-2 Automatic ..... 5-1, 5-4, 5-5, 5-6, 5-9, 5-11, 5-13, 5-14
As required ........................................................... 7-3 Air failure lock ..................................................5-1
Clutch.................................................................... 7-2 Positioner ........................................................5-1
Cylinder................................................................. 7-3 Solenoid valve .................................................5-1
Linkage ................................................................. 7-2 UP1 with air failure lock ...................................5-5
Periodic................................................................. 7-1 UP1 with positioner..........................................5-4
Positioner....................................................... 7-2, 7-3 UP1 with solenoid valve ..................................5-5
Reserve air tank.................................................... 7-2 UP2 with air failure lock ...................................5-5
Roller chain........................................................... 7-2 UP2 with positioner..........................................5-4
Rotary vane .......................................................... 7-3 UP2 with solenoid valve ..................................5-5
Manual operation UP3 with air failure lock ...................................5-9
Air failure lock ....................................................... 5-1 UP3 with positioner..........................................5-6
Positioner.............................................................. 5-1 UP3 with solenoid valve ..................................5-9
Solenoid valve ...................................................... 5-1 UP4 with air failure lock ...................................5-9
UP1 with air failure lock ........................................ 5-5 UP4 with positioner..........................................5-6
UP1 with positioner............................................... 5-2 UP4 with solenoid valve ..................................5-9
UP1 with solenoid valve........................................ 5-4 UP5 with air failure lock .................................5-14
UP2 with air failure lock ........................................ 5-5 UP5 with positioner........................................5-11
UP2 with positioner............................................... 5-2 UP5 with solenoid valve ................................5-13
UP2 with solenoid valve........................................ 5-4 UP6 with air failure lock .................................5-14
UP3 with air failure lock ........................................ 5-9 UP6 with positioner........................................5-11
UP3 with positioner............................................... 5-6 UP6 with solenoid valve ................................5-13
UP3 with solenoid valve........................................ 5-8
UP4 with air failure lock ........................................ 5-9
Index - 3
Index (continued)
Manual.... 5-1, 5-2, 5-4, 5-5, 5-6, 5-8, 5-9, 5-10, 5-12, UP5..................................................................... 3-41
5-13 UP6..................................................................... 3-41
Air failure lock ..................................................5-1 Positioner
Positioner.........................................................5-1 Automatic operation .............................................. 5-1
Solenoid valve .................................................5-1 Automatic operation with UP1 .............................. 5-4
UP1 with air failure lock ...................................5-5 Automatic operation with UP2 .............................. 5-4
UP1 with positioner..........................................5-2 Automatic operation with UP3 .............................. 5-6
UP1 with solenoid valve ..................................5-4 Automatic operation with UP4 .............................. 5-6
UP2 with air failure lock ...................................5-5 Automatic operation with UP5 ............................ 5-11
UP2 with positioner..........................................5-2 Automatic operation with UP6 ............................ 5-11
UP2 with solenoid valve ..................................5-4 Control loading.................................................... 3-38
UP3 with air failure lock ...................................5-9 Gain adjustment.................................................... 4-3
UP3 with positioner..........................................5-6 Input ranges ................................................... 1-1, 1-6
UP3 with solenoid valve ..................................5-8 Maintenance .................................................. 7-2, 7-3
UP4 with air failure lock ...................................5-9 Manual operation .................................................. 5-1
UP4 with positioner..........................................5-6 Manual operation with UP1................................... 5-2
UP4 with solenoid valve ..................................5-8 Manual operation with UP2................................... 5-2
UP5 with air failure lock .................................5-13 Manual operation with UP3................................... 5-6
UP5 with positioner........................................5-10 Manual operation with UP4................................... 5-6
UP5 with solenoid valve ................................5-12 Manual operation with UP5................................. 5-10
UP6 with air failure lock .................................5-13 Manual operation with UP6................................. 5-10
UP6 with positioner........................................5-10 Removal and replacement for UP1....................... 8-2
UP6 with solenoid valve ................................5-12 Removal and replacement for UP2....................... 8-2
UP1 operating controls - illustration ......................5-3 Removal and replacement for UP3....................... 8-2
UP5 operating controls - illustration ....................5-10 Span adjustment ................................................... 4-2
UP6 operating controls - illustration ....................5-10 Speed adjustment................................................. 4-3
Troubleshooting ............................................. 6-1, 6-2
P Tubing ........................................................ 3-11, 3-13
Tubing for UP1........................................... 3-11, 3-13
Periodic maintenance..................................................7-1 Tubing for UP2........................................... 3-11, 3-13
Pneumatic shaft position transmitter Tubing for UP3........................................... 3-12, 3-13
Adjustment procedure ...........................................4-5 Tubing for UP4........................................... 3-12, 3-13
Air supply.............................................................3-31 Tubing for UP5........................................... 3-12, 3-14
Calibration .............................................................4-5 Tubing for UP6........................................... 3-12, 3-14
Removal and replacement ..................................8-22 Wiring.................................................................. 3-13
Shipping weight ...................................................1-10 Wiring for UP1 .................................................... 3-13
Troubleshooting.....................................................6-2 Wiring for UP2 .................................................... 3-13
Tubing .................................................................3-30 Wiring for UP3 .................................................... 3-13
Tubing for UP2 ....................................................3-31 Wiring for UP4 .................................................... 3-13
Tubing for UP5 ....................................................3-31 Zero adjustment .................................................... 4-1
Tubing for UP6 ....................................................3-31 Pressure gage ............................................................ 1-9
Position indicator Pressure switch .......................................................... 1-9
Changing .............................................................3-41
UP1 .....................................................................3-41 R
UP2 .....................................................................3-41
UP3 .....................................................................3-41 Reference documents ................................................ 1-4
UP4 .....................................................................3-41 Regulators .................................................................. 1-9
Index - 4
Index (continued)
Regulators, air supply................................................. 3-8 Rotary vane housing cleaning for UP2..................8-5
Repair/replacement .................................................. 8-16 Rotary vane removal and replacement for UP1 ....8-3
Air failure lock for UP1 ........................................ 8-17 Illustration ........................................................8-4
Air failure lock for UP2 ........................................ 8-17 Rotary vane removal and replacement for UP2 ....8-3
Air failure lock for UP4 ........................................ 8-18 Rotary vane seals for UP1 ....................................8-5
Air failure lock for UP6 ........................................ 8-18 Rotary vane seals for UP2 ....................................8-5
Alarm/travel switches.......................................... 8-21 Illustration ........................................................8-4
Clutch fork for UP5 ............................................. 8-13 Solenoid valve removal and replacement for UP1 8-3
Illustration...................................................... 8-13 Solenoid valve removal and replacement for UP2 8-3
Clutch fork for UP6 ............................................. 8-13 Solenoid valve removal and replacement for UP3 8-3
Illustration...................................................... 8-13 Solenoid valve removal and replacement for UP4 8-3
Cylinder cleaning for UP3 ..................................... 8-7 Solenoid valve removal and replacement for UP5 8-3
Cylinder cleaning for UP4 ..................................... 8-7 Solenoid valve removal and replacement for UP6 8-3
Cylinder cleaning for UP5 ..................................... 8-7 Replacement parts......................................................9-1
Cylinder cleaning for UP6 ..................................... 8-7 Reserve air tank...............................................3-19, 8-16
Cylinder for UP3 ................................................... 8-7 Calibration .............................................................4-5
Cylinder for UP4 ................................................... 8-7 Description ............................................................1-9
Illustration........................................................ 8-9 Dimension drawing............................................... B-7
Cylinder for UP5 ................................................... 8-7 Maintenance..........................................................7-2
Illustration...................................................... 8-10 Repair/replacement.............................................8-16
Cylinder for UP6 ................................................... 8-7 Replacement for UP1 ..........................................8-16
Illustration...................................................... 8-11 Replacement for UP2 ..........................................8-16
Cylinder parts list for UP3 ..................................... 8-8 Replacement for UP3 ..........................................8-16
Cylinder parts list for UP4 ..................................... 8-9 Replacement for UP4 ..........................................8-16
Cylinder parts list for UP5 ................................... 8-10 Replacement for UP5 ..........................................8-16
Cylinder parts list for UP6 ................................... 8-11 Replacement for UP6 ..........................................8-16
Cylinder removal and replacement for UP3.......... 8-7 Shipping weight...................................................1-10
Cylinder removal and replacement for UP4.......... 8-7 Troubleshooting ....................................................6-3
Cylinder removal and replacement for UP5.......... 8-7 UP2 .....................................................................3-19
Cylinder removal and replacement for UP6.......... 8-7 UP3 ..............................................................1-9, 3-21
Electric shaft position transmitter........................ 8-20 UP4 ..............................................................1-9, 3-21
Feedback potentiometer ..................................... 8-21 UP5 ..............................................................1-9, 3-21
Pneumatic shaft position transmitter................... 8-22 UP6 ..............................................................1-9, 3-21
Positioner removal and replacement for UP1 ....... 8-2 Roller chain
Positioner removal and replacement for UP2 ....... 8-2 Adjustment for UP5 .............................................8-14
Positioner removal and replacement for UP3 ....... 8-2 Illustration ......................................................8-15
Positioner removal and replacement for UP4 ....... 8-2 Adjustment for UP6 .............................................8-14
Positioner removal and replacement for UP5 ....... 8-2 Illustration ......................................................8-15
Positioner removal and replacement for UP6 ....... 8-2 Maintenance..........................................................7-2
Reserve air tank.................................................. 8-16 Rotary vane
Reserve air tank for UP2 .................................... 8-16 Housing cleaning...................................................8-5
Reserve air tank for UP3 .................................... 8-16 Maintenance..........................................................7-3
Reserve air tank for UP4 .................................... 8-16 Removal and replacement for UP1 .......................8-3
Reserve air tank for UP5 .................................... 8-16 Illustration ........................................................8-4
Reserve air tank for UP6 .................................... 8-16 Removal and replacement for UP2 .......................8-3
Roller chain adjustment for UP5 ......................... 8-14 Illustration ........................................................8-4
Illustration...................................................... 8-15 Seal repair .............................................................8-5
Roller chain adjustment for UP6 ......................... 8-14 Illustration ........................................................8-4
Illustration...................................................... 8-15 Rotation.......................................................................1-6
Rotary vane housing cleaning for UP1 ................. 8-5
Index - 5
Index (continued)
S UP2....................................................................... 1-9
UP3....................................................................... 1-9
Shipping weights .......................................................1-10 UP4....................................................................... 1-9
Solenoid valve UP5....................................................................... 1-9
Automatic operation ..............................................5-1 UP6....................................................................... 1-9
Automatic operation with UP1 ...............................5-5 Wiring.................................................................. 3-37
Automatic operation with UP2 ...............................5-5 Wiring for UP2 .................................................... 3-38
Automatic operation with UP5 .............................5-13 Wiring for UP5 .................................................... 3-38
Automatic operation with UP6 .............................5-13 Wiring for UP6 .................................................... 3-38
Control loading ....................................................3-39 Stroke times................................................................ 1-6
Manual operation...................................................5-1
Manual operation with UP1 ...................................5-4
T
Manual operation with UP2 ...................................5-4
Manual operation with UP3 ...................................5-8 Technical documentation............................................ 9-1
Manual operation with UP4 ...................................5-8 Temperature limits
Manual operation with UP5 .................................5-12 Operating ..............................................1-6, 3-1, 3-37
Manual operation with UP6 .................................5-12 Thermoswitch
Removal and replacement for UP1 .......................8-3 Removal and replacement .................................. 8-24
Removal and replacement for UP2 .......................8-3 Torque
Removal and replacement for UP3 .......................8-3 Maximum operating .............................................. 3-8
Removal and replacement for UP4 .......................8-3 Operating .............................................................. 1-6
Removal and replacement for UP5 .......................8-3 UP1................................................1-4, 3-8, 3-9, 3-10
Removal and replacement for UP6 .......................8-3 UP2................................................1-4, 3-8, 3-9, 3-10
Tubing .................................................................3-14 UP3.......................................................1-4, 3-8, 3-11
Tubing for UP1 ....................................................3-14 UP4.......................................................1-4, 3-8, 3-11
Tubing for UP2 ....................................................3-14 UP5.......................................................1-4, 3-8, 3-11
Tubing for UP3 ....................................................3-14 UP6.......................................................1-4, 3-8, 3-11
Tubing for UP4 ....................................................3-14 Training....................................................................... 9-1
Tubing for UP5 ....................................................3-15 Travel limiting
Tubing for UP6 ....................................................3-15 Span adjustment ................................................... 4-2
Types.....................................................................1-4 Troubleshooting
Wiring ..................................................................3-14 Air failure lock ....................................................... 6-3
Wiring for UP1 .....................................................3-14 Alarm/travel switches ............................................ 6-3
Wiring for UP2 .....................................................3-14 Electric shaft position transmitter .......................... 6-2
Wiring for UP3 .....................................................3-14 Frozen air lines ..................................................... 6-2
Wiring for UP4 .....................................................3-14 Loud exhaust ........................................................ 6-2
Wiring for UP5 .....................................................3-15 Oscillation ............................................................. 6-2
Wiring for UP6 .....................................................3-15 Pneumatic shaft position transmitter..................... 6-2
Span adjustment Range ................................................................... 6-2
Positioner ..............................................................4-2 Reserve air tank.................................................... 6-3
Speed adjustment Slow response ...................................................... 6-2
Positioner ..............................................................4-3 Uprange zero ........................................................ 6-2
Speed control orifice ...................................................1-9 Tubing
Split ranging Air failure lock ..................................................... 3-22
Span adjustment ...................................................4-2 Master/slave installations.................................... 3-17
Strip heaters Positioner, I/P ..................................................... 3-13
Description ............................................................1-9 Positioner, pneumatic ......................................... 3-11
Removal and replacement ..................................8-23 Schematic for UP1 with air failure lock ............... 3-25
Shipping weights .................................................1-10 Schematic for UP2 with air failure lock ............... 3-27
Troubleshooting.....................................................6-2 Schematic for UP3 with air failure lock ............... 3-28
Index - 6
Index (continued)
Schematic for UP4 with air failure lock ............... 3-28 Alarm/travel switches removal and replacement.8-21
Schematic for UP5 with air failure lock ............... 3-30 Automatic operation with air failure lock................5-5
Schematic for UP6 with air failure lock ............... 3-30 Automatic operation with positioner ......................5-4
Solenoid.............................................................. 3-14 Automatic operation with solenoid valve ...............5-5
UP1....................................................................... 3-8 Electric shaft position transmitter calibration.........4-4
UP1 with air failure lock ...................................... 3-23 Electric shaft position transmitter removal and re-
UP1 with alarm pressure switch ......................... 3-24 placement............................................................8-20
UP1 with I/P positioner ....................................... 3-13 Enclosure removal ................................................3-2
UP1 with pneumatic positioner ........................... 3-11 Feedback potentiometer removal and replacement...
UP1 with solenoid ............................................... 3-14 8-21
UP2....................................................................... 3-8 I/P positioner tubing ............................................3-13
UP2 with air failure lock ...................................... 3-24 I/P positioner wiring.............................................3-13
UP2 with alarm pressure switch ......................... 3-26 Illustration.....................................................3-3, 3-15
UP2 with I/P positioner ....................................... 3-13 Manual operation with air failure lock....................5-5
UP2 with pneumatic positioner ........................... 3-11 Manual operation with positioner ..........................5-2
UP2 with pneumatic shaft position transmitter.... 3-31 Manual operation with solenoid valve ...................5-4
UP2 with solenoid ............................................... 3-14 Mechanical stop adjustment................................3-42
UP3....................................................................... 3-8 Operating controls - illustration .............................5-3
UP3 with air failure lock ...................................... 3-26 Operating lever adjustment .................................3-40
UP3 with I/P positioner ....................................... 3-13 Operating torque versus air supply .......................3-8
UP3 with pneumatic positioner ........................... 3-12 Pneumatic positioner tubing ................................3-11
UP3 with pneumatic shaft position transmitter.... 3-31 Position indicator .................................................3-41
UP3 with solenoid ............................................... 3-14 Positioner removal and replacement.....................8-2
UP4....................................................................... 3-8 Rated torque .........................................................1-4
UP4 with air failure lock ...................................... 3-26 Rotary vane housing cleaning...............................8-5
UP4 with I/P positioner ....................................... 3-13 Rotary vane removal and replacement .................8-3
UP4 with pneumatic positioner ........................... 3-12 Illustration ........................................................8-4
UP4 with pneumatic shaft position transmitter.... 3-31 Rotary vane seal repair .........................................8-5
UP4 with solenoid ............................................... 3-14 Illustration ........................................................8-4
UP5....................................................................... 3-8 Rotation.................................................................1-6
UP5 with air failure lock ...................................... 3-29 Shipping weights .................................................1-10
UP5 with I/P positioner ....................................... 3-14 Solenoid tubing ...................................................3-14
UP5 with pneumatic positioner ........................... 3-12 Solenoid valve removal and replacement .............8-3
UP5 with pneumatic shaft position transmitter.... 3-31 Solenoid wiring....................................................3-14
UP5 with solenoid ............................................... 3-15 Stall torque versus air supply .......................3-9, 3-10
UP6....................................................................... 3-8 Tubing ...................................................................3-8
UP6 with air failure lock ...................................... 3-29 Tubing schematic for air failure lock....................3-25
UP6 with I/P positioner ....................................... 3-14 Volume displacement ............................................1-6
UP6 with pneumatic positioner ........................... 3-12 Wiring for electric shaft position transmitter ........3-35
UP6 with pneumatic shaft position transmitter.... 3-31 UP2
UP6 with solenoid ............................................... 3-15 Air failure lock........................................................1-8
Trip valve adjustment ......................................4-6
U Air failure lock tubing ...........................................3-24
Alarm pressure switch tubing and wiring.............3-26
Unpacking and Inspection .......................................... 3-1 Alarm/travel switch calibration...............................4-4
UP1 Alarm/travel switch wiring....................................3-33
Air failure lock ....................................................... 1-8 Alarm/travel switches removal and replacement.8-21
Trip valve adjustment...................................... 4-6 Automatic operation with air failure lock................5-5
Air failure lock tubing .......................................... 3-23 Automatic operation with positioner ......................5-4
Alarm pressure switch tubing and wiring ............ 3-24 Automatic operation with solenoid valve ...............5-5
Alarm/travel switch calibration .............................. 4-4 Electric shaft position transmitter calibration.........4-4
Alarm/travel switch wiring ................................... 3-32 Electric shaft position transmitter removal and re-
Index - 7
Index (continued)
placement............................................................8-20 Automatic operation with positioner ...................... 5-6

Enclosure removal.................................................3-2 Automatic operation with solenoid valve............... 5-9
Feedback potentiometer removal and replacement ... Cylinder cleaning .................................................. 8-7
8-21 Cylinder parts list .................................................. 8-8
I/P positioner tubing.............................................3-13 Cylinder removal and replacement ....................... 8-7
I/P positioner wiring .............................................3-13 Cylinder repair ...................................................... 8-7
Illustration ............................................................3-16 Electric shaft position transmitter calibration ........ 4-4
Manual operation with air failure lock ....................5-5 Electric shaft position transmitter removal and re-
Manual operation with positioner...........................5-2 placement ........................................................... 8-20
Manual operation with solenoid valve ...................5-4 Enclosure removal ................................................ 3-3
Mechanical stop adjustment................................3-42 Feedback potentiometer removal and replacement ..
Operating controls - illustration..............................5-3 8-21
Operating lever adjustment .................................3-40 I/P positioner tubing ............................................ 3-13
Operating torque versus air supply .......................3-8 I/P positioner wiring ............................................ 3-13
Pneumatic positioner tubing ................................3-11 Manual operation with air failure lock ................... 5-9
Pneumatic shaft position transmitter calibration....4-5 Manual operation with positioner .......................... 5-6
Pneumatic shaft position transmitter removal and re- Manual operation with solenoid valve ................... 5-8
placement............................................................8-22 Operating controls - illustration ............................. 5-8
Pneumatic shaft position transmitter tubing ........3-31 Operating lever adjustment................................. 3-41
Position indicator .................................................3-41 Operating torque versus air supply ....................... 3-8
Positioner removal and replacement.....................8-2 Pneumatic positioner tubing ............................... 3-12
Rated torque..........................................................1-4 Pneumatic shaft position transmitter calibration ... 4-5
Reserve air tank .........................................3-19, 8-16 Pneumatic shaft position transmitter removal and re-
Rotary vane housing cleaning ...............................8-5 placement ........................................................... 8-22
Rotary vane removal and replacement .................8-3 Pneumatic shaft position transmitter tubing........ 3-31
Illustration ........................................................8-4 Position indicator ................................................ 3-41
Rotary vane seal repair .........................................8-5 Positioner removal and replacement .................... 8-2
Illustration ........................................................8-4 Rated torque ......................................................... 1-4
Rotation .................................................................1-6 Reserve air tank........................................... 1-9, 3-21
Shipping weight ...................................................1-10 Dimension drawing..........................................B-7
Solenoid tubing....................................................3-14 Rotation ................................................................ 1-6
Solenoid valve removal and replacement .............8-3 Shipping weight .................................................. 1-10
Solenoid wiring ....................................................3-14 Solenoid tubing ................................................... 3-14
Stall torque versus air supply .......................3-9, 3-10 Solenoid valve removal and replacement ............. 8-3
Strip heaters ..........................................................1-9 Solenoid wiring ................................................... 3-14
Strip heaters removal and replacement ..............8-23 Stall torque versus air supply.............................. 3-11
Thermoswitch removal and replacement ............8-24 Strip heaters ......................................................... 1-9
Tubing ...................................................................3-8 Strip heaters removal and replacement .............. 8-23
Tubing schematic for air failure lock....................3-27 Thermoswitch removal and replacement ............ 8-24
Volume displacement ............................................1-6 Tubing ................................................................... 3-8
Wiring for electric shaft position transmitter ........3-35 Tubing schematic for air failure lock ................... 3-28
Wiring for strip heaters ........................................3-38 Volume displacement ........................................... 1-6
UP3 .............................................................................2-1 Wiring for electric shaft position transmitter ........ 3-36
............................................................................8-16 Wiring for strip heaters........................................ 3-38
Air failure lock........................................................1-8 UP4
Lock valve adjustment .....................................4-7 Air failure lock ....................................................... 1-8
Air failure lock tubing ...........................................3-26 Lock valve adjustment..................................... 4-7
Alarm pressure switch tubing and wiring.............3-27 Trip valve adjustment ...................................... 4-6
Alarm/travel switch calibration...............................4-4 Air failure lock tubing .......................................... 3-26
Alarm/travel switch wiring....................................3-33 Alarm pressure switch tubing and wiring ............ 3-27
Alarm/travel switches removal and replacement.8-21 Alarm/travel switch calibration .............................. 4-4
Automatic operation with air failure lock................5-9 Alarm/travel switch wiring ................................... 3-33
Index - 8
Index (continued)
Alarm/travel switches removal and replacement 8-21 Air failure lock tubing ...........................................3-29
Automatic operation with air failure lock ............... 5-9 Alarm pressure switch tubing and wiring.............3-29
Automatic operation with positioner...................... 5-6 Alarm/travel switch calibration...............................4-4
Automatic operation with solenoid valve............... 5-9 Alarm/travel switch wiring....................................3-33
Cylinder cleaning .................................................. 8-7 Alarm/travel switches removal and replacement.8-21
Cylinder parts list .................................................. 8-9 Automatic operation with air failure lock..............5-14
Cylinder removal and replacement ....................... 8-7 Automatic operation with positioner ....................5-11
Cylinder repair ...................................................... 8-7 Automatic operation with solenoid valve .............5-13
Illustration........................................................ 8-9 Clutch fork removal, inspection and replacement8-13
Electric shaft position transmitter calibration ........ 4-4 Illustration ......................................................8-13
Electric shaft position transmitter removal and re- Cylinder cleaning...................................................8-7
placement ........................................................... 8-20 Cylinder parts list.................................................8-10
Enclosure removal ................................................ 3-3 Cylinder removal and replacement .......................8-7
Feedback potentiometer removal and replacement ... Cylinder repair .......................................................8-7
8-21 Illustration ......................................................8-10
I/P positioner tubing ............................................ 3-13 Electric shaft position transmitter calibration.........4-4
I/P positioner wiring ............................................ 3-13 Electric shaft position transmitter removal and re-
Manual operation with air failure lock ................... 5-9 placement............................................................8-20
Manual operation with positioner .......................... 5-6 Enclosure removal ................................................3-6
Manual operation with solenoid valve................... 5-8 Feedback potentiometer removal and replacement...
Operating controls - illustration .................... 5-8, 5-10 8-21
Operating lever adjustment................................. 3-41 I/P positioner tubing ............................................3-14
Operating torque versus air supply....................... 3-8 I/P positioner wiring.............................................3-14
Pneumatic positioner tubing ............................... 3-12 Illustration..............................................................3-6
Pneumatic shaft position transmitter calibration ... 4-5 Manual operation with air failure lock..................5-13
Pneumatic shaft position transmitter removal and re- Manual operation with positioner ........................5-10
placement ........................................................... 8-22 Manual operation with solenoid valve .................5-12
Pneumatic shaft position transmitter tubing........ 3-31 Operating controls - illustration ...........................5-10
Position indicator ................................................ 3-41 Operating lever adjustment .................................3-41
Positioner removal and replacement .................... 8-2 Operating torque versus air supply .......................3-8
Rated torque ......................................................... 1-4 Pneumatic positioner tubing ................................3-12
Reserve air tank........................................... 1-9, 3-21 Pneumatic shaft position transmitter calibration....4-5
Dimension drawing ......................................... B-7 Pneumatic shaft position transmitter removal and re-
Repair/replacement....................................... 8-16 placement............................................................8-22
Rotation ................................................................ 1-6 Pneumatic shaft position transmitter tubing ........3-31
Shipping weight .................................................. 1-10 Position indicator .................................................3-41
Solenoid tubing ................................................... 3-14 Positioner removal and replacement.....................8-2
Solenoid valve removal and replacement............. 8-3 Rated torque .........................................................1-4
Solenoid wiring ................................................... 3-14 Reserve air tank ...........................................1-9, 3-21
Stall torque versus air supply.............................. 3-11 Dimension drawing ......................................... B-7
Strip heaters ......................................................... 1-9 Repair/replacement .......................................8-16
Strip heaters removal and replacement.............. 8-23 Roller chain adjustment.......................................8-14
Thermoswitch removal and replacement............ 8-24 Illustration ......................................................8-15
Tubing................................................................... 3-8 Rotation.................................................................1-6
Tubing schematic for air failure lock ................... 3-28 Shipping weight...................................................1-10
Volume displacement ........................................... 1-6 Solenoid tubing ...................................................3-15
Wiring for electric shaft position transmitter........ 3-36 Solenoid valve removal and replacement .............8-3
Wiring for strip heaters........................................ 3-38 Solenoid wiring....................................................3-15
UP5 Stall torque versus air supply ..............................3-11
Air failure lock ....................................................... 1-8 Strip heaters ..........................................................1-9
Lock valve adjustment .................................... 4-7 Strip heaters removal and replacement ..............8-23
Trip valve adjustment...................................... 4-6 Thermoswitch removal and replacement ............8-24
Index - 9
Index (continued)
Tubing ...................................................................3-8 Rotation ................................................................ 1-6

Tubing schematic for air failure lock....................3-30 Shipping weight .................................................. 1-10
Volume displacement ............................................1-6 Solenoid tubing ................................................... 3-15
Wiring for electric shaft position transmitter ........3-36 Solenoid valve removal and replacement ............. 8-3
Wiring for strip heaters ........................................3-38 Solenoid wiring ................................................... 3-15
UP6 Stall torque versus air supply.............................. 3-11
Air failure lock........................................................1-8 Strip heaters ......................................................... 1-9
Lock valve adjustment .....................................4-7 Strip heaters removal and replacement .............. 8-23
Trip valve adjustment ......................................4-6 Thermoswitch removal and replacement ............ 8-24
Air failure lock tubing ...........................................3-29 Tubing ................................................................... 3-8
Alarm pressure switch tubing and wiring.............3-29 Tubing for master/slave installations .................. 3-17
Alarm/travel switch calibration...............................4-4 Tubing schematic for air failure lock ................... 3-30
Alarm/travel switch wiring....................................3-33 Volume displacement ........................................... 1-6
Alarm/travel switches removal and replacement.8-21 Wiring for electric shaft position transmitter ........ 3-36
Automatic operation with air failure lock..............5-14 Wiring for strip heaters........................................ 3-38
Automatic operation with positioner ....................5-11
Automatic operation with solenoid valve .............5-13 V
Clutch fork removal, inspection and replacement8-13
Illustration ......................................................8-13 Volume booster
Cylinder cleaning...................................................8-7 Tubing ................................................................. 3-31
Cylinder parts list.................................................8-11 Volume boosters
Cylinder removal and replacement........................8-7 Exhaust valves...................................................... 1-9
Cylinder repair .......................................................8-7 Shipping weight .................................................. 1-10
Illustration ......................................................8-11 Volume displacement ................................................. 1-6
Electric shaft position transmitter calibration .........4-4
Electric shaft position transmitter removal and re- W
placement............................................................8-20
Enclosure removal.................................................3-6 Wiring
Feedback potentiometer removal and replacement ... Alarm/travel switches .......................................... 3-31
8-21 Electric shaft position transmitter ........................ 3-34
I/P positioner tubing.............................................3-14 Electric shaft position transmitter reverse loading .....
I/P positioner wiring .............................................3-14 3-37
Illustration .....................................................3-6, 8-13 Grounding ............................................................. 3-8
Manual operation with air failure lock ..................5-13 Loop diagram for electric shaft position transmitter ...
Manual operation with positioner.........................5-10 3-35
Manual operation with solenoid valve .................5-12 Positioner, I/P ..................................................... 3-13
Master/slave Illustration.......................................3-17 Solenoid.............................................................. 3-14
Operating lever adjustment .................................3-41 Strip heaters ....................................................... 3-37
Operating torque versus air supply .......................3-8 Strip heaters for UP2 .......................................... 3-38
Pneumatic positioner tubing ................................3-12 Strip heaters for UP3 .......................................... 3-38
Pneumatic shaft position transmitter calibration....4-5 Strip heaters for UP4 .......................................... 3-38
Pneumatic shaft position transmitter removal and re- Strip heaters for UP5 .......................................... 3-38
placement............................................................8-22 Strip heaters for UP6 .......................................... 3-38
Pneumatic shaft position transmitter tubing ........3-31 UP1 with alarm pressure switch ......................... 3-24
Position indicator .................................................3-41 UP1 with alarm/travel switches ........................... 3-32
Positioner removal and replacement.....................8-2 UP1 with electric shaft position transmitter ......... 3-35
Rated torque..........................................................1-4 UP1 with I/P positioner ....................................... 3-13
Reserve air tank ...........................................1-9, 3-21 UP1 with solenoid ............................................... 3-14
Dimension drawing ......................................... B-7 UP2 with alarm pressure switch ......................... 3-26
Repair/replacement .......................................8-16 UP2 with alarm/travel switches ........................... 3-33
Roller chain adjustment.......................................8-14 UP2 with electric shaft position transmitter ......... 3-35
Illustration ......................................................8-15 UP2 with I/P positioner ....................................... 3-13
Index - 10
Index (continued)
UP2 with solenoid ............................................... 3-14 UP5 with I/P positioner........................................3-14

UP3 with alarm pressure switch ......................... 3-27 UP5 with solenoid ...............................................3-15
UP3 with alarm/travel switches........................... 3-33 UP6 with alarm pressure switch ..........................3-29
UP3 with electric shaft position transmitter......... 3-36 UP6 with alarm/travel switches ...........................3-33
UP3 with I/P positioner ....................................... 3-13 UP6 with electric shaft position transmitter .........3-36
UP3 with solenoid ............................................... 3-14 UP6 with I/P positioner........................................3-14
UP4 with alarm pressure switch ......................... 3-27 UP6 with solenoid ...............................................3-15
UP4 with alarm/travel switches........................... 3-33
UP4 with electric shaft position transmitter......... 3-36 Z
UP4 with I/P positioner ....................................... 3-13
UP4 with solenoid ............................................... 3-14 Zero adjustment
UP5 with alarm pressure switch ......................... 3-29 Positioner ..............................................................4-1
UP5 with alarm/travel switches........................... 3-33 Zero elevation .......................................................4-2
UP5 with electric shaft position transmitter......... 3-36
Index - 11
PN25059
The Companys policy is one of continuous product improvement and the

right is reserved to modify the information contained herein without notice.
2002 ABB Automation Inc. Printed in USA
ABB Inc. ABB Instrumentation Ltd ABB Instrumentation S.p.A ABB Automation Products GmbH
Instrumentation Division Howard Road, St. Neots Via Sempione 243 Industriestr. 28
125 East County Line Road Cambs. England, PE19 3EU 20016 Pero (Milano) Italy D-65760 Eschborn Germany
Warminster, PA 18974 USA Tel. +44 (0) 1480-475-321 Tel: +39 (02) 33928 1 Tel: +49 (0) 6196 800 0
Tel. 215-674-6000 FAX: +44 (0) 1480-217-948 Fax: +39 (02) 33928 240 Fax: +49 (0) 6196 800 1849
FAX: 215-674-7183
INSTALLATION AND MAINTENANCE INSTRUCTIONS
FOR ELECTRIC MOTORS ENGLISH
INSTRUCCIONES PARA LA INSTALACIN Y

MANTENIMIENTO DE MOTORES ELCTRICOS ESP
PAAOL
BETRIEBS - UND WARTUNGSANLEITUNGEN

FR ELEKTROMOTOREN DEUTSCH
INSTRUCTIONS POUR INSTALLATION ET

MANUTENTION DE MOTEURS LECTRIQUES FRANAIS
ISTRUZIONI DUSO E MANUTENZIONE

PER MOTORI ELETTRICI ITALIANO
INSTALLATIONS-OG VEDLIGEHOLDELSESVEJLEDNING
FOR ELEKTRISKE MOTORER DANSK
INSTALLATIONS- OCH UNDERHLLSINSTRUKTIONER

FR ELEKTRISKA MOTORER SVENSKA
PYCCKN
0280.1400
INSTALLATION AND MAINTENANCE
English
INSTRUCTIONS FOR ELECTRIC MOTORS
5-10
Espaol
INSTRUCCIONES PARA LA INSTALACIN Y
MANTENIMIENTO DE MOTORES ELCTRICOS
11-18
Deutsch
BETRIEBS - UND WARTUNGSANLEITUNGEN
FR ELEKTROMOTOREN
19-26
Franais
INSTRUCTIONS POUR INSTALLATION ET
MANUTENTION DE MOTEURS LECTRIQUES
27-34
Italiano
ISTRUZIONI DUSO E MANUTENZIONE
PER MOTORI ELETTRICI
35-42
INSTALLATIONS-OG Dansk
VEDLIGEHOLDELSESVEJLEDNING FOR
ELEKTRISKE MOTORER 43-48
INSTALLATIONS- OCH
Svenska
UNDERHLLSINSTRUKTIONER
FR ELEKTRISKA MOTORER 49-54
Pycckn
55-61
ENGLISH
In case the motors are stored for more than

READ CAREFULLY THIS MANUAL
two years, the bearings must be replaced or the
ENGLISH
BEFORE INSTALLING THE MOTOR
lubrication grease must be totally removed after
cleaning.
RECEIVING CHECK Single phase motors when kept in stock
for 2 years or more must have their capacitors
Check if any damage has occured during
replaced (if any).
transportation.
We recommend to turn the shaft (by hands)
Check nameplate data.
at least once a month, and to measure the
Remove shaft locking device (if any) before
insulation resistance before installing it, in cases
operating the motor.
of motors stored for more than 6 months or when
Turn the shaft with the hand to make sure it
subject to high humidity areas.
is turning freely. If motor is fitted with space heaters, these
HANDLING AND TRANSPORTATION should be switched on.
1 - General Insulation Resistance Check

MOTORS MUST NOT BE LIFTED BY Measure the insulation resistance before
THE SHAFT, BUT BY THE EYEBOLTS operating the motor and/or when there is any
sign of humidity in the winding.
Lifting devices, when supplied, are
designed only to support the motor. If the motor The resistance measured at 25C must be:
has two lifting devices then a double chain must
be used to lift it. Ri (20 x U) / (1000 + 2P) [M]
Lifting and lowering must be done gently (measured with a MEGGER at 500 V d.c.)
without any shocks, otherwise the bearings can where U = voltage (V); P = power (kW).
get damaged.
If the insulation resistance is less than 2
DURING TRANSPORTATION,
megaohms, the winding must be dried
MOTORS FITTED WITH ROLLER OR
according to the following:
ANGULAR CONTACT BEARINGS
Warm it up inside an oven at a minimum
ARE PROTECTED AGAINST
temperature of 80C increasing 5C every hour
BEARING DAMAGES WITH A
until 105C, remaining under this temperature
SHAFT LOCKING DEVICE.
for at least one hour.
Check if the stator insulation resistance
THIS LOCKING DEVICE MUST BE
remains constant within the accepted values. If
USED ON ANY FURTHER MOTOR
not, stator must be reimpregnated.
TRANSPORTATION, EVEN WHEN
THIS MEANS TO UNCOUPLE
THE MOTOR FROM THE DRIVEN
MACHINE. INSTALLATION
STORAGE 1 - Safety
If motors are not immediately installed, All personnel involved with electrical
they must be stored in dry places, free of installations, either handling, lifting, operation
dust, vibrations, gases, corrosive smokes, or maintenance must be well informed and
under constant temperature and in normal updated concerning safety standards and
position free from other objects. principles that govern the work and carefully
Motor storage temperature must remain follow them.
between 5C to 60C, with relative humidity not We strongly recommend that these jobs
exceeding 50%. are carried out by qualified personnel.
MAKE SURE THAT ELECTRIC designed in such a way to stop any vibration
MOTORS ARE SWITCHED OFF originated from resonance.
BEFORE STARTING ANY
MAINTENANCE SERVICE. 4 - Drain Holes
Motors must be protected against acci- Make sure the drains are placed in the
dental starts. lower part of the motor when the mounting
When performing any maintenance configuration differs from that specified on the
service, disconnect the motor from the power motor purchase order.
supply. Make sure all accessories have been
switched off and disconnected. 5 - Balancing
In order to prevent from penetrating dust
and/or water into the terminal box, cable glands WEG MOTORS ARE DYNAMICALLY
or threaded pipe in the lead holes must be BALANCED WITH HALF KEY, AT NO
installed. LOAD AND UNCOUPLED.
Do not change the regulation of the
protecting devices to avoid damaging. Transmission elements such as pulleys,
couplings, etc must be dynamically balanced
2 - Operating Conditions with half key before installation.
Use always appropriate tools for installation and
Electric motors, in general, are designed removal.
for operation at an altitude of 1000m above sea
level for an ambient temperature between 0C 6 - Alignment
and 40C. Any variation is stated on the
ALIGN THE SHAFT ENDS AND
nameplate.
USE FLEXIBLE COUPLING,
COMPARE THE CURRENT, VOLTAGE, WHENEVER POSSIBLE.
FREQUENCY, SPEED, OUTPUT AND
Ensure that the motor mounting devices
OTHER VALUES DEMANDED BY THE
do not allow modifications on the alignment and
APPLICATION WITH THE DATA GIVEN
further damages to the bearings.
ON THE NAMEPLATE.
When assembling a half-coupling, be sure
Motors supplied for hazardous locations to use suitable equipment and tools to protect
must be installed in areas that comply with that the bearings.
specified on the motor nameplate. Suitable assembly of half-coupling:
Check that clearance Y is less than
KEEP AIR INLET AND OUTLET FREE 0.05 mm and that the difference X1 to X2 is less
AND CLEAN. THE AIR BLOWN OUT than 0.05 mm, as well.
BY THE MOTOR SHALL NOT ENTER
AGAIN. THE DISTANCE BETWEEN
THE AIR INLET AND THE WALL
MUST BE AROUND OF THE
INLET OPENING DIAMETER.
3 - Foundation
Note: Dimension X1 and X2 must be
Motors provided with feet must be installed 3mm minimum
on solid foundations to avoid excessive Figure and alignment tolerances
vibrations.
The purchaser is fully responsible for the 7 - Belt Drive
foundation.
Metal parts must be painted to avoid When using pulley or belt coupling, the
corrosion. following must be observed:
The foundation must be uniform and suf- Belts must be tighten just enough to avoid
ficiently tough to support any schock. It must be slippage when running, according to the
specifications stated on the belt supplier Make sure to use the correct cable
recommendation. dimension, based on the rated current stamped
on the motor nameplate.
WARNING:
ENGLISH
Excessive tension on the pulleys will BEFORE ENERGIZING THE
damage the bearings and lead to a TERMINALS, CHECK IF THE
probable shaft rupture. GROUNDING IS MADE
ACCORDING TO THE CURRENT
STANDARDS. THIS IS ESSENTIAL
8 - Connection AGAINST ACCIDENT RISKS.
WARNING: When the motor is supplied with

Voltage may be connected at standstill protective or monitor temperature device such
inside the terminal box for heating elements or as thermostats, thermistors, termal protector, etc,
direct winding heating. connect their terminals to the corresponding
devices on the control panel.
WARNING:
The capacitor on single-phase motors 10 - Start-Up
can retain a charge which appears across the
THE KEY MUST BE FASTENED OR
motor terminals, even when the motor has
REMOVED BEFORE STARTING THE
reached standstill.
MOTOR.
A WRONG CONNECTION CAN a) The motor must start and operate
BURN THE MOTOR. smoothly. In case this does not occur, turn it off
and check the connections and the mounting
before starting it again.
Voltage and connection are indicated on
b) If there is excessive vibration, check if
the nameplate. The acceptable voltage the fastening screws are correctly fastened.
variation is 10%; the acceptable frequency Check also if the vibration comes from a
variation is 5% and the total acceptable neighbour machine. Periodical vibration checks
variation is 10%. must be done.
c) Run the motor under rated load for a
9 - Starting Methods short period of time and compare if the running
current is equal to that stamped on the
The motor is rather started through direct nameplate.
starting. In case this is not possible, use
compatible methods to the motor load and MAINTENANCE
voltage.
The rotation direction is clockwise if the WARNING:
motor is viewed from DE side and if the SAFETY CHECK LIST
phases are connected according to the
sequence L1, L2, L3. 1 - General Inspection
To change the rotation direction, inter-
change two of the connecting leads. Check the motor periodically.
Keep the motor clean and assure free air flow.
THE CONNECTION TO THE POWER Check the seals or V Ring and replace them, if
SUPPLY MUST BE DONE BY required.
QUALIFIED PERSONNEL AND WITH Check the connections as well as supporting
FULL ATTENTION TO ASSURE A SAFE screws.
AND PERMANENT CONNECTION. Check the bearings and observe: Any excessive
AFTER CONNECTING THE MOTOR, noise, vibration, bearing temperature and grease
CHECK FOR ANY STRANGE BODY condition.
INSIDE THE TERMINAL BOX. THE When a change, under normal conditions, is
CABLE INLETS NOT IN USE MUST BE detected, check the motor and replace the
CLOSED. required parts.
The frequency of the inspections depends 2 - Machines Fitted with Grease Nipples
on the motor type and on the application
conditions. It is strongly recommended to grease the
machine while running. This allows the grease
LUBRICATION renewal in the bearing housing. When this is
not possible due to turning parts by the grease
FOLLOW THE REGREASING device (pulleys, bushing, etc) that offer some
INTERVALS. THIS IS FUNDAMENTAL risk to the physical integrity of the operator,
FOR PROPER MOTOR OPERATION. proceed as follows:
Clean the area near the grease nipple.
1 - Machines without Grease Nipples Put approximately half of the total grease and
run the motor for 1 minute at full speed.
Motors up to frame 200 are normally fitted Then turn off the motor and insert the rest of the
without grease nipples. In these cases the grease.
regreasing shall be done at the preventive The injection of all the grease with the motor in
maintenance job observing the following standstill can make the grease penetrate into the
aspects: motor, through the inner seal of the bearing
housing.
Disassemble carefully the motors.
Take all the grease out. FOR LUBRICATION USE ONLY
Wash the bearing with querosene or diesel. MANUAL GREASE GUN.
Regrease the bearing immediately.
RELUBRICATION INTERVALS
TABLE 1 - BALL BEARINGS - Series 62/63

Relubrication intervals (running hours horizontal position)
II pole IV pole VI pole VIII pole X pole XII pole Grease
Serie 62
Bearing 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz (g)
6209 18400 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 9
6211 14200 16500 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 11
6212 12100 14400 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
Serie 63
6309 15700 18100 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
6311 11500 13700 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 18
6312 9800 11900 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 21
6314 3600 4500 9700 11600 14200 16400 17300 19700 19700 20000 20000 20000 27
6316 - - 8500 10400 12800 14900 15900 18700 18700 20000 20000 20000 34
6319 - - 7000 9000 11000 13000 14000 17400 17400 18600 18600 20000 45
6322 - - 5100 7200 9200 10800 11800 15100 15100 15500 15500 19300 60
TABLE 2 - ROLLER BEARINGS - Series NU 3

Relubrication intervals (running hours horizontal position)
II pole IV pole VI pole VIII pole X pole XII pole Grease
NU 309 9800 13300 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
NU 311 6400 9200 19100 20000 20000 20000 20000 20000 20000 20000 20000 20000 18
NU 312 5100 7600 17200 20000 20000 20000 20000 20000 20000 20000 20000 20000 21
NU 314 1600 2500 7100 8900 11000 13100 15100 16900 16900 19300 19300 20000 27
NU 316 - - 6000 7600 9500 11600 13800 15500 15500 17800 17800 20000 34
NU 319 - - 4700 6000 7600 9800 12200 13700 13700 15700 15700 20000 45
NU 322 - - 3300 4400 5900 7800 10700 11500 11500 13400 13400 17300 60
NU 324 - - 2400 3500 5000 6600 10000 10200 10200 12100 12100 15000 72
Note: The stator grips must be applied over the
The ZZ bearings from 6201 to 6307 do not side face of the inner ring to be disassembled or
require relubrication as its life time is about over an adjacent part.
20,000 hours. It is essential that bearings assembly be
Tables 1 and 2 are intended for the lubrication
ENGLISH
done under cleanning conditions to ensure
period under bearing temperature of 70C (for good operation and to avoid damages. New
bearings up to 6312 and NU 312) and bearings shall only be taken out from their cases
temperature of 85C (for bearings 6314 and NU when assembling them.
314 and larger). Before installing a new bearing it is
For each 15C of temperature rise, the required to check the shaft fitting for any sharp
relubrication period is reduced by half. edge or strike signals.
The relubrication periods given above are For bearing assembly warm their inner
for those cases applying Polyrex EM grease. parts withsuitable equipment - inductive pocess
When motors are used on the vertical - or use suitable tools.
position, their relubrication interval is reduced SPARE PARTS
by half if compared to horizontal position
motors. When ordering spare parts, please specify
WE RECOMENDED TO USE BALL the full type designation and product code as
BEARINGS FOR MOTORS DIRECTLY stated on the motor nameplate. Please also
inform the motor serial number stated on the
COUPLED TO THE LOAD. nameplate.
WARNING: MOTORS FOR HAZARDOUS
EXCESS OF GREACE CAN CAUSE
BEARNING OVERHEATING LOCATIONS
RESULTING IN COMPLETE Besides the recommendations given
DAMARGE. previously, these ones must be also followed:
Compatibility of Polyrex EM grease THE SPECIFICATION OF THE MOTOR

with other types of grease: INSTALLATION PLACE IS FOR
CUSTOMERS RESPONSIBILITY,
Containing polyurea thickener and mineral WHO WILL ALSO DETERMINE THE
oil, the Polyrex EM grease is compatible with ENVIRONMENT CHARACTERISTICS.
other types of grease that contain:
Lithium base or complex of lithium or polyurea Motors for hazardous locations are
and highly refined mineral oil. manufactured according to specific standards
Inhibitor additive against corrosion, rust and for such environments and they are certified by
anti-oxidant additive. worldwide certifying entities.
Notes: 1 - Installation
Although Polyrex EM is compatible with types
of grease given above, we do not recommended The complete installation must follow
to mix it with any other greases. procedures given by the local legislation in effect.
If you intend to use a type of grease different
than those recommended above , first contact THE INSTALLATION OF HAZARDOUS
WEG. LOCATION MOTORS MUST BE
On applications (with high or low temperatures, CARRIED OUT BY SKILLED PEOPLE,
speed variation, etc), the type of grease and
relubrification interval are given on an additional AND THE THERMAL PROTECTION
nameplate attached to the motor. MUST BE ALWAYS INSTALLED,
EITHER INSIDE OR OUTSIDE THE
THE USE OF STANDARD MOTORS
MOTOR, OPERATING AT THE RATED
IN SPECIFIC AREAS OR SPECIAL
CURRENT.
APPLICATIONS MUST BE DONE BY
CONSULT TO THE GREASE 2 - Maintenance
MANUFACTURER OR WEG
Maintenance must be carried out by repair
shops authorized by WEG.
DISASSEMBLY AND ASSEMBLY Repair shops and people without Wegs
authorization who will perform any service on
Disassembly and assembly must be done hazardous location motors will be fully
by qualified personnel using only suitable tools responsible for such service as well as for any
and appropriated methods. consequential damage.
Lower efficiency.
ANY ELECTRICAL OR MECHANICAL
Higher vibration.
MODIFICATION MADE ON
Higher noise level.
HAZARDOUS LOCATION MOTORS Higher rated current.
WILL VOID THE CERTIFICATION. Higher temperature rise.
When performing maintenance, Reduced motor insulation.
installation or relubrication, follow these Reduced bearing life.
instructions:
1- Standard Motors
Check if all components are free of edges,
knocks or dirt.
Make sure all parts are in perfect conditions. Voltages lower than 440V do not require filter.
Lubricate the surfaces of the endshield fittings Voltages equal or higher than 440V or lower
with protective oil to make the assembly easier. than 575V require filter for motor power supply
Use only rubber hammer to fit the parts. cables longer than 20 meters.
Check for correct bolts tightening. Voltages equal or higher than 575V require
Use clearance calibrator for correct T-box fitting filter for any size of power supply cables.
(smaller than 0.05mm).
DO NOT REUSE DAMAGED OR IF SUCH RECOMMENDATIONS ARE
WORN PARTS. REPLACE THEM BY NOT FOLLOWED ACCORDINGLY,
NEW ONES SUPPLIED BY THE MOTOR WARRANTY WILL BE VOID.
FACTORY.
2- Inverter Duty Motors:
MOTORS DRIVEN BY VFD Check power supply voltage of the forced
Applications using VFDs without filter cooling set.
can affect motor performance as follows: Filters are not required.
WARRANTY TERMS
Weg warrants its products against defects in This warranty does not include disassembly
workmanship and materials for twelve (12) services at the purchaser facilities,
months from the invoice date issued by the transportation costs with product, tickets,
factory, authorized distributor or agent limited accomodation and meals for technical personnel
to eighteen (18) months from manufacturing date when requested by the customer.
independent of installation date as long as the The warranty service will be only carried out at
following items are fulfilled accordingly: Weg Authorized Repair Shops or at Wegs
facilities.
- Proper transportation, handling and storage;
- Correct installation based on the specified Components whose useful life, under normal
ambient conditions and free of corrosive use, is shorter than the warranty period are not
gases; covered by these warranty terms.
- Operation under motor capacity limits; The repair and/or replacement of parts or
- Observation of the periodical maintenance components, when effected by Weg and/or any
services; Weg Authorized Repair Shop, will not give
- Repair and/or replacement effected only by warranty extension.
personnel duly authorized in writing by Weg;
- The failed product be available to the supplier This constitutes Wegs only warranty in
and/or repair shop for a required period to connection with this sale and the company will
detect the cause of the failure and have no obligation or liability whatsoever to
corresponding repair; people, third parties, other equipment or
- Immediate notice by the purchaser about installations, including without limitation, any
failures accured and that these are accepted claims for consequential damages or labor costs.
by Weg as manufacturing defects.
ESPAOL
LEA ATENTAMENTE ESTE MANUAL ALMACENAMIENTO

ANTES DE INICIAR LA
INSTALACIN DEL MOTOR. Si los motores no fueran inmediatamente
instalados, deben ser almacenados en un local
VERIFICACIN EN LA RECEPCIN seco, libre de polvo, vibraciones, gases y
vapores corrosivos; dotado de temperatura
Verifique si ocurrieron daos durante el uniforme, colocndolos en posicin normal y
transporte. sin apoyar sobre ellos otros objetos.
ESPAOL
Verifique los datos de la placa de caractersticas. La temperatura de almacenaje de los
Retire el dispositivo de bloqueo del eje motores debe quedar entre 5C y 60C, con
(cuando exista), antes de poner el motor en humedad relativa no excediendo a 50%.
funcionamiento. En el caso de motores con ms de dos
Gire el eje con la mano para verificar si est aos de almacenaje, se debe proceder al cambio
girando libremente. de rodamientos o a la substitucin total de la
grasa lubricante despus de la limpieza de los
MANIPULACIN Y TRANSPORTE mismos.
1 - General En los motores monofsicos

almacenados durante dos aos o ms, se debe
LOS MOTORES NO DEBEN SER adems cambiar los condensadores (cuando
IZADOS POR EL EJE, USE PARA ELLO existan).
LOS CNCAMOS DE SUSPENSIN,
YA QUE LOS MISMOS ESTN Recomendamos girar el eje del motor (con
DISEADOS SOLAMENTE PARA la mano) al menos una vez al mes y medir la
SOPORTAR EL PESO DEL MOTOR. resistencia del aislamiento antes de instalarlo,
en caso de motores almacenados durante ms
Si el motor por su diseo constructivo
de 6 meses o cuando estn sometidos a
tiene dos cncamos de suspensin, use
ambientes con alta humedad.
dispositivos que permitan el izaje por ambos
elementos al mismo tiempo.
Si el motor dispone de resistencias de
calefaccin, estas debern ser conectadas.
El izaje as como el descenso del motor
deben ser realizados en forma suave, sin golpes,
Medicin de la resistencia del aislamiento
caso contrario los rodamientos pueden sufrir
daos.
Mida la resistencia del aislamiento antes
de poner el motor en servicio y/o cuando haya
LOS MOTORES CON indicios de humedad en el bobinado.
RODAMIENTOS DE RODILLOS O
DE CONTACTO ANGULAR ESTN La resistencia, medida a 25C, debe ser:
PROTEGIDOS, DURANTE EL Ri (20 x U) / (1000 + 2P) [M]
TRANSPORTE, CONTRA DAOS (medido con MEGGER a 500 V c.c.);
POR MEDIO DE UN DISPOSITIVO donde U = tensin (V); P = potencia (kW).
DE BLOQUEO.
LOS DISPOSITIVOS DE BLOQUEO Si la resistencia del aislamiento medida

DEBEN SER USADOS SIEMPRE es inferior a 2 Mohm, el bobinado deber ser
QUE SE TRANSPORTE EL MOTOR, secado de acuerdo con lo que sigue:
AUNQUE ESTO IMPLIQUE EN
TENERLO QUE DESACOPLAR Calentar el estator bobinado en un horno
NUEVAMENTE DE LA MQUINA partiendo de una temperatura de 80C y
ACCIONADA. elevando 5C por hora hasta llegar a los 105C;
esta ltima temperatura debe permanecer COMPARE LA CORRIENTE,
durante un perodo mnimo de una hora. TENSIN, FRECUENCIA,
Medir nuevamente la resistencia del VELOCIDAD, POTENCIA Y OTROS
aislamiento del bobinado para comprobar si es VALORES EXIGIDOS POR LA
constante y con valores dentro de los mnimos APLICACIN, CON LOS DATOS
recomendados; caso contrario, se deber CONTENIDOS EN LA PLACA DE
proceder a una nueva impregnacin del estator IDENTIFICACIN.
bobinado.
Motores para reas clasificadas debern
INSTALACIN ser instalados en lugares de conformidad con
la identificacin en la placa del motor.
1 - Seguridad
MANTENER LA ENTRADA Y SALIDA
Los profesionales que trabajan en DE AIRE DEL MOTOR SIEMPRE
instalaciones elctricas, sea en el montaje, en la LIMPIAS. EL AIRE EXPELIDO POR
operacin o en el mantenimiento, debern estar EL MOTOR NO DEBE SER
permanentemente informados y actualizados ASPIRADO NUEVAMENTE. LA
sobre las normas y requisitos vigentes en materia DISTANCIA ENTRE LA ENTRADA
de seguridad y cuidadosamente ponerlas en DE AIRE DEL MOTOR Y LA PARED,
prctica. NO DEBE SER INFERIOR A DEL
DIMETRO DE LA ABERTURA DE
Se recomienda que stos servicios sean LA ENTRADA DE AIRE QUE POSEE
efectuados por personal cualificado. DICHO MOTOR.
3 - Fundaciones del motor

VERIFIQUE QUE LOS MOTORES
ELCTRICOS ESTN
Los motores con patas debern ser
DESCONECTADOS ANTES DE
instalados sobre apoyos rgidos para evitar
INICIAR CUALQUIER TRABAJO DE
excesivas vibraciones.
MANTENIMIENTO.
El comprador es totalmente responsable
de estos apoyos.
Los motores deben estar protegidos
contra arranques accidentales. Las partes metlicas debern estar
pintadas para evitar la corrosin.
Al realizar servicios de mantenimiento
sobre el motor, desconecte la red de alimentacin. La base debe ser uniforme y lo
Verifique si todos los accesorios fueron suficientemente robusta para soportar fuertes
desconectados. choques. Debe ser diseada de manera que
impida las vibraciones originadas por
Para impedir la penetracin de polvo y/o
resonancias.
agua en el interior de la caja de conexiones, es
necesario instalar prensaestopas o tapones
4 - Agujeros de drenaje
roscados en la salida de los cables de conexin.
No modifique el ajuste de los dispositivos Asegrese que los agujeros de drenaje
de proteccin, para evitar daos. del motor se siten en su parte inferior, cuando
la forma de montaje del motor difiera de la
2 - Condiciones de Operacin especificada en la compra del mismo.
Las mquinas elctricas, en general, estn
diseadas para operacin a una altitud hasta 5 - Equilibrado
1000m sobre el nivel del mar con temperaturas LOS MOTORES WEG SON
ambientes de 0 a 40C. Variaciones respecto a EQUILIBRADOS DINMICAMENTE
los valores mencionados deben estar indicados CON MEDIA CHAVETA, EN VACO
en la placa de caractersticas. Y DESACOPLADOS.
Los elementos de transmisin, tales como, 8 - Conexin
poleas, acoplamientos, etc., precisan ser
equilibrados dinmicamente con media PELIGRO:
chaveta antes de ser instalados. Utilice siempre An con el motor detenido, puede existir
herramientas apropiadas tanto en la instalacin energia elctrica en el interior de la caja de
como en el desacople de los motores. conexiones debido a la presencia de resistencias
calefactoras o en el mismo bobinado en el caso
6 - Alineacin de que ste sea usado como elemento de
calefaccin de reposo.
ALINEAR LAS PUNTAS DE EJE Y
ESPAOL
PELIGRO:
UTILICE SIEMPRE QUE FUERA
Los condensadores de los motores
POSIBLE ACOPLAMIENTOS
monofsicos pueden tener energia elctrica, la
FLEXIBLES.
misma estar presente en los terminales del
motor an cuando el motor estuviere detenido.
Certifiquese de que los dispositivos de
montaje del motor no permitan alteraciones en
TODA CONEXIN EFECTUADA DE
la alineacin y futuros daos en los rodamientos.
FORMA INCORRECTA PUEDE
QUEMAR EL MOTOR.
Cuando se proceda al montaje de una
mitad del acoplamiento, deben ser usados los La tensin y forma de conexin estn
medios adecuados y las herramientas necesarias indicadas en la placa de caractersticas. La
para no daar los rodamientos. variacin aceptable de tensin es de 10%,
la variacin admitida en la frecuencia es de 5%
Montaje correcto de la mitad del y la variacin simultnea total de ambas es de
acoplamiento:compruebe que la distancia y sea 10%.
inferior a 0,05 mm y que la diferencia de X1 a X2
tambin sea menor que 0,05mm. 9 - Sistema de arranque
Es preferible que el motor arranque en

forma directa, en el caso de que esto no sea
posible, utilizar mtodos alternativos que sean
compatibles con la carga y tensin del motor.
El sentido de giro es el horario, mirando
el motor desde el extremo del eje y conectando
las fases en la secuencia L1, L2 y L3.
Para cambiar el sentido de giro, invertir
Obs.: X1 y X2 deberan ser inferiores a 3mm dos de los tres cables de alimentacin.
Figura y tolerancias para la alineacin
LA CONEXIN DE LOS CABLES DE
7 - Poleas ALIMENTACIN ELCTRICA DEBE
SER EFECTUADA POR PERSONAL
Cuando se utilice un acoplamiento por CUALIFICADO CON MUCHA
medio de correas y poleas, se debe observar: ATENCIN PARA ASEGURAR UN
CONTACTO SEGURO Y
Las correas deben ser tensadasapenas lo PERMANENTE.
suficiente como para evitar deslizamento en el DESPUS DE HABER CONECTADO
funcionamiento, de acuerdo con las EL MOTOR, VERIFIQUE QUE
recomendaciones del fabricante de las correas. NINGN CUERPO EXTRAO
PERMANEZCA EN EL INTERIOR DE
AT E N C I N : LA CAJA DE CONEXIONES. TODA
Una excesiva tensin en las correas daar ENTRADA DE CABLES A LA CAJA
los rodamientos y hasta puede provocar la QUE NO EST SIENDO UTILIZADA,
rotura del eje. DEBE SER CERRADA.
Asegrese de utilizar el dimetro correcto 1 - Inspeccin General
para el cable de alimentacin, tomando como
base la corriente nominal indicada en la placa Inspeccionar el motor peridicamente.
de caractersticas del motor. Mantener limpio el motor y asegurar libre flujo
de aire.
ANTES DE CONECTAR EL MOTOR, Verifique el sello o V Ring y efecte la
VERIFIQUE QUE LA CONEXIN A sustitucin caso sea necesario.
TIERRA FUE REALIZADA DE Verifique el ajuste de las conexiones del motor
ACUERDO CON LAS NORMAS Verifique el estado de los rodamientos
VIGENTES. ESTE DETALLE ES teniendo en cuenta: aparicin de fuertes ruidos,
FUNDAMENTAL PARA EVITAR vibraciones, temperatura excesiva y condiciones
ACCIDENTES. de la grasa.
Cuando se detecte un cambio en las
condiciones de trabajo normales del motor,
Cuando el motor est equipado con analice el motor y reemplaze las piezas
dispositivos de proteccin o control de requeridas.
temperatura como termostatos, termistores, La frecuencia adecuada para realizar las
protectores trmicos, etc., conecte sus inspecciones depender del tipo de motor y de
respectivos terminales al panel de control que le las condiciones de aelicacin.
corresponda.
10 - Puesta en Marcha Inicial (Start-Up)

LUBRICACIN
PROCEDA DE ACUERDO CON

LA CHAVETA DEBE ESTAR LOS INTERVALOS DE REENGRASE
COMPLETAMENTE ASEGURADA O RECOMENDADOS. ESTO ES VITAL
POR EL CONTRARIO RETIRADA PARA LA OPERACIN DEL MOTOR.
ANTES DE PONER EN MARCHA EL
MOTOR. 1 - Motores sin engrasador
a) El motor debe arrancar y funcionar de Los motores hasta la carcaza IEC 200
manera suave. En el caso de que esto no ocurra, normalmente no llevan engrasador. En stos
desconecte el motor y verifique nuevamente el casos el reengrase deber ser efectuado
sistema de montaje y de conexiones antes de conforme al plan de mantenimiento preventivo
nueva puesta en marcha existente, teniendo en cuenta los siguientes
b) Si se perciben vibraciones excesivas, aspectos:
verifique el sistema de fijacin del motor a la base
as como el acoplamiento motor-mquina. Desarmar cuidadosamente los motores.
Puede ocurrir tambin que la vibracin sea Retirar toda la grasa.
originada por mquinas adyacentes se Lavar los rodamientos con keroseno o gasleo.
recomienda hacer controles peridicos de las Reengrasar el rodamiento inmediatamente.
vibraciones.
c) Dejar en marcha el motor bajo carga 2 - Motores con engrasador
nominal durante un pequeo periodo de tiempo
y comparar la corriente de operacin con la placa Es aconsejable efectuar el reengrase
de caractersticas del motor. durante el funcionamiento del motor, de modo
que permita la renovacin de la grasa en el
MANTENIMIENTO alojamiento del rodamiento. Si esto no fuera
posible debido a la presencia de piezas
giratorias cerca de la entrada de grasa (poleas,
PELIGRO: acoplamientos, etc.) que puedan poner en
CONTROL DE SEGURIDAD riesgo la integridad fsica del operador, se
(CHECK LIST) procede de la siguiente manera:
Limpiar las proximidades del orificio del La inyeccin de toda la grasa con el motor
engrasador. parado puede llevar a la penetracin de parte
Inyectar aproximadamente la mitad de la del lubricante al interior del motor, a travs del
cantidad total de grasa estimada y poner en orificio de pasaje de eje en las tapas de
marcha el motor durante 1 minuto rodamientos interiores.
aproximadamente en rotacin nominal
Desconectar nuevamente el motor y colocar la PARA LA LUBRICATIN, USE
grasa restante. EXCLUSIVAMENTE PISTOLA
ENGRASADORA MANUAL.
ESPAOL
INTERVALOS DE RELUBRICACION
TABLA 1 - RODAMIENTOS DE ESFERAS - Series 62/63

Intervalo de relubricacin (horas de operacin - posicin horizontal)
II polos IV polos VI polos VIII polos X polos XII polos Grasa
Serie 62
Rodamiento 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz (g)
6209 18400 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 9
6211 14200 16500 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 11
6212 12100 14400 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
Serie 63
6309 15700 18100 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
6311 11500 13700 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 18
6312 9800 11900 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 21
6314 3600 4500 9700 11600 14200 16400 17300 19700 19700 20000 20000 20000 27
6316 - - 8500 10400 12800 14900 15900 18700 18700 20000 20000 20000 34
6319 - - 7000 9000 11000 13000 14000 17400 17400 18600 18600 20000 45
6322 - - 5100 7200 9200 10800 11800 15100 15100 15500 15500 19300 60
TABLA 2 - RODAMIENTOS DE ROLLOS - Serie NU 3

Intervalo de relubricacin (horas de operacin - posicin horizontal)
II polos IV polos VI polos VIII polos X polos XII polos Grasa
NU 309 9800 13300 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
NU 311 6400 9200 19100 20000 20000 20000 20000 20000 20000 20000 20000 20000 18
NU 312 5100 7600 17200 20000 20000 20000 20000 20000 20000 20000 20000 20000 21
NU 314 1600 2500 7100 8900 11000 13100 15100 16900 16900 19300 19300 20000 27
NU 316 - - 6000 7600 9500 11600 13800 15500 15500 17800 17800 20000 34
NU 319 - - 4700 6000 7600 9800 12200 13700 13700 15700 15700 20000 45
NU 322 - - 3300 4400 5900 7800 10700 11500 11500 13400 13400 17300 60
NU 324 - - 2400 3500 5000 6600 10000 10200 10200 12100 12100 15000 72
Observacin: NU 314 y mayores).

Para cada 15C de elevacin, el periodo de
Los rodamientos ZZ que van del 6201 hasta relubricacin se reduce a la mitad.
el 6307 no necesitan ser relubricados, una vez Los periodos presentados en las tablas
que la vida til de estos rodamientos es anteriores, son para el uso de grasa Polyrex
aproximadamente de 20.000 horas. EM.
Las tablas 1 y 2 se destinan al periodo de Motores instalados en la posicin vertical
relubricacin para temperatura de cojinete de deben tener periodo de relubricacin reducido
70C (para rodamientos hasta 6312 y NU 312) por la mitad.
y temperatura de 85C (para rodamientos 6314,
RECOMENDAMOS EL USO DE Es esencial que el montaje de los
ROLAMIENTOS DE ESFERAS PARA rodamientos sea ejecutado en condiciones de
MOTORES ACOPLADOS rigurosa limpieza, para asegurar el buen
DIRECTAMENTE A LA CARGA. funcionamiento y evitar daos. En el caso de
colocar rodamientos nuevos, stos debern
GRASA EN EXCESO PUEDE ser retirados de su embalaje solamente en el
PROVOVAR SOBRECALENTAMIENTO momento previo de su montaje al motor.
DE LOS RODAMIENTOS, Antes de la colocacin de un rodamiento
RESULTANDO DE DANOS nuevo, es necesario verificar si el alojamiento
COMPLETOS. del mismo en el eje se encuentra exento de
rebarbas o seales de golpes.
Compatibilidad de la grasa Polyrex Para el montaje de los rodamientos
EM con otros tipos de grasa: calentar la pista interna de los mismos utilizando
mquinas adecuadas (proceso inductivo de
Conteniendo espesante polyureia y aceite calentamiento), o en su defecto utilizar
mineral, la grasa Polyrex EM es compatible con herramientas apropiadas.
otros tipos de grasa las cuales contengan:
Base de litio o complejo de litio o polyureia y
aceite mineral altamente refinado. PARTES Y PIEZAS - REPUESTOS
Aditivo inhibidor contra corrosin, herrumbre
y aditivos antioxidantes. Al solicitar piezas para reposicin, es
conveniente indicar la designacin completa del
Notas: motor, as como el cdigo del mismo que
Aunque la grasa Polyrex EM sea compatible aparecen marcados en la placa de caractersticas.
con lis tipos de grasa mencionados arriba, no Rogamos informen tambin el nmero
recomendamos la mezcla con cualquier tipo de de serie indicado en la placa de caractersticas.
grasa.
Si Ud. necesita utilizar otro tipo de grasa
distinta de las recomendables arriba, MOTORES PARA AMBIENTES
primeramente se contacte con Weg. PELIGROSOS
Para aplicaciones en elevada o baja
temperatura ambiente, variacin de velocidad, Adems de las recomendaciones
etc, el tipo de grasa y el intervalo de lubrificacin anteriores se deben tener en cuenta las
son dados en una placa adicional fijada al motor. siguientes:
LA UTILIZACIN DE MOTORES
LA ESPECIFICACIN DEL LOCAL
NORMALES EN LOCALES Y/O
PARA LA INSTALACIN DEL MOTOR
APLICACIONES ESPECIALES
ES DE RESPONSABILIDAD DEL
DEBE ESTAR PRECEDIDA DE UNA
USUARIO, QUE DETERMINAR LAS
CONSULTA AL FABRICANTE DE
CARACTERSTICAS DE LA
GRASAS Y/O A WEG.
ATMOSFERA AMBIENTE.
DESMONTAJE Y MONTAJE Los motores para ambientes peligrosos

son fabricados conforme normas especficas
El desmontaje y montaje del motor deber para estos ambientes, siendo certificados por
ser efectuado por personal cualificado, organismos acreditados.
utilizando solo herramientas y mtodos
adecuados. 1 - Instalacin
Las garras del extractor debern estar
aplicadas sobre la pista interna del rodamiento La instalacin debe seguir
o sobre la tapa de rodamiento interior al intentar procedimentos elaborados por la legislacin
extraer el rodamiento. vigente en el lugar.
LA INSTALACIN DE MOTORES MOTORES ACCIONADOS POR
PARA AMBIENTES PELIGROSOS
DEBE SER EJECUTADA POR
CONVERTIDOR DE FRECUENCIA
PERSONAL ESPECIALIZADO Y LA
PROTECCIN TRMICA DEBER Instalaciones con Convertidores de
SIEMPRE SER INSTALADA, SEA Frecuencia sin filtro pueden modificar las
ESTA INTRINSECA AL MOTOR O siguientes caractersticas de funcionamiento
EXTERNA AL MISMO, OPERANDO del motor:
CON CORRIENTE NOMINAL.
Rendimiento menor.
ESPAOL
Vibracin mayor.
2 - Mantenimiento Ruido mayor.
Corriente nominal mayor.
El mantenimiento debe ser ejecutado por Elevacin de temperatura mayor.
talleres tecnicos autorizados y acreditados por Vida util del aislamiento menor.
Weg Motores. Vida util de los rodamientos menor.
Talleres y personal sin autorizacin que
realicen reparacin en los motores para 1- Motores normales.
ambientes peligrosos, sern totalmente
responsables por el trabajo ejecutado y los Para tensin menor a 440V no hay necesidad
daos ocurridos en su servicio. de utilizar filtros.
Para tensin mayor o igual a 440V y menor a
575V, debe ser utilizado filtro para cables de
alimentacin de motor mayores a 20 metros.
CUALQUIER MODIFICACIN
Para tensin igual o superior a 575V debe ser
ELCTRICA O MECNICA EN LOS
utilizado filtro para cualquier largo de cable.
MOTORES PARA AMBIENTES
PELIGROSOS ACARREAR LA
PRDIDA DE LA CERTIFICACIN EL NO CUMPLIMIENTO DE ESTAS
DE LOS MISMOS ORIENTACIONES CAUSA LA
PRDIDA DE GARANTA DEL
MOTOR.
En la ejecucin del mantenimiento,
instalacin y relubricacin, se deben seguir las
2- Motores Inverter Duty
siguientes orientaciones:
Observar tensin de alimentacin del conjunto
Verificar si los componentes estn exentos de
ventilacin forzada.
rebabas, golpes y suciedad.
No necesita instalacin de filtros.
Observar si las piezas estn en perfectas
condiciones.
Lubricar superficialmente los encastres de las
tapas con aceite protector para facilitar el montaje.
Utilizar solamente martillo de material blando
en la colocacin de las piezas.
Verificar si todos los tornillos estn bien
apretados.
Utilizar sonda calibrada para verificar asiento
de la caja de conexiones (menor de 0,05 mm).
NO RECUPERAR PIEZAS
DAADAS O CON DESGASTE.
SUSTITUIR POR NUEVAS,
ORIGINALES DE FBRICA.
GARANTIA
Weg ofrece garanta contra defectos de comprador, de los defectos detectados y que
fabricacin o de materiales para sus productos, los mismos sean posteriormente analizados
por un perodo de 12 meses, contados a partir por Weg como causados por defectos de
de la fecha de la emisin de la factura por parte fabricacin.
de fbrica o del distribuidor/revendedor,
teniendo como lmite 18 meses de la fecha de La garanta no incluye los servicios de
fabricacin independiente de la fecha de desmontaje del motor en las instalaciones del
instalacin del motor, siempre y cuando hayan comprador, costos de transporte del producto
sido satisfechos los siguientes requisitos: y gastos de traslado, alojamiento y alimentacin
del personal de Asistencia Tcnica cuando
transporte, manipulacin y almacenamiento sean solicitados por el cliente.
adecuados;
instalacin correcta y en condiciones Los servicios en garanta sern prestados
ambientales especficas y sin presencia de exclusivamente en talleres de Asistencia
gases corrosivos; Tcnica Autorizada Weg o en la propia fbrica.
operacin dentro de los lmites de la
capacidad del motor; Se excluyen de esta garanta los componentes
realizacin peridica del debido cuya vida til, en uso normal, sea inferior al
mantenimiento preventivo; perodo de garanta otorgado por Weg . Las
realizacin de reparaciones y/o reparaciones o substituciones de piezas o
modificaciones al producto original efectuada productos, a criterio de Weg o su Asistencia
solo por los agentes autorizados de la Red de Tcnica Autorizada, no prorrogar el plazo de
Asistencia Tcnica Weg; garanta original.
entregar el producto al provedor en el caso
de ocurrir un fallo con reclamacin de garanta La presente garanta se limita al producto
en un perodo mnimo suficiente como para entregado, no siendo responsable Weg por
identificar la causa de la anomalia y su daos a personas, a terceros, a otros equipos
conveniente reparacin; e instalaciones, lucros cesantes o cualquier
dar aviso inmediato a Weg, por parte del otro dao emergente o consecuente.
DEUTSCH
VOR MONTAGE DES MOTORS, LAGERUNG

BITTEN WIR SIE DIESE
BETRIEBSANLEITUNG MIT ALLER
Motoren, die nicht sofort nach Lieferung
SORGFALT DURCHZULESEN! installiert werden, sind in geschlossenen,
trockenen Rumen, frei von Staub, Gasen,
EINGANSPRFUNG korrosiven Dmpfen und Schwingungen, bei
gleichmiger Temperatur und in normaler
Unmittelbar nach dem Empfang ist der Motor Montageposi-tion zu lagern. Es drfen keine
auf uerliche Transportbeschdi-gungen zu anderen Teile gegen den Motor gestellt werden.
untersuchen. Die Temperatur fr das Largen von
Die auf dem Leistungschild angegebenen Motren muss zwischen 5C und 60C, mit einer
Daten prfen. Luftfeuchtigkeit nicht bes 50% fiegen.
Wenn vorhanden,Tranportsicherung vor Werden Motoren lnger als als zwei Jahre
Inbetriebnahme entfernen. gelagert werden, mssen vor Inbetriebnahme
Motorwelle mu von Hand frei drehbar sein. die Kugellager gewechselt werden, oder nach
DEUTSCH
entfernen des alten Fettes neu geschmiert
HANDHABUNG UND TRANSPORT werden.
Bei Einphasenmotoren, die lnger als zwei
1 - Allgemein Jahre gelagert werden, mssen die
Kondensatoren vor Inbetriebnahme gewechselt
MOTOREN DRFEN NIEMALS AN werden.
DER WELLE, SONDERN NUR AN Werden Motoren lnger als 6 Monate in
DIE DAFR VORGESEHENE Rumen mit hoher Feuchtigkeit gelagert,
RINGSCHRAUBE GEHOBEN empfehlen wir die Welle des Motors mindestens
WERDEN. einmal pro Monat von Hand zu drehen und vor
Hebevorrichtungen, wenn vorgesehen, Inbetriebnahme den Isolationaswiderstand zu
messen.
haben allein den Zweck den Motor zu heben. Ist
Ist der Motor mit Stillstandsheizung
der Motor mit zwei Hebevorrichtungen
versehen, ist es empfehlenswert diese stndig
versehen, mu zum Transport eine Kette durch
eingeschaltet zu lassen.
diese Hebesen gezogen werden.
Prfung des Isolationswiderstandes
Anheben und Ablegen der Motoren mu
vorsichtig ohne Aufschlag gemacht werden, da Vor erstmaliger Inbetriebnahme und/oder
sonst die Kugellager beschdigt weden knnen. bei Feststellung von Feuchtigkeit an den
Wicklungen, mu der Isolationswider-stand der
MOTOREN MIT
Wicklungen ermittelt werden.
ZYLINDERROLLENLAGERN
BZW.SCHRGKUGELLAGERN
Der Widerstand bei 25C gemessen,
HABEN EINE
betrgt:
LUFERHALTEVORRICHTUNG, UM
Ri (20 x U) / (1000 + 2P) [M]
TRANSPORTSCHDEN AN DEN (gemessen mit einem Widerstandsme-gert
LAGERN ZU VERMEIDEN. bei 500 Vdc); wo: U = Spannung (V); P =
DIE TRANSPORTSICHERUNGEN Leistung (kW).
ODER
Liegt der gemessene Isolationswider-
LUFERFESTSTELLVORRICHTUNGEN
stand der Wicklung unter 2 MW, mu sie nach
NSSEN IMMER BEIM
der unten angegebenen Methode getrocknet
TRANSPORT DES MOTORS
werden:
VERWENDET WERDEN, AUCH
WENN DIES DIE ABKUPPLUNG Den Motor in einem Trockenschrank
DER ANGETRIEBENEN MASCHINE mit einer Temperatur von 80C lagern.Die
ERFORDERT. Temperatur jede Stunde um 5C bis auf 105C
erhhen. Den Motor mindestens eine Stunde Motoren fr gefhrdeten Zonen dr-fen
bei dieser Temperatur halten. nur in Gebieten eingebaut werden, wenn die
Angaben des Leistungsschildes dieser Zone
berprfen, ob der Isolationswider- entsprechen.
stand der Wicklung sich konstant verhlt und
dem Mindestwiderstand entspricht. Wenn nicht, BEI MASCHINEN MIT KHLUNG
eine neue Trnkung des Stnders vornehmen. DURCH UMGEBUNGSLUFT, MU
DIE KHLLUFT UNGEHINDERT
INSTALLATION ZU- UND ABSTRMEN KNNEN.
1 - Wartung und Installation DIE WARNE VOM MOTOR AB-
GEGEBEN LUFT DARF NICHT
Der elektrische Anschlu und die WIEDER VOM LFFTER
Motorschutzvorrichtungen mssen nach den ANGESAUGT WERDEN. DER
rtlichen Vorschriften ausgefhrt werden. In- ABSTAND ZWISCHEN DEN LUFT-
stallation, Inbetriebnahme, Wartung und EINTRITTSFFNUNGEN DES
Reparaturen drfen nur von qualifiziertem MOTORS UND DER WAND SOLL
Fachpersonal durchgefhrt werden. UNGEFHR DES
DURCHMESSERS DER LUFTEIN-
BEVOR WARTUNGSARBEITEN TRITTSFFNUNG ENTSPRECHEN.
GEMACHT WERDEN, VERGE
WISSERN SIE SICH BITTE, DA 3 - Fundament
DER MOTOR VOM NETZ
GETRENNT IST. Motoren mit Fen mssen auf einem
Die Motoren mssen gegen zuflliges festen Fundament aufgebaut werden um
Eisnchalten geschtzt sein. Schwingungen zu vermeiden.
Bei Wartungsarbeiten darauf achten, da Der Kufer trgt die Verantwortung fr die
Zusatzgerte, wie Kondensatoren, Vorbereitung des Maschinenfun-damentes.
Frequenzumwandler oder hnliches vom Netz
getrennt und entladen sind. Stahlstrukturen sollten einen korro-
sionsschtzenden Anstrich erhalten.
Um das Eindringen von Staub oder
Wasser in den Innern des Klemmen-kastens zu 4 - Entwsserungsffnungen
verhindern, mssen die ffnungen mit
Kabelverschraubung oder Genwinderohr Falls die Bauform des Motors nicht der
geschlossen werden. Standarddausfhrung entspricht, ist zu
gewhrleisten, da alle Entwsserungs-
2 - Betriebsbedingungen ffnungen nach unten gerichtet sind.
Elektrische Motore knnen 5 - Auswuchten

normalerweise bis zu einer Hhe von 1000 m
ber den Meeresspiegel und einer DIE WEG MOTOREN SIND
Umgebungstemperatur bis hchstens 40C WERKSEITIG DYNAMISCH MIT
ohne Leistungsreduktion eingebaut werden. HALBER PASFEDER OHNE LAST,
Abweichung sind auf dem Leistungschild ABGEKUPPELT AUSGEWUCHTET.
angegeben.
DIE STROM-, SPANNUNGS, Die Antriebselemente, wie Riemen-
FREQUENZ-, UMDREHUNGS-, scheiben, Kupplungen, usw. mssen
LEISTUNGSWERTE, USW., DIE ZUM dynamisch mit halber Passfeder vor dem Einbau
BETRIEB ERFORDERLICH SIND, ausgewuchtet Werden. Zum Auf-und Abziehen
MIT DEN DATEN DES LEISTUNGS- der Antriebselemente immer dafr geeignete
SCHILDES VERGLEICHEN. Werkzeuge verwenden.
6 - Ausrichten 8 - Anschlu
WARNUNG:
Auch beim Stillstand des Motors knnen
DIE WELLENENDEN GEGENSEITIG gefhrliche Spannungen im Klemmenkasten fr
AUSRICHTEN. WENN MGLICH die Versorgung vom Heizelementen oder fr
FEXIBLE KUPPLUNGEN eine direkte Wicklungsbeheizung anliegen.
VERWENDEN.
WARNUNG:
Vor Inbewtriebnahme vergewissern, da Bei Einphasenmotoren, kann die Rest-
Paralelitt der Wellen gewhrleitet ist. ladung des Kondensators auch beim
Stillstanddes Motors eine elektrische Spannung
Beim Auf- und Abziehen von Riemen- ber die Motorklemmen zur Folge haben.
scheiben, Kupplungen, usw. geeignete
Werkzeuge zur Vermeidung von Lagerschden FALSCHER ANSCHLU KANN DIE
benutzen. WICKLUNG DES MOTORS
ZERSTREN.
DEUTSCH
Bei Montage von Kupplungshlften
sicherstellen, da der Luftspalt Y kleiner als Netz- und Anschlsspannung laut
-0,05 mm und der Unterschied von X1 bis X2 Leistunschild beachten. Spannungs-
kleiner als 0,05 mm ist. schwankungen von 10%, Frequenz-
schwankungen von 5% und Schwankungen
der Summe der beiden von 10% sind zulssig.
9 - Motorschaltungen
Motore sollten bevorzugt direkt

eingeschaltet werden. Falls dies nicht mglich
ist, sollten geeignete Last- und
Spannungsschaltungen gewhlt werden.
Der Anschlu der Phasen in der

Bemerkung: Ma X1 und X2 mu Reihenfolge L1, L2, L3 ergibt Rechtslauf, auf die
min. 3mm sein Kupllung gesehen.
Ausrichtungstoleranz Der Drehsinn kann durch Vertauschen
zweier beliebiger Kabel gendert werden.
7 - Riemenscheiben UM EINE SICHERE VERBINDUNG

ZU GEWHRLEISTEN, SOLL DER
Wenn die bertragung ber Scheiben ANSCHLU VON QUALIFIZIERTEM
und Riemen erfolgt, mu beachtet werden: FACHPERSONAL
Da die Riemen nur so viel gespannt sind, DURCHGEFHRT WERDEN. NACH
da sie whrend des Betriebes nicht schlupfen; DEM ANSCHLU MU
maximal zulssige Riemenspannung, den BERPRFT WERDEN, OB NICHT
entsprechenden Katalogen entnehmen. FREMDKRPER IM
ANSCHLUKASTEN VERGESSEN
WURDEN. NICHT BENUTZTE
KABELEINGNGE MSSEN
ACHTUNG: VERSCHLOSSEN SEIN.
bermiges Spannen der
Antriebsriemen hat Beschdigung der Anschlukabel entesprechend dem
Lager und Bruch der Welle Leistungsschild angegebener Stromstrke
zur Folge ! auswhlen.
VOR DEM EINSCHALTEN DES 1 - Allgemeine berprfung
MOTORS, DIE ERDUNG PRFEN
UND SICHER-STELLEN, DA SIE berprfen Sie den Motor in regel-migen
VORSCHRIFTSMIG Abstnden.
AUSGEFHRT WURDE. Halten Sie den Motor sauber und sorgen Sie
GEEIGNETE ERDUNG IST fr eine freie Khllufzufhrung und Abfhrung.
WICHTIG UM UNFLLE ZU berprfen Sie den Zustand der
VERMEIDEN. Wellendichtungen (z. B. - V-Ring) und ersetzen
Sie sie , wenn ntig.
berprufen Sie den Zustand aller
Verbindungen und Verbindungselemente (z. B.
Wenn der Motor mit Schutzeinrich-
Schrauben).
tungen, wie Temperaturfhler, Thermostate,
berprfen Sie den Zustand der
Thermistore, thermische Schutzeinrichtungen,
Lager auf ungewhnliche Gerusche,
usw. ausgerstet ist, sind die entsprechenden
Lagertemperaturerhgung und Zustand des
Anschlsse zu machen um die grte Sicherheit
Schmierfettes.
zu gewhrleisten.
Im Falle von Zustandsvernderungen ist der
Motor zu zerlegen, die Bauteile zu untersuchen
10 - Einschalten
und ggf. zu erneuern.
Diese berprfungsintervalle hngen
vom Motortyp und von den Arbeits - und
Umweltsbedingungen ab.
BEVOR DER MOTOR
EINGESCHALTEN WIRD,
PASSFEDER SICHERN ODER
SCHMIERUNG
ENTFERNEN.
UM EINEN SICHEREN BETRIEB
DES MOTORS ZU
a) Der Motor mu ruhig laufen. Falls dies GEWHRLEISTEN, SIND DIE
nicht der Fall ist, Motor abschalten und Montage VORGESEHENEN
und Anschlsse vor einem neuen Einschalten SCHMIERFRISTEN DER
berprfen. KUGELLAGER EINZUHALTEN.
1 - Motoren ohne Nachmiereinrichtung

b) Treten zu hohe Schwingungen auf,
berprfen, ob die Befestigungsschrau-ben Bis Achshhe 200 sind die Motoren in der
angezogen sind, oder bestimmen, ob die Regel ohne Nachschmiervorrichtung gebaut.
Schwingungen von angekuppelten Maschinen Diese Motoren mssen wie folgt nach dem
bertragen werden. Wartungspaln nachgeschmiert werden:
Motor sorgfltig zerlegen.
Altes Schmierfett entfernen.
c ) Whrend einer kurzer Zeit die Lager mit geeignetem Waschmittel
Maschine mit Nennlast betreiben und den auswaschen und mit Druckluft ausblasen.
Betriebsstrom mit dem des Leistungs-schildes Lager sofor wieder mit neuem Fett fllen.
vergleichen.
2 - Motoren mit Nachmiervorrichtung
Um einen einwandfreiem Fettwechsel im

WARTUNG Innern des Lagers zu gewhrleisten, wird
empfohlen den Motor whrend des Laufes
nachzuschmieren. Falls dies wegen drehender
WARNUNG: Teile (Riemenscheiben, Kupplungen, usw.) in
SICHERHEITS - CHECK LIST der Nhe des Schmiernipples nicht mglich ist,
soll folgendermaen vorgegangen werden: Das Einpressen des ganzen vorge-sehenen
Schmiernippel und Schmiernippelumgebung Fettes mit einem mal kann das Eindringen des
reinigen. Fettes im Innern des Motors verursachen.
Ungefhr die Hlfte Menge des vorgesehenen
Fettes einpressen und den Motor whrend eine ZUR NACHMIERUG NUR
Minute bei Nenn-drehzahl betreiben; den Motor HANDFERRPRESSEN
ausschal-ten und das restliche Fett einpressen. VERWENDEN
NACHSCHMIERINTERVALLER
TABELLE 1 - KUGELLAGER - Serie 62/63

Nachschmierintervalle (Betriebsstunden horizontale Aufstellung)
II polig IV polig VI polig VIII polig X polig XII polig Fettmenge
Serie 62
Lager 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz (g)
6209 18400 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 9
DEUTSCH
6211 14200 16500 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 11
6212 12100 14400 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
Serie 63
6309 15700 18100 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
6311 11500 13700 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 18
6312 9800 11900 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 21
6314 3600 4500 9700 11600 14200 16400 17300 19700 19700 20000 20000 20000 27
6316 - - 8500 10400 12800 14900 15900 18700 18700 20000 20000 20000 34
6319 - - 7000 9000 11000 13000 14000 17400 17400 18600 18600 20000 45
6322 - - 5100 7200 9200 10800 11800 15100 15100 15500 15500 19300 60
TABELLE 2 - ROLLENLAGER - Serie NU 3

Nachschmierintervalle (Betriebsstunden horizontale Aufstellung)
II polig IV polig VI polig VIII polig X polig XII polig Fettmenge
NU 309 9800 13300 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
NU 311 6400 9200 19100 20000 20000 20000 20000 20000 20000 20000 20000 20000 18
NU 312 5100 7600 17200 20000 20000 20000 20000 20000 20000 20000 20000 20000 21
NU 314 1600 2500 7100 8900 11000 13100 15100 16900 16900 19300 19300 20000 27
NU 316 - - 6000 7600 9500 11600 13800 15500 15500 17800 17800 20000 34
NU 319 - - 4700 6000 7600 9800 12200 13700 13700 15700 15700 20000 45
NU 322 - - 3300 4400 5900 7800 10700 11500 11500 13400 13400 17300 60
NU 324 - - 2400 3500 5000 6600 10000 10200 10200 12100 12100 15000 72
Bemerkung: Fr jede Temperaturerhhung von 15 0C

reduziert sich der Nachmierintervall wiederum
ZZ Kugellager von 6201 bis 6307 brauchen um die Hlfte.
nicht nachgeschmiert werden. Sie haben eine Die oben angegebenen Schmierintervalle
Lebensadauerschmierung ber 20.000 beziehen nur fr den Einsatz von Polyrex-
Betriebsstunden. Fette.
Tabelle 1 und Tabelle 2 geben Bei Motoren der vertikalen Bauform reduziert
Nachmierintervalle an fr Lagertemperaturen sich der Nachschmierintervall um die Hlfte im
bis zu 700C (fr Lager bis 6312 und NU 312) Vergleich zu den Motoren der horizontalen
und Temperaturen bis 850C (fr Lager 6314 Bauform.
und NU 314 und grer).
WIR EMPFEHLEN KUGELLAGER Vorrichtungen werwenden, die auf die
FR DIREKT GEKUPPELTE Seitenflche des abzuziehenden Innen-deckel
MOTOREN. oder auf ein Nebenteil drcken mssen.
Um einen sicheren Betrieb zu gewhr-
leisten und sptere Schden zu vermei-den, is
ACHTUNG
es wichting, da der Wechsel von Kugellagern
BERSCHUSS AN SCHMIERFETT
mit groer Sorgfalt und Sauberkeit
KANN LAGERBERHITZUNG
vorgenommen wird. Neue Kugellager sollen erst
VERURSACHEN UND DAS LAGER
kurz vor dem Einbau ausgepackt werden.
VOLLSTNDIG ZERSTREN.
Vor dem Einbau neuer Kugellager
sicherstellen, da Lagersitz gratfrei und ohne
Vertrglichkeit von Polyrex E M Schlagmarken ist.
Schmierfett mit anderen Fetten: Zum aufziehen sollte das Lager im lbad
oder induktiv erhitzt werden. Niemals mit harten
Polyrex EM enthlt Verdickung auf Gegestnden auf das Lager schlagen.
Polyuhrethanbasis und Minerall. Es ist daher
kompatibel mit anderen Schmierfetten, die
folgende Komponenten enthalten: ERSATZTEILE
Lithium-Basis oder Zusammensetzungen aus
Lithium oder Polyuhrethan und hoch-raffiniertes
Minerall. Bei der Bestellung von Ersatzteilen sollte
Additive gegen Korrosion, Rost und Additive die vollstndige Typenbezeichnung des Motors
gegen Oxidation. (Leistungschild) angegeben werden.
Wenn der Motor mit einer Seriennummer
Anmerkung: gekennzeichnet ist, so ist diese ebenfalls
Obwohl Polyrex EM kompatibel ist mit anzugeben.
Schmierfetten wie oben beschrieben, empfehlen
wir es nicht mit anderen Fetten zu mischen .
Wenn Sie beabsichtigen andere Schmierfette MOTOREN FR
als die oben empfohlenen einzusetzen, fragen
Sie bitte bei WEG nach.
EXPLOSIONSGEFHRDETE
Fr Anwendungen mit hohen oder tiefen BEREICHE
Temperaturen, Drehzahlwechseln, etc., wird der
Typ des Schmierfettes und die Nachschmierfrist Ausser den oben genannten
auf einen zustzlichen Typenschild am Motor Empfehlungen is noch folgendes zu beachten:
ausgewiesen.
DIE EINORDUNG DER
AUFSTELLUNGS-RUME NACH
BEI DER ANWENDUNG VON
VORKOMMENDEN
STANDARDMOTOREN IN
EXPLOSIONSFHIGEN
SONDERUMGEBUNGEN ODER
GEMISCHEN IST
SONDERANWENDUNGEN,
VERANTWORTLICHKEIT DES
BITTEN WIR SIE SICH VON WEG
KUNDES.
BERATEN ZU LASSEN.
Motoren fr explosionsgefhrdete
DEMONTAGE UND MONTAGE Bereiche werden nach bestimmten Normen
hergestellt und von Prfgesellschaften fr diese
Demontage und Montage soll nur von Bereiche Breiche bescheinigt.
Fachpersonal, unter Verwendung von
geeigneten Werkzeugen und Methoden, 1 -Aufstellung
durchgefhrt werden. Die Aufstellung muss unter Berck-
Zum Abziehen von Kugellagern, sichtung der lokalen Gesetzen vorge-nommen
Abdrckscharauben bzw. geeignete werden.
DIE AUFSTELLUNG DER NICHT VERSUCHEN
MOTOREN IN BESCHDIGTE TEILE ZU
EXPLOSIONSGEFHRDETEN REPARIEREN. BESCHDIGTE
BEREICHEN MUSS VON TEILE MSSEN GEGEN NEUE
QUALIFIZIERTEM PERSSONAL VOM WERK HERGESTELLTE
VORGENOMMEN WERDEN. DIE TEILE ERSETZT WERDEN.
MOTOREN, WENN BEI
NENNSTROM BETRIEBEN,
MSSEN IMMER MIT
ENTSPRECHENDEM MOTOREN BER
THERMOSCHUTZ VERSEHEN
FREQUENZUMRICHTER BETRIEBEN
SEIN.DIESE SCHUTZEIN-
RICHTUNG KANN BESTANDTEIL
DES MOTORS SEIN ODER
Wird der Motor ber Fequenzumrichter ohne
USSERLICH ANGEBAUT
WERDEN. Filter betrieben, knnen folgende
Motoreigenschaften negativ beeinflusst werden:
DEUTSCH
2 - Wartung Wirkungsgrad.
Die Wartung sollte nur von geschultem Schwingung.
Fachpersonal oder WEG-Servicedienst Geruschpegel.
ausgefhrt werden. Nennstrom.
Wird die Reparatur dieser Motoren in nicht bertemperatur.
zugelassenen Werksttten von nicht Lebensdauer der Isolation.
genehmeigtem Service-Personal durchge-fhrt, Lebendauer der Wlzlager.
trgt der Kunde alleinige Verantwor-tung fr alle
Schaden, die durch diese Arbeit verursacht 1 - Normmotoren
werden knnen.
Bei Betriebsspannungen unter 440V, braucht
kein Filter eingesetzt werden
JEDE ELEKTRISCHE ODER
Bei Betriebsspannungen gleich oder hher
MECHANI-SCHE NDERUNG
als 440V, aber niedriger als 575V, mssen, wenn
DER MOTOREN FR
EXPLOSIOSGEFHRDETE die Kabel zwischen Motor und Umrichter
BEREICHE ERKLRT DIE lnger als 20 m sind, Filter eingesetzt werden.
BESCHEINIGUNG DIESER Bei Betriebsspannungen gleich oder hher
MOTOREN UNGLTIG. als 575V, mssen immer, unab-gesehen von
der Kabellnge, Filter eingesetzt werden.
Bei der Auftellung, Wartung und

Nachschmierung mu folgendes beachtet
werden: DIE NICHTEINHALTUNG DIESER
Sicherstellen, dass die Bauteile frei von Grat, EMPFEHLUNGEN FHRT ZUR
Schmutz oder Schlagmarken sind. AUFHEBUNG DER GARANTIE.
Besichtigen, ob die Bauteile einwand-freiem
Betriebszustand aufweisen.
Die Zusammenbauflchen der Lagerschilder 2 - Motoren fr Umrichterbetrieb (Inverter
einlen um den Einbau zu erleichtern. Duty)
Zur Montage nur Gummihammer verwenden
Sicherstellen, dass alle Schrauben fest Bei Motoren fr Umrichterbetrieb, die
engezogen sind. Betriebsspannung des Motors fr die
Zur Messung des Spieles des auferzwungene Khlung beobachten.
Klemmenkastensitzes eine Lehre benutzen Motoren diese Reihen erfordern keinen
(kleiner als 0,05mm). Einsatz von Filter Filter.
GEWHRLEISTUNGEN
Die Gewhrleistungsfrist der WEG- Produkte verbundenen Kosten ein, wie Transport des
betrgt 12 Monate fr Material-mngel, sofortige Benachrichtigung des Kunden
Konstruktion oder Ausfhrung. Sie Beginnt mit ber die aufgetretenen Fehler, die spter von
dem Rechnungsdatum des Herstellers oder WEG als Herstellungsfehler besttigt werden
Verteiler/Verkufer und endet sptestens 18 mssen. Produktes, Reise-, und
Monate nach dem Herstellungsdatum,unter Aufenthaltskosten des Kundendienst-
Bercksich-tigung und Einhaltung folgender personals, sowie die Kosten fr den Ein- und
Bedingungen: Ausbau beim Besteller. Die
Kundendienstleistungen whrend der
geeigneter Transport, Handhabung und Gewhrleistungsfrist werden allein in WEG
Lagerung; Kundendienstwerksttten oder im Werk des
Korrekte Aufstellung unter vorgeschrie- Herstellers vorgenommen.
benen Umgebungsbedingungen, ohne die
anwesenheit von aggressiven Mitteln; Von dieser Gewhrleistung sind
Betrieb unter Bercksichtigung der Daten ausgeschlossen die Bauteile, deren
des Leistungschildes; Lebensdauer unter normalem Einsatz krzer
Ausfhrung der vorbeugenden Wartung in ist als die vorgesehene Gewhrleistungsfrist.
vorgesehenen Zeitabstnden;
Ausfhrung von Reparaturen / nde-rungen Eine whrend der Garantiezeit ausgefhrte
nur durch WEG-Service-Personal; Reparatur oder Ersatzteilleistung verlngert
Das fehlerhafte Produkt whrend einer die Garantiezeit nicht.
Mindestzeitspanne zur Reparatur zur
Verfgung stellen, um whrend dieser Zeit die Diese Gewhrleistung beschrnkt sich allein
Ursache des aufgetretenen Problems auf das gelieferte Produkt. WEG trgt keine
festzustellen und die entsprechende Haftung fr Personenver-letzung,oder
Reparatur ausfhren zu knnen; Schaden an andere Einrichtungen/Gerten,
Gewinnverlust oder irgendwelche sich
Die Gewhrleistung schliet nicht die damit ergebende Folgenschden.
FRANAIS
LIRE ATTENTIVEMENT CETTE STOCKAGE

NOTICE AVANT DINSTALLER LE
MOTEUR. Les moteurs qui ne sont pas directement
installs doivent tre stocks dans un endroit
sec, labri des poussires, des vibrations, des
CONTROLE A LA RECEPTION fumes et vapeurs corrosives, des variations de
temprature, et en position normale, spars des
Vrifier que le moteur na subi aucun dommage autres objets.
pendant le transport. La temprature de stockage des moteurs
Vrifier les donnes de la plaque signaltique. doit rester parmi 5C et 60C, avec lhumidit
Enlever le dispositif de blocage de Iaxe (sil y pas excdant 50%.
en a un) avant de faire tourner le moteur.
Faire tourner larbre la main pour sassurer Si un moteur est conserv en stockage
quil tourne librement. pour plus de deux ans, les roulements doivent
tre remplacs, ou la graisse compltement
limine et nettoye.
MANUTENTION ET TRANSPORT Pour les moteurs monophass, aprs
deux ans de stockage il faut remplacer les
1 - Gnralits condensateurs (sil y en a).
UN MOTEUR NE DOIT JAMAIS Nous recommandons de faire tourner
FRANAIS
TRE SOULEV PAR SON ARBRE, larbre, la main, au moins une fois par mois, et,
MAIS PAR LES OEILLETS DE avant installation, de mesurer la rsistance
LEVAGE, QUI SONT CALCULS disolation des moteurs stocks depuis plus de
POUR EN SUPPORTER LE POIDS. 6 mois, ou dans des zones forte humidit.
Les accessoires de levage, sil y en a, sont Si le moteur est muni de rsistances de

calculs pour supporter uniquement le poids rchauffage, celles-ci devraient tre mises en
du moteur. Sil y en a deux, il faut utiliser une service.
chane double pour soulever le moteur.
Vrification de la rsistance disolement
Les mouvements de leve et de pose
doivent tre faits en douceur, sans aucun choc, II faut mesurer la rsistance disolement
sinon les roulements pourraient tre avant de mettre le moteur en service, et / ou si
endommags. lon suspecte que les enroulements soient
humides.
PENDANT LE TRANSPORT, LES
ROULEMENTS DES MOTEURS La rsistance, mesure 25C doit tre:
ROULEMENTS ROULEAUX OU
CONTACT ANGULAIRE SONT Ri (20 x U) / (1000 + 2P) [M]
PROTGS PAR UN DISPOSITIF DE (mesur avec un MEGGER 500 V CC);
BLOCAGE DE IAXE. ou U = tension (en V); P = puissance (en kW).
Si la rsistance disolement est infrieure

CE DISPOSITIF DE BLOCAGE DOIT 2 Mohms, les enroulements doivent tre schs
TRE UTILIS LORS DE TOUT en chauffant le moteur dans une tuve, un
TRANSPORT ULTRIEUR DU minimum de 80C, augmentant de 5C toutes
MOTEUR, MME SI CECI IMPLIQUE les heures jusque 105C, et restant cette
LE DMONTAGE DE SON temprature pour au moins 1 heure.
ACCOUPLEMENT AVEC LA
MACHINE ENTRANE. Vrifier que la rsistance disolement reste
constante et conforme aux valeurs prvues. Si Les moteurs fournis pour installation en
non, limprgnation du stator doit tre refaite. zone risques ne peuvent tre installs que dans
des zones dont les caractristiques
INSTALLATION correspondent celles dfinies sur la plaque
signaltique.
1 - Scurit
VEILLER GARDER LES ORIFICES
Tout le personnel qui installe des DENTRE ET DE SORTIE DAIR
systmes lectriques (y compris manutention, BIEN DGAGS ET PROPRES. LAIR
levage), en utilise ou en assure la maintenance EXTRAIT DU MOTEUR NE DEVRAIT
doit tre bien au courant des normes et rgles PAS SE MLANGER LAIR
de scurit applicables, et doit les respecter ENTRANT. LA DISTANCE ENTRE
soigneusement. LENTRE DAIR ET LA PAROI NE
DEVRAIT PAS TRE INFRIEURE
Nous recommandons de rserver ces DU DIAMTRE DE LORIFICE
activits du personnel dment qualifi. DENTRE DAIR.
3 - Fondation
SASSURER DE CE QUE
LALIMENTATION DES MOTEURS
Les moteurs munis de pattes doivent tre
LECTRIQUES SOIT COUPE
installs sur une fondation rigide pour viter les
AVANT TOUTE OPRATION DE
vibrations excessives.
MAINTENANCE, ET PROTGE
CONTRE TOUTE MISE SOUS
Lacheteur est entirement responsable de
TENSION ACCIDENTELLE.
cette fondation.
Dconnecter le moteur de son alimenta-
tion, et vrifier que tous les accessoires, soient Les pices mtalliques doivent tre peintes
galement mis larrt et dconnects. pour les protger de la corrosion.
Pour viter toute pntration de poussire
et / ou deau dans la bote bornes, munir les La fondation doit tre plane et
orifices dentre des conducteurs de presse- suffisamment rsistante pour supporter tout
toupes ou de tubes filets. effort de chocs elle doit tre conue pour amortir
toute vibration qui serait due mise en
Pour viter tout dommage, ne pas rsonnance.
modifier la rgulation des dispositifs de
protection. 4 - Orifices de drainage
2 - Conditions de service Si la configuration dinstallation est

diffrente de celle prvue la commande,
Sauf autre indication sur la plaque sassurer, dans la configuration envisage, de
signaltique, les moteurs sont en gnral ce que les orifices de drainage des condensats
calculs pour tre utiliss une altitude dau se trouvent bien la partie infrieure.
maximum 1000 m au dessus du niveau de la
mer, des tempratures ambiantes comprises 5 - Equilibrage
entre 0 et 40C.
LES MOTEURS WEG FONT IOBJET
DUN QUILIBRAGE DYNAMIQUE,
VRIFIER LA CONFORMIT DES AVEC DEMI-CLAVETTE, VIDE ET
CARACTRISTIQUES DE SANS ACCOUPLEMENT.
TENSION, INTENSIT,
FRQUENCE, VITESSE, Les lments de transmission, tels que les
PUISSANCE, ETC. DU MOTEUR, poulies, accouplements, etc.; doivent faire Iobjet
INDIQUES SUR LA PLAQUE dun quilibrage dynamique avec demi-clavette,
SIGNALTIQUE, AUX VALEURS avant installation. Toujours utiliser un outillage
PRVUES LA COMMANDE. appropri pour le montage et le dmontage.
6 - Alignement ATTENTION:
Le condensateur dun moteur
ALIGNER LES BOUTS DARBRE ET monophas peut conserver une charge
UTILISER DES ACCOUPLEMENTS rsiduelle, qui apparat aux bornes du moteur,
FLEXIBLES CHAQUE FOIS QUE mme aprs larrt.
CEST POSSIBLE.
Sassurer de ce que les fixations du moteur

UN RACCORDEMENT ERRON
ne permettent pas daltrations de lalignement, PEUT GRILLER LE MOTEUR!
qui pourraient tre cause de dommages aux
quipements.
La tension et le mode de connexion sont
Lors du montage dun demi- indiqus sur la plaque signaltique. Les
accouplement, veiller utiliser un outillage variations maximum acceptables sont de 10%
appropri pour protger les roulements. pour la tension, de 5% pour la frquence, et de
10% pour le total des deux.
Montage correct dun demi-
accouplement: vrifier que le jeu Y soit infrieur 9 - Mthode de dmarrage
0,05 mm, et que la diffrence X1 - X2 soit
galement infrieure 0,05 mm. De prfrence, dmarrer le moteur en
direct. Si ce nest pas possible, employer une
mthode compatible avec la charge et la tension
du moteur.
FRANAIS
Le sens de rotation est le sens horlogique,
lorsque le moteur est vu du ct de
Iaccouplement et si la squence de connexion
des phases est L1, L2, L3.
Note: Lecarts X1 et X2 doit tre dun Pour changer le sens de rotation,

minimum de 3mm intervertir deux des trois conducteurs
Figure, dessin et tolrances dalignement dalimentation.
7 - Transmission par courroie
En cas de transmission par poulie et LE RACCORDEMENT AU RSEAU

courroie, il faut tendre la courroie juste assez DALIMENTATION DOIT TRE
pour viter le glissement en fonctionnement, EFFECTU PAR DU PERSONNEL
conformment aux spcifications du COMPTENT, EN VEILLANT
fournisseur. ASSURER UNE CONNEXION SRE
ET DURABLE. APRS
ATTENTION: RACCORDEMENT DU MOTEUR,
Une tension excessive peut VRIFIER QUIL NE RESTE AUCUN
endommager les roulements et conduire CORPS TRANGER DANS LA
la rupture de larbre. BOTE CONNEXIONS,
8 - Raccordement lectrique ET VEILLER FERMER LES
ENTRES DE CBLE NON
ATTENTION: UTILISES.
Mme lorsque le moteur est larrt,
certaines bornes de la bote connexions
peuvent rester sous tension, pour lalimentation Veiller utiliser les dimensions de cbles
de rsistances de rchauffage, ou pour le correctes, correspondant aux intensits
chauffage direct des enroulements. indiques sur la plaque signaltique.
AVANT DE METTRE LES BORNES Si, en fonctionnement normal, une variation
SOUS TENSION, VRIFIER QUE LA est dcele, vrifier le moteur et remplacer les
MISE LA TERRE SOIT FAITE pices qui devraient ltre.
CONFORMMENT AUX NORMES
APPLICABLES. CECI EST ESSENTIEL La priodicit des vrifications est
POUR LA PROTECTION CONTRE fonction du type de moteur et des conditions de
LES RISQUES DACCIDENT. service.
Si le moteur est muni de dispositifs de LUBRIFICATION

protection thermique, ou de surveillance de la
temprature, tels que thermostats, thermistors, RESPECTER LA PRIODICIT DE
etc., veiller raccorder ceux-ciaux appareils GRAISSAGE, CELLE-CI EST
correspondants du tableau de commande. FONDAMENTALE POUR LE BON
FONCTIONNEMENT DU MOTEUR.
10 - Dmarrage
1 - Moteurs sans graisseurs
LA CLAVETTE DOIT TRE BIEN
FIXE, OU ENLEVE, AVANT TOUT Les moteurs jusquau type 200 ne
DMARRAGE DU MOTEUR. comportent normalement pas de graisseur. Dans
ce cas, le graissage se fait, lors de la maintenance
a) Le moteur doit dmarrer et fonctionner prventive, de la faon suivante:
de faon rgulire. Si ce nest pas le cas, Iarrter
et vrifier les connexions et le montage avant de Dmonter prcautionneusement le moteur.
le dmarrer nouveau. Enlever toute la graisse.
Nettoyer le roulement avec du krosne ou du
b) En cas de vibration excessive, vrifier diesel.
que les fixations soient correctement serres. Directement renouveler le graissage du
Vrifier galement si les vibrations ne roulement.
proviennent pas dune machine voisine. Un
contrle priodique des vibrations doit tre 2 - Moteurs avec graisseurs
effectu.
II est fortement conseill deffectuer le
c) Faire fonctionner le moteur sa charge graissage pendant le fonctionnement, pour
nominale pendant une courte dure, et vrifier assurer la rpartition de la graisse dans le carter
que le courant correspond celui indiqu la de palier. Si ce nest pas possible, cause de
plaque signaltique. pices en rotation trop proches des graisseurs
(poulies, etc.), qui risqueraient de blesser
loprateur, procder comme suit:
MAINTENANCE
Nettoyer la zone autour du graisseur.
ATTENTION: Injecter environ la moiti de la quantit de
LISTE DE SECURIT graisse et faire tourner le moteur pendant une
minute pleine vitesse; puis larrter et injecter le
1 - Vrification gnrale restant de la quantit de graisse.
Linjection de la quantit totale de graisse en
Vrifier rgulirement le moteur. une fois quand le moteur est Iarrt, risquerait
Le garder propre et assurer une bonne de faire pntrer la graisse dans le moteur, au
ventilation. travers du joint dtanchit intrieur du
Vrifier les joints dtanchit des V Ring, les roulement.
remplacer si ncessaire.
Vrifier ltat des connexions et des fixations. POUR LUBRIFICATION SI DOIT
Vrifier les roulementes, et plus USER SEULEMENT UN
particulirement leur temprature, leur graissage COMPRESSEUR A GRAISE
et labsence de bruit excessif. MANUAL.
PERIODICIT DU GRAISSAGE
TABLE 1 - ROULEMENTS BILLES - Srie 62/63

Periodicit du graissage (heures de travail - position horizontale)
Pole II Pole IV Pole VI Pole VIII Pole X Pole XII Graisse
Srie 62
Palier 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz (g)
6209 18400 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 9
6211 14200 16500 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 11
6212 12100 14400 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
Srie 63
6309 15700 18100 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
6311 11500 13700 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 18
6312 9800 11900 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 21
6314 3600 4500 9700 11600 14200 16400 17300 19700 19700 20000 20000 20000 27
6316 - - 8500 10400 12800 14900 15900 18700 18700 20000 20000 20000 34
6319 - - 7000 9000 11000 13000 14000 17400 17400 18600 18600 20000 45
6322 - - 5100 7200 9200 10800 11800 15100 15100 15500 15500 19300 60
TABLE 2 - ROULEMENTS ROULEAUX - Srie NU 3
FRANAIS
Periodicit du graissage (heures de travai - position horizontale)
Pole II Pole IV Pole VI Pole VIII Pole X Pole XII Graisse
NU 309 9800 13300 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
NU 311 6400 9200 19100 20000 20000 20000 20000 20000 20000 20000 20000 20000 18
NU 312 5100 7600 17200 20000 20000 20000 20000 20000 20000 20000 20000 20000 21
NU 314 1600 2500 7100 8900 11000 13100 15100 16900 16900 19300 19300 20000 27
NU 316 - - 6000 7600 9500 11600 13800 15500 15500 17800 17800 20000 34
NU 319 - - 4700 6000 7600 9800 12200 13700 13700 15700 15700 20000 45
NU 322 - - 3300 4400 5900 7800 10700 11500 11500 13400 13400 17300 60
NU 324 - - 2400 3500 5000 6600 10000 10200 10200 12100 12100 15000 72
Note: verticale, leur intervalle de regraissage est rduit

a la moiti si compar aux moteurs utiliss en
Les paliers ZZ de 6201 jusqu 6307 nexigent position horizontale.
pas de regraissage car leur vie utile est autour
de 20,000 heures. NOUS RECOMMANDONS
Les tables 1 et 2 sont destins pour le temps LUTILISATION DES ROULEMENTS
de graissage sous une temperature du palier A BILLES POUR LES MOTEURS
de 70C (pour paliers jusqu 6312 et NU 312) MONTES EN ACCOUPLEMENT
et temprature de 85C (pour les paliers 6314 DIRECT.
et les NU 314 et plus grand).
Pour chaque augmentation de 15C de la
temperature du palier, le temps de regraissage ATTENTION :
est rduit a la moiti. UN EXCES DE GRAISSE PEUT
Les termps de regraissages donnes ci- CAUSER DES DOMMAGES
dessus sont pour les cas qui sappliquent la IRREMEDIABLES AU ROULEMENT
graisse Polyrex EM. DUS A UNE SURCHAUFFE.
Quand les moteurs sont utiliss en position
Comptabilit de la graisse Polyrex EM Pour monter un roulement, chauffer sa
avec les autres graisses : partie interne avec lquipement adquat
(procd inductif) ou utiliser loutil adquat.
La graisse Polyrex EM contient du
polyurea et lhuile minrale qui la rend PIECES DE RECHANGE
compatible avec les graisses contenant :
Lithium, compos de lithium ou polyurea et
huile minrale hautement raffine. Lors de la commande de pices de
Additif anti-corrosion, anti-rouille et anti- rechange, veuillez veiller spcifier la
oxydant. dsignation complte de type et le code de
produit, de mme que le numro de srie du
Notes : moteur, tels quindiqus sur la plaque
Bien que la graisse Polyrex EM soit signaltique.
compatible avec les graisses mentionnes ci-
dessus, nous dconseillons le mlange avec
dautres graisses. MOTEURS POUR ZONES A RISQUES
Avant toute utilisation dune autre graisse que
celle prconise, nous vous prions de contacter Veiller respecter les recommandations
WEG. suivantes, en plus de celles indiques
Les applications en hautes ou basses prcdemment:
tempratures, variation de vitesse, etc, le type
de graisse et lintervalle de lubrification seront
indiqus sur une plaque signaltique LA DFINITION DE LENDROIT
additionnelle fixe sur le moteur. O INSTALLER LE MOTEUR, DE
MME QUE LA DTERMINATION
TOUJOURS CONSULTER LE DES CARACTRISTIQUES DE
FABRICANT DES LUBRIFIANTS OU LENVIRONNEMENT, SONT DU
WEG, EN CAS DUTILISATION DE DOMAINE DE RESPONSABILIT
MOTEURS STANDARDS DANS DES DU CLIENT.
ZONES SPCIALES OU POUR DES
UTILISATIONS PARTICULIRES.
Les moteurs pour zones risques sont
DEMONTAGE ET MONTAGE fabriqus suivant les normes spcifiques ces
environnements, et sont certifis par des
Le dmontage et le remontage doivent tre organisations de certification internationales.
effectus selon procdure approprie, par du
personnel qualifi, utilisant Ioutillage 1 - Installation
convenable.
Linstallation doit se faire en conformit
Lextracteur doit tre appliqu sur la face avec la rglementation locale applicable.
latrale de Ianneau intrieur dmonter, ou sur
une pice adjacente.
LINSTALLATION DE MOTEURS
II est essentiel que le dmontage et le
POUR ZONES RISQUES NE
remontage des roulements soient faits dans un
DOIT TRE EFFECTUE QUE PAR
environnement propre, pour assurer un bon
DU PERSONNEL COMPTENT, ET
fonctionnement et viter toute avarie. Les
LA PROTECTION THERMIQUE
nouveaux roulements ne seront extraits de leur
DOIT TOUJOURS TRE
emballage quau moment de les monter.
INSTALLE, QUE CE SOIT
EXTERNE OU INTERNE AU
Avant dinstaller un nouveau roulement,
MOTEUR, POUR FONCTIONNER
il faut vrifier labsense dartes vives ou de traces
LINTENSIT NOMINALE.
de coups sur Iarbre.
2 - Maintenance Hausse de la temprature.
Isolation du moteur rduite.
La maintenance doit tre assure par un Dure de vie des roulements rduite.
atelier de rparation agr par Weg.
1 - Moteurs standards
Un atelier ou du personnel non agr par
Weg, qui effectue toute intervention de mainte- Tensions infrieures 440 V nexige pas
nance sur un moteur pour zones risques, sera de filtre.
pleinement responsable de cette intervention et Tensions quivalentes ou suprieure 440 V
de tout dommage qui en rsulterait. ou infrieures 575 V exigent un filtre pour des
cables dalimentation en puissance du moteur
plus long que 20 mtres.
TOUTE MODIFICATION Tensions quivalentes ou plus leves que
LECTRIQUE OU MCANIQUE 575 V exigent un filtre pour toute dimension de
DUN MOTEUR POUR ZONES cables dalimentation.
RISQUES INVALIDE SA
CERTIFICATION. SI DE TELLES
RECOMMANDATIONS NE SONT
Lors de toute intervention de PAS SUIVIES, LA GARANTIE DU
maintenance, installation, graissage, respecter MOTEUR SANNULE.
les consignes suivantes: 2 - Nouvelle srie de Moteurs adapts au
convertisseur
Vrifier que tous les composants sont propres,
FRANAIS
exempts dartes ou coups. Contrler la tension fournie par lensemble
Vrifier que toutes les pices sont en tat parfait. de refroidissement forc.
Graisser les surfaces des garnitures de Filtres ne sont pas demands.
protection avec une huile de protection pour
faciliter lassemblage.
Nutiliser que des marteaux en caoutchouc
pour assembler les pices.
Vrifier le serrage correct des crous.
Utiliser une jauge pour vrifier le jeu de
lassemblage de la bote bornes (moins de
0,05 mm).
NE PAS RUTILISER DE PICES

ENDOMMAGES OU USES. LES
REMPLACER PAR DES PICES
NEUVES DORIGINE.
MOTEURS ENTRAINES PAR

CONVERTISSEUR DE FREQUENCE
Applications comportant lutilisation dun
convertisseur de frquence sans filtre peut
affecter les performances de la manire
suivante:
Rendement moins lv.

Vibration plus leve.
Niveau de bruit plus lev.
Courant nominal plus lev.
CONDITIONS DE GARANTIE
Weg garantit ses produits contre tout dfaut Cette garantie ninclut pas le dmontage dans
de matriaux et de main doeuvre pour douze les installations de lacheteur, ni les cots de
(12) mois partir de la date de la facture mise transport, les frais de logement et subsistance
par lusine, le distributeur autoris ou lagent, du personnel technique si requis par le client.
avec une limite de dix-huit (18) mois aprs la Le service de la garantie ne sera assur que
date de fabrication, indpendamment de la dans des Ateliers Agrs Weg ou dans les
date dinstallation, pour autant que les usines de Weg.
conditions suivantes soient satisfaites:
Les composants dont la vie utile, en usage
Transport, manutention et stockage normal, est infrieure la dure de la garantie,
appropris; ne sont pas couverts par les termes de la
Installation correcte sur base des conditions prsente garantie.
dambiance spcifies, et absence de vapeurs
corrosives; La rparation et / ou le remplacement de
Fonctionnement dans les limites dutilisation; pices ou composants, effectus par Weg et
Respect de la priodicit des interventions / ou tout Atelier Agr Weg, ne donne pas lieu
de maintenance; extension de la garantie.
Rparation et / ou remplacement effectus
seulement par du personnel dment autoris Ceci constitue la seule garantie de Weg pour
par crit par Weg; cette vente, et la socit nest en rien lie ou
Le produit defaillant sera mis disposition du oblige en quoi que ce soit vis--vis de
fournisseur et / ou de latelier de rparation le personnes, tierces parties, autres
temps ncessaire pour dterminer la cause quipements ou installations, y compris, sans
de la dfaillance et la rparation aucune limitation, toute rclamation pour
correspondante; dommages consquents ou cots de
Information immdiate par lacheteur de toute production.
dfaillance survenue, et que celle-ci soit
accepte par Weg comme dfaut de
fabrication.
ITALIANO
SI PREGA DI LEGGERE CON IMMAGAZZINAGGIO

ATTENZIONE QUESTO MANUALE
PRIMA DINIZIARE Se i motori non sono installati
IINSTALLAZIONE. immediatamente, devono essere immagazzinati
in luogo asciutto, privo di polvere, di vibrazioni,
di gas, di fumi corrosivi, con temperatura
CONTROLLO DI RICEVIMENTO uniforme, mettendoli in posizione normale e
senza accostarli con altri oggetti.
Verificare se il motore non ha subito danni La temperatura di stoccaggio dei motori
durante il trasporto. dovr rimanere tra 5C e 60C, con una umidit
Verificare i dati di targhetta. relativa non oltre 50%.
Rimuovere il dispositivo di bloccaggio Nel caso di motori con pi di 2 anni di
dellalbero usato per il trasporto (quando il magazzinaggio, si devono cambiare i cuscinetti
caso), prima di far partire il motore. o sostituire tutto il grasso dopo la pulizia.
Girare lalbero per verificare se lo stesso libero. Nei motori monofasi in magazzino da 2
anni si devono cambiare i condensatori
MANEGGIAMENTO E TRASPORTO (quando provvisti).
Si raccomanda che lalbero dei motori sia

1 - Generale girato a mano almeno una volta al mese e che la
resistenza disolamento sia misurata prima della
I MOTORI NON DEVONO ESSERE installazione, nel caso che i motori siano in
SOLLEVATI PER LALBERO, MA PER magazzino da pi di 6 mesi o immagazzinati in
GLI ANELLI DI SOLLEVAMENTO, condizioni dumidit sfavorevoli.
CHE SONO PROGETTATI PER IL Se il motore provvisto di scaldiglie,
PESO DEL MOTORE. queste devono di preferenza essere alimentate.
Dispositivi di sollevamento, quando Controllo della resistenza disolamento
ITALIANO
forniti, servono appena per alzare il motore. Se
il motore provvisto di due dispositivi di Misurare la resistenza disolamento prima
sollevamento, si deve usare una catena doppia. della messa in servizio del motore e/o quando si
sospetti lesistenza di umidit nellavvolgimento.
II sollevamento e deposito deve essere
dolce, senza urti, perch altrimenti i cuscinetti La resistenza, misurata a 25C, deve
possono essere danneggiati. essere:
MOTORI CON CUSCINETTI A RULLI Ri (20 x U) / (1000 + 2P) [M]

O CONTATTO ANGOLARE SONO (misurato con MEGGER a 500 V.c.c.);
PROTETTI DURANTE IL dove U = tensione (V); P = potenza (kW).
TRASPORTO, PER EVITARE DANNI,
MEDIANTE UN DISPOSITIVO DI Se la resistenza disolamento inferiore a
BLOCCAGGIO. 2 megaohms, lavvolgimento deve essere
essicato come segue:
I DISPOSITIVI DI BLOCCAGGIO Riscaldare in forno alla temperatura

DEVONO ESSERE USATI PER minima di 80C, aumentando di 5C adogni ora,
QUALSIASI ALTRO TRASPORTO fino a 105C. A questa temperatura deve rimanere
DEL MOTORE, ANCHE SE QUESTO per una durata minima di una ora.
ESIGA CHE LO STESSO SIA DI
NUOVO DISACCOPPIATO DALLA Verificare se la resistenza disolamento
MACCHINA AZIONATA. dello statore rimane costante ed entro i valori
minimi raccommandati, contrariamente si dovr I Motori per ambienti a rischio dovranno
fare una nuova impregnazione dello statore. essere installati in aree in conformit con la
identificazione sulla targhetta del motore.
INSTALLAZIONE
MANTENERE IENTRATA E LUSCITA
1 - Sicurezza DEL MOTORE SEMPRE PULITA.
LARIA CONVOGLIATA VERSO IL
II personale che lavora con installazioni MOTORE NON DOVR ESSERE
elettriche, sia nel montaggio, che nelle ASPIRATA DI NUOVO DALLA
operazioni o manutenzione, dovr essere VENTOLA. LA DISTANZA TRA
continuamente informato ed aggiornato al IENTRATA DI ARIA DEL MOTORE E
riguardo delle norme di sicurezza che il servizio LA PARETE DEVE ESSERE ALMENO
richiede con Iobbligo che dette norme vengano DI DEL DIAMETRO DELLA
scrupolosamente seguite. APERTURA DELLA ENTRATA DARIA.
Si raccomanda che tali servizi siano
sempre fatti da personale qualificato.
3 - Fondazione
ACCERTARSI SEMPRE CHE I
MOTORI ELETTRICI SIANO I motori con piedi dovranno essere
DISINSERITI PRIMA DINIZIARE installati sopra fondazioni rigide per evitare
QUALSIASI LAVORO DI eccessiva vibrazione.
MANUTENZIONE.
Lacquirente ha la piena responsabilit per
I motori devono essere protetti contro la preparazione della fondazione.
avviamenti accidentali.
Le parti metalliche delle stesse devono
Quando occorrono servizi di essere verniciate per evitare la corrosione.
manutenzione del motore, disinserire tutta la rete
dalimentazione. Verificare che tutti gli accessori Le fondazioni dovranno essere in piano
siano stati scollegati e disinnestati. e sufficientemente rigide per sopportare eventuali
sollecitazioni da urti. Devono essere
Per evitare la penetrazione di polvere e/o dimensionate in modo da evitare vibrazioni
acqua nellinterno della morsettiera necessario dovute alle risonanze.
istallare pressa cavi o elettrocondoti filettati nella
uscita dei cavi collegamento. 4 - Fori di scarico condensa
Non alterare la taratura dei dispositivi di Controllare che i fori di scarico condensa
protezione, perch gli stessi potrebbero siano situati nella parte inferiore quando il
diventare non operanti. montaggio diverso da quello specificato nella
ordinazione del motore.
2 - Condizioni di operazione
5 - Bilanciamento
Le macchine elettriche in genere sono
indicate per la installazione e servizi ad altitudine
I MOTORI WEG SONO BILANCIATI
fino a 1000m sopra il livello del mare, con una
DINAMICAMENTE CON MEZZA
temperatura ambiente da 0C a 40C. Variazioni
CHIAVETTAA VUOTO E
sono definite sulla targhetta.
DISACCOPPIATI.
COMPARARE I VALORI DI
CORRENTE, TENSIONE, Gli elementi di trasmissione, come per
FREQUENZA, ROTAZIONE, esempio, pulegge, giunti, etc devono essere
POTENZA, ETC, RICHIESTI PER LA bilanciati dinamicamente con mezza
APPLICAZIONE, CON I DATI chiavettaprima che essi siano installati.
CONTENUTI SULLA TARGHETTA Usare sempre utensili adeguati nella installazione
DEL MOTORE. e smontaggio.
6 - Allineamento 8 - Collegamento
ALLINEARE LE ESTREMIT AVVERTENZA

DELLALBERO OD USARE UN Con il motore fermo si pu avere tensione
ACCOPPIAMENTO FLESSIBILE allinterno della scatola morsetti utilizzata per
SEMPRE CHE QUESTO SIA alimentare le scaldiglie o direttamente
lavvolgimento per tenerlo in temperatura. a
POSSIBILE.
motore fermo.
Controllare che i dispositivi di montaggio AVVERTENZA:

del motore non comportino alterazioni Nei motori monofasi i terminali dei
nellallineamento e conseguenti condensatori possono essere in tensione anche.
danneggiamenti nell equipaggiamento.
Nel montaggio della puleggia si devono II COLLEGAMENTO FATTO IN MODO

usare mezzi adeguati ed utensili necessari per NON ADEGUATO PU BRUCIARE IL
non danneggiare i cuscinetti. MOTORE.
Montaggio corretto della puleggia:

assicurarsi che il gioco sia inferiore allo 0,05mm La tensione ed il collegamento sono
e che la differenza da X1 a X2 sia inferiore allo indicati sulla targhetta. La tolleranza accettabile
0,05mm di tensione del 10% la tolleranza accettabile
per la freqenza del 5% e la tolleranza
accettabile nella somma di ambedue del 10%.
9 - Metodo DAvviamento
Di preferenza il motore deve partire con

avviamento diretto. Nel caso che non sia
possibile, usare metodi compatibili con il carico
e la tensione del motore.
ITALIANO
II senso di rotazione orario visto dal lato
comando, collegando le fasi nella sequenza L1,
Nota: Le misure X1 e X2 deve avere al L2, L3.
minimo 3mm
Figura e tolleranze del allineamento Per invertire il senso di rotazione
(in nero) scambiare tra loro i collegamenti di due terminali
qualsiasi.
7 - Azionamento con cinghie
II COLLEGAMENTO DEI TERMINALI
Quando usato un accoppiamento a DELLA RETE DOVR ESSERE FATTA
mezzo pulegge e cinghie si deve verificare: DA UNA PERSONA QUALIFICATA E
Le cinghie devono avere la tensione CON MOLTA ATTENZIONE PER
appena sufficiente per evitare lo slittamento nel GARANTIRE UN CONTATTO
funzionamento, seguendo i limiti del manuale SICURO E PERMANENTE. DOPO IL
del produttore delle cinghie. COLLEGAMENTO DEL MOTORE SI
VERIFICHI CHE NESSUN
OGGETTO STRANO SIA STATO
LASCIATO ALL INTERNO DELLA
ATTENZIONE MORSETTIERA. LE ENTRATE DEI
Uneccessiva tensione delle cinghie TERMINALI CHE NON VENGONO
dannegger i cuscinetti e potr anche USATE DOVRANNO ESSERE
causare una rottura dellalbero. CHIUSE.
Assicurarsi di utilizzare la sezione Controllare le condizioni delle connessioni e
adeguata per i cavi d alimentazione del motore dei bulloni di fissaggio e fondazione.
alla rete, in base alla corrente nominale riportata Controllare le condizioni dei cuscinetti
sulla targhetta dello stesso. prestando attenzione: ad eventuali rumori forti,
vibrazioni, temperatura dei cuscinetti e
PRIMA DI ALIMENTARE I TERMINALI, condizioni del grasso.
VERIFICARE CHE LA MESSA A Quando si rilevino condizioni anomale nel
TERRA SIA STATA FATTA IN funzionamento, si devono controllare le parti e,
ACCORDO CON LE NORME se necessario, sostituirle.
VIGENTI. QUESTO ESSENZIALE
CONTRO IL RISCHIO D INCIDENTI. La frequenza delle ispezioni dipende dal
tipo del motore e dalle condizioni locali di
Quando il motore provvisto di
utilizzo.
dispositivi di protezione di temperatura come:
termostati, termistori, protettori termici etc,
collegare i loro corrispondenti terminali nel
dispositivo adeguato per ottenere il corretto
funzionamento. LUBRIFICAZIONE
10 - Messa in marcia
VERIFICARE GLI INTERVALLI DI
LA CHIAVETTA DEVE ESSERE LUBRIFICAZIONE DEI CUSCINETTI.
COMPLETAMENTE FISSA O TOLTA QUESTO VITALE PER LI BUON
PRIMA DI ATTACCARE IL MOTORE FUNZIONAMENTO DEL MOTORE.
ALLA RETE.
a) II motore deve partire e funzionare in 1 - Motori non provvisti di ingrassatori

modo regolare. In caso contrario fermare il
motore e verificare di nuovo il montaggio ed i I motori fino alla grandeza 200 sono
giunti prima del nuovo avviamento. normalmente forniti con cuscinetti ad
ingrassaggio permanente. In questo caso il
b) Se si verificata una vibrazione reingrassaggio dovr essere effetuato durante
eccessiva, controllare se le viti di fissaggio sono la manutenzione periodica, controllando i
allentate o se la vibrazione proveniente da seguenti aspetti:
macchine adiacenti.
Smontare con attenzione i motori.
c) Adoperare il motore sotto carico Togliere tutto il grasso.
nominale per un certo periodo di tempo e Pulire i cuscinetti con cherosene o gasolio.
comparare la corrente desercizio con quella Rilubrificare i cuscinetti immediatamente.
della targhetta.
2 - Motori provvisti di ingrassatori
MANUTENZIONE
Si raccomanda di fare la rilubrificazione
del motore quando in funzione, per permettere
AVVERTENZA:
la penetrazione ed il ricambio del grasso
CHECK LIST DI SICUREZZA
nellalloggiamento del cuscinetto. Se questo
non fosse possibile a causa della presenza
1 - Ispezione generale diparti in movimento prossime al dispositivo
dingrassaggio(pulegge, giunti etc) che
Ispezionare il motore periodicamente. possono essere un rischio per lintegrit fisica
Mantenere il motore pulito e assicurare una delloperatore, procedere come segue:
buona ventilazione prodotta dalla ventola.
Controllare le condizioni di anelli di tenuta o Pulire I orifizio dellingrassatore.
V-ring e cambiarli se necessario. Iniettare pi o meno la met della quantit totale
stimata di grasso e far girare il motore per un(1) PER LA LUBRIFICAZIONE USARE
minuto circa a piena rotazione. ESCLUSIVAMENTELA PISTOLA
Fermare il motore per iniettare il restante DINGRASSAGGIO.
grasso.
Con la iniezione di tutto il grasso a motore
fermo pu succedere che parte del grasso.
INTERVALI LUBRICAZIONE
TABELLA 1 - CUSCINETTI A SFERE - Serie 62/63

Intervalli lubricazione (ore di lavoro-posizione orizzontale)
Polo II Polo IV Polo VI Polo VIII Polo X Polo XII Grasso
Serie 62
Cuscinetto 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz (g)
6209 18400 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 9
6211 14200 16500 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 11
6212 12100 14400 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
Serie 63
6309 15700 18100 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
6311 11500 13700 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 18
6312 9800 11900 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 21
6314 3600 4500 9700 11600 14200 16400 17300 19700 19700 20000 20000 20000 27
6316 - - 8500 10400 12800 14900 15900 18700 18700 20000 20000 20000 34
6319 - - 7000 9000 11000 13000 14000 17400 17400 18600 18600 20000 45
6322 - - 5100 7200 9200 10800 11800 15100 15100 15500 15500 1930O 60
ITALIANO
TABELLA 2 - CUSCINETTI A RULLI - Serie NU 3
Intervalli lubricazione (ore di lavoro-posizione orizzontale)
Polo II Polo IV Polo VI Polo VIII Polo X Polo XII Grasso
NU 309 9800 13300 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
NU 311 6400 9200 19100 20000 20000 20000 20000 20000 20000 20000 20000 20000 18
NU 312 5100 7600 17200 20000 20000 20000 20000 20000 20000 20000 20000 20000 21
NU 314 1600 2500 7100 8900 11000 13100 15100 16900 16900 19300 19300 20000 27
NU 316 - - 6000 7600 9500 11600 13800 15500 15500 17800 17800 20000 34
NU 319 - - 4700 6000 7600 9800 12200 13700 13700 15700 15700 20000 45
NU 322 - - 3300 4400 5900 7800 10700 11500 11500 13400 13400 17300 60
NU 324 - - 2400 3500 5000 6600 10000 10200 10200 12100 12100 15000 72
Nota: Per ogni 15C di aumento su la temperatura,

il periodo del reingrassaggio ridotto a met.
I cuscinetti ZZ da 6201 a 6307 non richiedono I periodi di reingrassaggio dati sopra sono
reingrassaggio poirch il suo tempo di vita per quelli casi dove applicano il grasso
utile circa di 20,000 ore. Polyrex EM.
I Tabelle 1 e 2 sono intesi per il periodo de Quando i motori sono utilizzati in la
ingrassaggio sotto la temperatura del posizione verticale, loro intervallo di
cuscinetto di 70C (per cunscinetti su a 6312 e reingrassaggio ridotto a met se compar a
NU 312) e la temperatura di 85C (per cuscinetti motori della posizione orizzontali.
6314 e NU 314 e pi grande).
RACCOMANDIAMO LUSO DEI applicati sulla faccia laterale dellanello interno
CUSCINETTI A SFERE NEI MOTORI che deve essere smontato, o ad un pezzo
AD ACCOPPIAMENTO DIRETTO AL adiacente.
CARICO. essenziale che il montaggio dei
cuscinetti sia fatto in condizioni di completa
pulizia, per avere un buon funzionamento ed
ATTENZIONE! evitare danneggiamenti. I cuscinetti nuovi
UN ECCESSO DI GRASSO PUO dovranno essere tolti dallimballaggio nel
PROVOCARE momento del montaggio.
SOVRARISCALDAMENTO DEL Prima del montaggio dun cuscinetto
CUSCINETTO E CONSEGUENTE nuovo, sar necessario controllare che la sede
C0MPLETO DANNEGGIAMENTO. dellalbero sia senza sbavature o segni di colpi.
Per il montaggio dei cuscinetti riscaldare
la pista interna degli stessi con macchina
Compatibilita del grasso Polyrex EM specifica a processo induttivo od utilizzare
con altri tipi di grasso: utensile adeguato.
Il grasso Polyrex EM, in virtu del

contenuto di indurente poliurea e di olio PARTI DI RICAMBIO
minerale, e compatibile con altri tipi di grasso
contenenti:
Nellordinare le parti di ricambio per un
Una base di litio o una miscela di lito-poliurea
motore indicare i dati completi del motore con
e un olio minerale raffinato.
codice del prodotto, come stampigliati sulla
Un additivo inibitore della corrosione, della
targhetta del motore stesso.
ruggine e un additivo antiossidante.
Sulla targhetta c il numero di serie del
motore, questo dovr essere comunicato nella
Note:
richiesta delle parti di ricambio.
Anche se il grasso Polirex EM e compatibile
con i tipi di grasso sopraindicati, non
raccomandiamo di mescolarlo con altri tipi di MOTORI DA UTILIZZARSI IN
grasso. LUOGHI PERICOLOSI
Prima dimpiegare grassi diversi da quelli
raccomandati, si prega di contattare Weg.
Oltre alle raccomandazioni fatte in
Nelle applicazioni speciali (con alte o basse
precedenza, si aggiungano le seguenti:
temperature, con variazioni di velocita ecc...) Gli
intervalli di rilubrificazione sono riportati nella
targhetta aggiuntiva, applicata sul motore.
LE SPECIFICHE DEL LUOGO DI
INSTALLAZIONE DEI MOTORI DI
LUSO DI MOTORI IN AREE RESPONSABILIT DEI CLIENTI,
SPECIALI O APPLICAZIONI CHE DECIDERANNO ANCHE LE
SPECIALI DEVE ESSERE CARATTERISTICHE
PRECEDUTO D UNA RICHIESTA AL DELLAMBIENTE.
FORNITORE DEL GRASSO O ALLA
WEG. I motori destinati ad ambienti pericolosi
sono fabbricati secondo standard specifici per
questi luoghi e sono garantiti da certificazioni
valide in tutto il mondo.
SMONTAGGIO E MONTAGGIO
1 - Installazione
Lo smontaggio e montaggio dovr essere
fatto da personale qualificato, utilizzando solo Linstallazione completa deve seguire le
utensili e metodi adeguati. regolamentazioni previste dalla legislazione
I ganci dellestrattore dovranno essere locale vigente.
LINSTALLAZIONE DEI MOTORI IN MOTORI ALIMENTATI CON
AMBIENTI PERICOLOSI DEVE
ESSERE EFFETTUATA DA
INVERTER
PERSONALE ESPERTO E LA
PROTEZIONE TERMICA DEVE Le installazioni con convertitori di
ESSERE SEMPRE INSTALLATA SIA frequenza senza filtro possono modificare le
ALLINTERNO CHE ALLESTERNO prestazioni del motore come segue:
DEL MOTORE FUNZIONANTE A
CORRENTE ADEGUATA.
Minore rendimento.
Maggiori vibrazioni.
Maggiore rumore.
2 - Assistenza
Maggiore corrente nominale.
Maggiore temperatura.
Lassistenza deve essere affettuata da
Minore durata dellisolamento.
officine per riparazioni autorizzate dalla WEG.
Minore durata dei cuscinetti.
Le officine di assistenza e le persone non
autorizzate dalla WEG che effettueranno
1 - Motori standard
riparazioni ai motori in ambienti pericolosi
dovranno assumersi la piena responsabilit per
Per tensioni minori di 440 V non necessario
questo servizio e ogni eventuale danno
installare il filtro.
provocato.
Per tensioni uguali o maggiori di 440 V e
minori di 575 V necessario installare il filtro se
i cavi di collegamento del motore sono lunghi
QUALSIASI MODIFICA ELETTRICA pi di 20 metri.
O MECCANICA APPORTATA (AI Per tensioni maggiori di 575 V necessario
MOTORI) IN QUESTI LUOGHI A installare il filtro qualunque sia la lunghezza dei
RISCHIO RENDER NULLA LA cavi di collegamento.
GARANZIA.
ITALIANO
LA MANCATA OSSERVANZA DELLE
Durante le operazioni di assistenza, SUDDETTE RACCOMANDAZIONI
installazione o lubrificazione, si seguano le COMPORTA IL DECADIMENTO
segenti norme: DELLA GARANZIA.
Controllare che tutti i componenti siano privi
di parti affilate, deformate o sporche.
Assicurarsi che tutte le parti siano in ottime
condizioni. 2 - Motori per inverter
Lubrificare le superfici degli scudi di fissaggio
con olio protettivo per facilitare lassemblaggio. Controllare lalimentazione del
Usare esclusivamente martelli di gomma per servoventilatore.
inserire le parti. I filtri non sono necessari.
Controllare el corretto serraggio delle viti.
Usare uno spessimetro per un corretto
fissaggio della scatola a T (meno di 0,05 mm).
NON RIUTILIZZARE LE PARTI

DANNEGGIATE O CONSUMATE.
SOSTITUIRLE CON PARTI NUOVE
FORNITE DALLA DITTA.
GARANZIA
La WEG offre per i suoi prodotti garanzia per i Che vi sia stata la denunzia immediata, da
difetti riguardanti la fabbricazione o i materiali, parte dellacquirente, dei difetti presenti e che
per un periodo di 12 mesi, che decorrono dalla la WEG li abbia riconosciuti in seguito come
data della fattura emessa dalla fabbrica o dal diffeti di fabbricazione.
distributore / rivenditore, limitatamente a 18
mesi dalla data di fabbricazione, La garanzia non include i servizi di smontaggio
indipendentemente dalla data di installazione delle installazioni dellacquirente, i costi di
e a patto che siano soddisfatti i seguenti trasporto del prodotto e le spese di trasferta, di
requisiti: vito e alloggio del personale dellAssistenza
Tecnica quando richiesta dal cliente. I servizi
Che il trasporto, il trattamento e in garanzia saranno prestati esclusivamente
Iimmagazzinaggio siano stati adeguati; presso officine di Assistenza Tecnica
Che Iinstallazione sia stata corretta e sia stata autorizzate dalla WEG o nel proprio
effettuata in condizioni ambientali idonee e stabilimento.
senza la presenza di agenti aggressivi;
Che ogni operazione sia stata svolta entro i Sono esclusi da questa garanzia i componenti
limiti delle proprie competenze; la cui vita media di utilizzo, in condizioni
Che siano stati realizzati periodicamente i normali duso, sia minore del periodo di
necessari interventi di manutenzione garanzia. La riparazione e/o la sostituzione di
preventiva; pezzi o prodotti, di competenza della WEG
Che le riparazioni e/o modifiche siano state durante il periodo di garanzia, non prorogher
effettuate solamente da persone autorizzate il periodo di garanzia originario.
per iscritto dalla WEG;
Che nel caso di una anomalia il prodotto sia La presente garanzia limitata al prodotto
stato reso disponibile al fornitore per il periodo fornito e la WEG non responsabile per i danni
minimo necessario per Iidentificazione della a persone, a terzi, ad altre attrezzature o
causa della stessa anomalia e per la installazioni, per il lucro cessante o qualunque
realizzazione della dovuta riparazione; altro danno emergente o conseguente.
DANSK
LS DENNE MANUAL GRUNDIGT mellem 5C and 60C, med en relativ

FR INSTALLATION AF MOTOREN. luftfugtighed der ikke overstiger 50%.
For motorer, der har vret lagret i mere
end to r, skal lejerne udskiftes eller tmmes for
CHECK VED MODTAGELSEN smrefedt og renses grundigt.
Fjern lseanordningen p akselen fr motoren Enfasede motorer skal desuden have
idriftsttes. fornyet kondensatorerne (hvis sdanne er
Drej akselen manuelt for at sikre at den drejer monteret).
frit.
Fjern aksel lseanordning (hvis en sdan Det anbefales at dreje akselen manuelt
findes) fr idriftsttelse af motoren. mindst en gang om mneden og at mle
Drej akslen med hnden for at sikre at den isolationsmodstanden p motorer, der har
roterer frit. vret lagret mere end 6 mneder eller har vret
udsat for fugt.
HNDTERING OG TRANSPORT
Motorer med stilstandsvarme skal have
1 - Generelt denne tilsluttet.
MOTOREN M IKKE LFTES VED Kontrol af isolationsmodstand

AKSELEN, MEN KUN I JEBOLTEN,
SOM ER DIMENSIONERET I Ml isolationsmodstanden inden drift af
FORHOLD TIL MOTORENS VGT. motoren eller hvis der er tegn p fugt i viklingen.
Lfteanordningerne er kun beregnet til Modstanden mlt ved 25 grader C skal

al lfte motoren. Hvis motoren er udstyret vre:
med to jebolte, skal der benyttes en dobbelt
kde til loftet. Ri (20 x U) / (1000 + 2P) [M]
(mlt med en MEGGER ved 500 V);
Lft og snkning skal foretages med U = spnding (V); P = effekt (kW).
forsigtighed og uden rystelser, da lejerne
ellers kan beskadiges. Hvis isolationsmodstanden viser sig at
vre mindre end 2Mohm, skal viklingen trres
MOTORER UDSTYRET MED RULLE p flgende mde:
ELLER VINKELKONTAKTLEJER ER
BESKYTTTET MOD Varm den op i en ovn til 80 grader C og
TRANSPORTSKADER VED EN forhj temperaturen med 5 grader hver time til
DANSK
AKSEL LSEANORDNING. 105 grader, hvor den skal st mindst en time.
DENNE ANORDNING SKAL Kontroller at stator isolationsmodstanden

BENYTTES VED ENHVER er konstant indenfor de tilladte vrdier. Hvis ikke,
TRANSPORT AF MOTOREN, SELVOM skal statoren imprgneres om.
DETTE NDVENDIGGR
ADSKILLELSE AF MOTOR OG INSTALLATION
MASKINE. 1 - Sikkerhed
OPBEVARING Personale der arbejder med elektriske
Motorer, som ikke tages i brug straks, skal installationer, hndtering, drift eller
opbevares trt, stvfrit, ikke udsttes for vedligeholdelse skal instruereres grundigt om
vibrationer, gasser, tsende eller korroderende sikkerhedsnormer og principper p omrdet og
luftarter og ved konstant temperatur. det anbefales, at kun kvalificerede teknikere
Motorenes lager temperatur skal ligge beskftiges med disse opgaver.
4 - Drnhuller
MAN SKAL SIKRE SIG, AT MOTOREN
ER SPANDINGSLOS, FR
Drn skal vre placeret lavest p
VEDLIGEHOLDESESARBEJDER
motoren, hvis montageformen afviger fra
PBEGYNDES.
indkbsordrens specifikation.
Der skal tages forholdsregler, s
utilsigtede starter ikke kan forekomme. 5 - Afvejning
Ved enhver form for service afbrydes WEG MOTORER ER DYNAMISK

strmforsyningen fra motoren og alt tilbehr skal AFBALANCERET MED HALV NOT,
frakobles og afbrydes. UDEN LAST OG UKOBLET.
Trasmissionselementer, ssom remskiver,

Der m ikke ndres p indstillingen af koblinger etc. skal dynamisk afbalanceres med
beskyttelsesudstyret. halv not inden installation. Anvend altid korrekt
vrktj.
2 - Driftsforhold
6 - Opretning
Generelt er el-motorer konstrueret til drift
i en hjde af 1000 meter over havet og for en OPRET AKSELENDERNE OG
omgivelsestemperatur mellem 0 og 40 Grader ANVENDE FLEXIBEL KOBLING, NR
C. Eventuelle afvigelser fremgr af motorens DETTE ER MULIGT.
typeskilt.beskyttelsesudstyret.
Tilbehr for motormontagen m ikke
SAMMENLIGN DEN STRM,
muliggre modifikationer af opretningen til
SPNDING, FREKVENS,
skade for lejerne.
OMDREJNINGSTAL, EFFEKT OG
ANDRE VRDIER, DER ER
Ved samling af halvkoblinger skal der
NDVENDIGE FOR DEN
benyttes de rigtige udstyr og vrktjer, s lejerne
RESPEKTIVE ANVENDELSE, MED
ikke lider overlast.
DE P TYPESKILTET ANFRTE DATA.
Motorer leveret til aggressive miljer skal Korrekt samling af halvkoblinger:
installeres i overensstemmelse med det p Kontroller at slret er mindre end 0.05 mm og at
typeskiltet specificerede. forskellen mellem X1 og X2 ligeledes er mindre
end 0.05 mm.
HOLD IND-OG UDGANG FOR LUFT
FRI OG REN. UDGANGSLUFTEN FRA
MOTOREN M IKKE RE-CIRKULERE
I MOTOREN. AFSTANDEN MELLEM
LUFTINDGANG OG VG SKAL
MINIMUM VRE 1/4 AF
INDGANGSBNINGENS DIAMETER.
Bemrk: Dimensioner X1 i X2 skal minimum
3 - Fundament ucere 3mm.
Figur og opretnings tolerancer
Motorer forsynet med fdder skal
installeres p et solidt fundament for at 7 - Remtrk
forebygge undige vibrationer.
Fundamentet skal vre jvn og Nr der anvendes remskiver eller
tilstrkkelig hrd udformet for at forebygge remkoblinger skal flgende bemrkes.
undige mekaniske vibrationer.
Kber har det fulde ansvar for Remmene skal strammes netop
fundamentet. tilstrkkeligt, s slip ved drift undgs, i henhold
Metaldelene skal males for at undg til de af remtrk - leverandren specificerede
korrosion. anbefalinger.
ADVARSEL: INDEN TILSLUTNING TIL NETTET
En for hrd stramning af remtrkket vil KONTROLLER AT JORDING ER
beskadige lejerne og sandsynligvis fre til FORETAGET EFTER GLDENDE
et akselbrud NORMER. DETTE ER NDVENDIGT
FOR AT UNDG UHELD.
8 - Tilslutning Hvis motoren er leveret med temperatur
beskyttelses eller styringsanordning, ssom
ADVARSEL: termostat, termistor, termisk beskyttelse etc., skal
Ved stilstand kan spnding tilsluttes i disses terminaler forbindes til de tilsvarende p
klemkassen til varmeelementer eller direkte kontrolpanelet.
viklingsvarme.
10 - Start
ADVARSEL:
KILEN SKAL SPNDES ELLER
Kondensatoren i en-fasede motorer kan
FJERNES INDEN MOTOREN
holde ladningen, der forekommer over
STARTES.
motorterminalerne, selv efter motorstilstand.
a) Motoren skal starte og kre ubesvret.
EN FORKERT TILSLUTNING KAN Hvis dette ikke er tilfldet, skal den afbrydes og
AFBRNDE MOTOREN. tilslutningerne og montagen kontrolleres inden
den startes igen.
Spnding og forbindelsesdiagram er
angivet p motorens typeskilt. Acceptable b) Hvis der forekommer unormale
spndingsvariation er +/- 5% og den totale vibrationer, skal fastgrelsesboltene
acceptable variation +/- 10%. kontrolleres. Desuden br det konstateres, om
vibrationerne eventuelt kan hidrre fra en anden
nrstende motor.
9 - Startmetoder
c) Lad motoren kre med den nominelle
Motoren startes almindeligvis ved direkte last i en kort periode og sammenlign, om
start. Skulle dette ikke vre muligt, skal metoder strmmen svarer til den p motorskiltet anfrte.
forenelige med motorlast og spnding
anvendes. VEDLIGEHOLDELSE
Omdrejningsretning er med uret set fra
drivenden (DE), forudsat faserne er forbundet i ADVARSEL:
faseflge L1, L2, L3. SIKKERHEDSKONTROLLISTE.
For at ndre omdrejningsretningen skal 1 - Generelt eftersyn DANSK

to af lederne ombyttes.
Efterse motoren regelmssigt.
FORBINDELSE TIL Motoren skal holdes ren og en fri, uhindret
KRAFTFORSYNINGEN SKAL luftstrm skal sikres.
UDFRES AF KVALIFICERET Kontroller pakningerne eller V-ringen og
PERSONALE OG udskift disse hvis ndvendigt.
MED OMHU FOR AT OPN EN Kontrollr tilslutninger og fastgrelser.
SIKKER OG Kontrollr lejer og bemrk eventuel fremmed
PERMANENT TILSLUTNING. EFTER stoj, lejetemperatur og smringstilstand.
TILSLUTNING AF MOTOREN SKAL Hvis unormale forhold afslres, skal motoren
KLEMKASSEN KONTROLLERES OG gennemgs og dele om ndvendigt udskiftes.
EVENTUELLE UBENYTTEDE
KABELINDGANGE SKAL LUKKES. SMRING
Kablerne skal vre i de korrekte FLG NJE INTERVALLERNE FOR
dimensioner, baseret p den nominelle strm EFTERSMRING. DETTE ER
stemplet p motorskiltet. AFGRENDE FOR DRIFTEN.
1 - Motorer uden smrenippler huset. Er smrenipplen ikke let tilgngelig, sker
udskiftning af smrefedt p flgende mde:
Motorer til strrelse 200 er normalt uden
smrenippler. Eftersmring af disse skal foretage Fjern generende genstande.
ved de normale vedligeholdelseseftersyn: Sprjt det halve af fedtmngden ind i lejet og
lad motoren kre et minut ved fuld hastighed.
Adskil motoren omhyggeligt. Afbryd motoren og pfyld resten at
Fjern al smrefedt. fedtmngden.
Vask lejet i petroleum eller dieselolie. Indsprjtning af hele fedtmngden i en
Nyt smrefedt tilsttes. stillestende motor kan medfre, at smrefedtet
siver ind i selve motoren gennem den indre
2 - Motorer med smrenippler ttning.
Det anbefales, at motoren smres under VED SMRING, ANVEND KUN

drift. P denne mde fornys smrefedtet i leje MANUEL SMREPISTOL.
EFTERSMRINGSINTERVALLER
TABEL 1 - KUGLELEJER - Serie 62/63

Eftersmringsintervaller (driftstimer - horisontal montage)
II IV VI VIII X XII Fedtmngde
Serie 62
Lejer 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz (g)
6209 18400 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 9
6211 14200 16500 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 11
6212 12100 14400 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
Serie 63
6309 15700 18100 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
6311 11500 13700 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 18
6312 9800 11900 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 21
6314 3600 4500 9700 11600 14200 16400 17300 19700 19700 20000 20000 20000 27
6316 - - 8500 10400 12800 14900 15900 18700 18700 20000 20000 20000 34
6319 - - 7000 9000 11000 13000 14000 17400 17400 18600 18600 20000 45
6322 - - 5100 7200 9200 10800 11800 15100 15100 15500 15500 19300 60
TABEL 2 - RULLELEJER - Serie NU 3

Eftersmringsintervaller (driftstimer - horisontal montage)
II IV VI VIII X XII Fedtmngde
NU 309 9800 13300 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
NU 311 6400 9200 19100 20000 20000 20000 20000 20000 20000 20000 20000 20000 18
NU 312 5100 7600 17200 20000 20000 20000 20000 20000 20000 20000 20000 20000 21
NU 314 1600 2500 7100 8900 11000 13100 15100 16900 16900 19300 19300 20000 27
NU 316 - - 6000 7600 9500 11600 13800 15500 15500 17800 17800 20000 34
NU 319 - - 4700 6000 7600 9800 12200 13700 13700 15700 15700 20000 45
NU 322 - - 3300 4400 5900 7800 10700 11500 11500 13400 13400 17300 60
NU 324 - - 2400 3500 5000 6600 10000 10200 10200 12100 12100 15000 72
Bemrk: Tabellerne 1 og 2 er smringsperioder ved

ZZ lejerne fra 6201 til 6307 krver ingen lejetemperatur p 70C (lejer op til 6312 og NU
eftersmring, da deres levetid er omkring 312) og temperatur p 85C (lejer 6314 og NU
20.000 timer. 314 og strre).
For hver 15C temperaturstigning halveres Inden montagen af nye lejer skal akselen
eftersmringsperioden. efterses for skarpe kanter eller anden form for
Eftersmringsperioderne nvnt ovenfor beskadigelser.
omhandler Polyrex EM Grease.
For vertikalt monterede motorer halveres RESERVEDELE
eftersmringsinter-vallerne sammenlignet
Ved bestilling af reservedele bedes den
med horisontalt opstillede motorer.
fulde typebetegnelse og produkt-kode som
anfrt p motorskiltet opgivet.
ADVARSEL OVERSKUD AF FEDT KAN
Desuden bedes motorens serie-nummer,
FORAARSAGE OVEROPHEDNING AF
som ligeledes er anfrt p motorskiltet, opgivet.
LEJET MED TOTAL-SKADE TIL
FOELGE. MOTORER TIL EKSPLOSIONSFARLIGE

OMRDER
Polyrex EM smoeremidlets forenelighed
Foruden de allerede givne vejledninger
med andre fedttyper:
skal flgende iagttages:

Polyrex EM indeholder polyurea STEDET FOR INSTALLATION AF
fortykningsmiddel og mineralolie og er derfor EN MOTOR ER KUNDENS
compatibelt med andre fedttyper indeholdende: ANSVAR, DENNE SKAL VURDERE
Lithium eller en sammensaetning med lithium INSTALLATIONSFORHOLDENE.
eller polyurea og mineralolie.
Motorer til eksplosionsfarlige omrder er
Tilsaetningsstof mod corrosion, rust og
fremstillet efter specifikke standarder for sdanne
oxidering.
omrder, og de er certificeret af globalt
anerkendte klassifikationsselskaber.
Bemaerk:
1. Installation
Selvom Polyrex EM er foreneligt med de
naevnte fedttyper, kan det ikke anbefales at blande
Den Komplette installation skal flge de
med andre typer.
procedurer.
Har De til hensigt at anvende andre fedttyper
end de anbefa-lede, s kontakt foerst WEG. MOTORER I EKSPLOSIONSFARLIGE
Ved anvendelsesomraader (med hoeje eller OMRDER SKAL INSTALLERES AF
lave temperaturer, varierende hastigheder etc.) FAGFOLK OG DEN TERMISKE
angives fedttype og efter-smoeringsinterval paa BESKYTTELSE SKAL ALTID
en separat maerkeplade paa motoren. MONTERES, ENTEN I SELVE
MOTOREN ELLER SEPARAT, FOR
VED ANVENDELSE AF STANDARD DRIFT VED DEN NOMINELLE DANSK
MOTORER I SPECIELLE OMRDER STRM.
ELLER TIL SPECIELLE FORML
SKAL ENTEN OLIELEVERANDREN 2. Vedligeholdelse
ELLER WEG KONTAKTES.
Vedligeholdelse skal foretages af WEG
- autoriserede vrksteder.
DEMONTAGE OG MONTAGE Ikke WEG - autoriserede vrksteder
eller andre, der foretager enhver service p
Demontage og montage skal udfres af motorer til eksplosionsfarlige omrder vil
kvalificeret personale og kun egnede vrktjer blive holdt ansvarlig for sdan service og for
m anvendes. enhver flgeskade.
Fastspndelse af stator foretages p den
indre rings sideflade eller p en tilsluttende del. CERTIFICERINGEN BORTFALDER,
Det er vigtigt at en demontage/montage af HVIS DER FORETAGES ELEKTRISKE
lejer foretages under rene forhold for at sikre en ELLER MEKANISKE
god drift og undg beskadigelser. Nye lejer skal MODIFIKATIONER P EN MOTOR TIL
frst tages ud af emballagen ved montering. EKSPLOSIONSFARLIGT OMRDE.
Flg disse instrukser ved vedligeholdelse Hjere stjniveau.
installation eller smring: Hjere nominel strm.
Kontroller at alle konponenter er under grater, Reduceret motorisolation.
std eller snavs. Nedsat leje-levetid.
Kontroller at alle delle er i perfekt stand.
Smr overfladerne p endeskjoldets fittings 1- Standard motorer
med beskyttende olie for at gre montage lettere.
Benyt kun gummihammer til montage af dele.
Kontroller bolte for korrekt stramning. For spndinger under 400 V krves ikke
Benyt kalibrator for korrekt slr ved klemkasse- filter.
montage(mindre end 0,05 mm). For spndinger p over 440 V og indtil 575 V
er filter ndvendigt for motorforsyningskabler
GENANVEND IKKE BESKADIGEDE p mere end 20 meter.
ELLER SLIDTE DELE. UDSKIFT Spndinger p eller over 575 V kver filter for
SDANNE MED NYE ORIGINAL- alle forsyningskabel-dimensioner.
DELE FRA WEG.
HVIS DISSE PUNKTER IKKE
MOTORER MED FLGES NJE, BORTFALDER
FREKVENSOMFORMER MOTORGARANTIEN.
Anvendelse af frekvensomformere uden 2- Frekvensomformermotorer:

filter kan influere sledes p motorfunktionen: Kontroller kraftforsyning til den forcerede
Lavere virkningsgrad. klingsventilator.
Hjere vibrationer. Filtre er ikke ndvendige.
GARANTI
WEG garanterer sine produkter imod opstede fejl og at disse af WEG godkendes
fabrikations - og materialefejl i 12 mneder som fabrikationsfejl.
regnet fra fabrikens faktureringstado,
autoriseret distributr eller agent begrnset Garantien omfatter ikke demontage hos kber,
til 18 mneder fra fabrikationsdato, uafhngigt transportomkostninger, rejseudgifter for
af dato for installation, forudsat flgende er teknikere, logi og fortring. Garanti-service
opfyldt: udfres kun af vrksteder med WEGs
autorisation eller i WEGs egne virksomheder.
Forsvarlig transport, hndtering og
oplagring; Komponenter, hvis levetid normalt er kortere
Korrekt installation baseret p de end garantiperioden er ikke omfattet af
specificerede ydre forhold, uden garantien. Reparation og/eller udskiftining af
korroderende gasser; dele eller komponenter udfrt af WEG og/eller
Drift indenfor motorens kapacitet; WEG autoriseret vrksted, medfrer ikke
Under hensyntagen til de periodiske forlngelse af garantien.
vedligeholdelseseftersyn;
Reparationer og/eller udskiftninger foretaget Dette angiver WEGs garanti i forbindelse med
af teknikere med skriftlig autorisation fra WEG; salget og selskabet har in gen forpligtelse eller
En defekt motor eller dele stilles til ansvar overfor personer, trediepart, andet
leverandrens rdighed for konstatering af udstyr eller installationer og enhver fordring
fejlrsag; for flgeudgifter eller arbejdsomkostninger er
Omgende advisering fra kber om WEG uvedkommende.
SWEDISH
Om motorerna lagras mer n 2 r mste

LS IGENOM INSTRUKTIONERNA antingen lagren bytas ut eller smrjfettet
INNAN NI INSTALLERAR MOTORN. avlgsnas totalt efter rengring.
MOTTAGNINGSKONTROLL P enfas motorer som lagras i 2 r eller

lngre mste kondensatorerna bytas ut.
Kontrollera om ngot har skadats under
transporten. Om motorerna lagras mer n 6 mnader
Kontrollera informationen p mrkskylten. eller om motorerna lagras p ett fuktigt stlle
Avlgsna transportlsningen (om det finns rekommenderar vi att man vrider axeln, fr hand,
ngon) innan motorn tas i bruk. minst en gng i mnaden och mter
Vrid axeln fr hand fr att kontrollera att den isolationsresistansen innan installation.
rr sig fritt.
Om motorn installeras med
HANTERING OCH TRANSPORT stillestndsuppvrmning skall den vara
ansluten.
1. Allmnt
Isolationsresistanskontroll
MOTORERNA SKALL INTE LYFTAS I
AXELN UTAN I LYFTGLORNA SOM Mt isolationsresistansen innan Ni
R KONSTRUERADE FR ATT anvnder motorn och/eller vid minsta tecken p
KLARA MOTORNS VIKT. fukt i lindningen.
Lyftglorna r enbart till fr att stdja Mtningen genomfrd vid 25o C skall vara:
motorn. Om motorn har tv skall tv kedjor
anvndas fr att lyfta motorn.
Ri > (20 x U) / (1000 + 2P) [Mohm]
(mt med en MEGGER vid 500 V c.c);
Hjning och snkning mste ske frsiktigt U = Volt (V); P = Effekt (kW).
utan slag och sttar fr att inte skada lagren.
Om isolationsresistansen r mindre n 2
UNDER TRANSPORT R MOTORER
megaohm mste lindningen torkas enligt
FRSEDDA MED RULL- ELLER
fljande:
VINKELKONTAKTLAGER, UTRUSTADE
MED TRANSPORTLSNING FR ATT
Vrm upp den i en ugn vi minimum 80oC
FRHINDRA SKADA P LAGREN.
ka temperaturen 5oC varje timma upp till 105oC,
behll denna temperatur i minst en timma.
TRANSPORTLSNINGEN MSTE
ANVNDAS VID ALL TRANSPORT AV Kontrollera att statorns isolationsresistans
MOTORN, VEN VID URKOPPLING frblir konstant inom accepterade vrden, om
FRN DEN ENHETEN SOM DRIVS inte mste statorn impregneras igen.
AV MOTORN.
INSTALLATION
SVENSKA
LAGRING
1. Skerhet
Om motorerna inte installeras direkt,
mste de frvaras i ett torrt utrymme fritt frn All personal som berrs av elektrisk
damm, vibrationer, gaser, korrosionspverkan installation, vad gller hantering, lyft, drift eller
och vid konstant temperatur och i normal underhll mste vara vl informerad om skerhet
position och skilt frn andra freml. och vriga rutiner som berr arbetet och flja
Lagringstemperatur fr motorn skall vara dessa noggrant.
mellan 5C och 60C, och den relativa Detta arbete fr endast utfras av behrig
fuktigheten fr ej verstiga 50%. personal.
KONTROLLERA ATT ELEKTRISKA Fundamentet mste vara jmt och
MOTORER R FRNKOPPLADE tillrckligt hrt fr att kunna st emot eventuella
INNAN UNDERHLLSSERVICE sttar. Det mste vara konstruerat s att det
PBRJAS. frhindrar vibrationer som eventuellt
uppkommer pga resonans.
Motorer mste skyddas mot ofrivilliga
starter.
4. Drneringshl
Bryt strmmen innan underhllsservice
Frskra Er om att drneringshlen r
pbrjas. Se till att alla tillbehr r avstngda
placerade i den nedre delen av motorn om
och bortkopplade.
monteringen skiljer sig frn vad som sagts i
inkpshandlingarna.
Fr att undvika att damm och/eller
vatten kommer in i kopplingsboxen,
5. Balansering
br frskruvningar installeras i
kabelgenomfringen. WEG MOTORER R DYNAMISK
BALANSERADE MED HALV KIL
Frndringar fr ej gras p UTAN LAST OCH URKOPPLAD.
skyddsutrustningen. Transmissionsdelar ssom remskiva,
kopplingar etc mste vara dynamiskt balanserade
2. Anvndningsvillkor med halv kil innan installation. Anvnd alltid
lmpliga verktyg vid installation och
Elektriska motorer r i allmnhet borttagande.
konstruerade fr att anvndas <1000 m ver
havet vid en temperatur mellan 0oC och 40oC. 6. Instllning
Varje avvikelse frn detta finns noterat p
mrkskylten. STLL IN AXELNDAN OCH
ANVND OM MJLIGT EN
JMFR STRMSTYRKA, FLEXIBEL KOPPLING.
SPNNING, FREKVENS, HASTIGHET,
ANGIVEN EFFEKT OCH ANDRA Se till att motorns monteringsanordning
VRDEN. inte ndrar instllningen och dessutom inte
skadar lagren.
Motorer som levererats fr riskfyllda
utrymmen skall installeras i ett utrymme som Vid montering av en halv-koppling,
verensstmmer med specifikationen p anvnd alltid rtt utrustning och verktyg fr att
motorns mrkskylt. skydda lagren.
SE TILL ATT LUFTINTAG OCH
LUFTUTSLPP R RENA OCH FRIA. Lmplig montering av halv-koppling:
UTSLPPSLUFTEN SKALL INTE G Kontrollera att Y r mindre n 0,05 mm och att
IN I MOTORN IGEN. AVSTNDET ven skillnaden mellan X1 och X2 r mindre n
MELLAN LUFTINTAG OCH VGGEN 0,05 mm.
MSTE VARA CA 1/4 AV
DIAMETERN P LUFTINTAGET.
3. Fundament
Motorer frsedda med ftter skall

installeras p ett fast fundament fr att undvika OBS: Dimensionen mellan X1 Och X2 skall
fr stor vibration. vara 3 mm minimum.
Kparen har fullt ansvar fr fundament. 7. Remdrift
Metalldelar mste mlas fr att undvika Vid anvndning av remskiva eller

korrosion. remkoppling mste fljande iakttagas:
Remmen mste spnnas tillrckligt fr att Om motorn r frsedd med
undvika slirning nr den anvnds, enligt temperaturvakter eller givare som termostater,
specifikationen frn leverantren. termistorer mm koppla in dessa i motsvarande
kontrollpanel.
VARNING:
verdriven dragning av remskivan 10. Uppstart
skadar lagren och kan leda till axelbrott.
KILEN SKALL FSTAS ELLER
8. Koppling AVLGSNAS INNAN MOTORN
VARNING: STARTAS.
Vid stillastende kan spnning a) Motorn mste starta och arbeta jmnt,
varainkopplad kopplingsldan fr om detta inte sker skall starten avbrytas och
vrmeelement eller fr direkt anslutningarna och kopplingarna kontrolleras
lindningsuppvrmning. fre omstart..
VARNING: b) Om det frekommer onormala

Kondensatorn p enfas motorer kan vibrationer kontrollera att skruvarna r korrekt
innehlla laddning, som frekommer ver tdragna. Kontrollera ocks om vibrationerna
kommer frn en nrstende maskin.
motorplinten, ven efter avstngning.
Vibrationskontroller mste gras med jmna
mellanrum.
EN FELAKTIG KOPPLING KAN
MEDFRA ATT MOTORN BRNNER. c) Kr motorn med maximal belastning
Spnning och koppling anges p en kort stund och kontrollera att/om
mrkskylten. strmtillfrseln verensstmmer med det som
r angivet p mrkplten.
Hgsta tilltna variation i spnningen r
+/- 10% Hgsta tilltna i frekvensvariation r
UNDERHLL
+/-5%.
VARNING!
UNDERHLL
SKERHETSKONTROLLISTA.
9. Start metoder
Motorn startas helst genom direktstart. 1. Allmn inspektion

Om detta inte r mjligt, skall metoder frenliga
med motorlast och spnning anvndas. Kontrollera motorn med jmna mellanrum.
Motorn roterar medsols, sedd mot D- Hll motorn ren och se till att luftintag inte
ndan och ntets fasfljd r L1, L2, L3. hindras.
Om motsatt rotationsriktning nskas, Kontrollera packningar eller v-ringar och byt
vxlas tv av ledningarna som r anslutna till ut dessa vid behov.
motor. Kontrollera kopplingar svl som skruvar.
Kontrollera lagren och observera eventuella
INSTALLATION FR ENDAST SKE AV
ovanliga ljud, vibrationer, lagrens temperatur
BEHRIG PERSONAL. SE TILL ATT
och smrjmedlets kondition.
INGA FRMMANDE FREML
Nr en frndring, under normala
FREKOMMER I KOPPLINGSLDAN
frhllanden, upptcks, kontrollera motorn och
SVENSKA
EFTER ANSLUTNING.
byt even tuellt ndvndiga delar.
KABELINGNGARNA SOM INTE
Hur ofta man behver gra dessa inspektioner
ANVNDS MSTE TILLSLUTAS.
beror p motortyp och p
Anvnd alltid rtt kabeldimension enligt anvndningsfrhllandet.
strmmen p mrkskylten.
SMRJNING
INNAN SPNNINGEN SLPPS P
KONTROLLERA ATT JORDNINGEN R FLJ NOGA INTERVALLERNA FR
KORREKT, DETTA R VSENTLIGT EFTERSMRJNING. DETTA R
FR ATT UNDVIKA OLYCKOR. AVGRANDE FR DRIFTEN.
1. Motorer utan smrjnipplar under drift. P detta vis frnyas smrjfettet i
lagerhusen. r smrjnippeln inte tillgnglig sker
Motorer upp till storlek 200 tillverkas smrjning p fljande stt:
normalt utan smrjnipplar. Dessa skall Avlgsna ev kpor.
eftersmrjas i samband med underhll och p Tillstt ca hlften av smrjfettet som behvs
fljande stt: och kr motorn med full hastighet ca 1 minut.
Montera ner motorn frsiktigt. Stng av motor och tillstt resten av smrjfettet.
Avlgsna allt gammalt fett. Insprutningen av hela fettmngden i en
Tvtta lagren med bensin eller dieselolja. stillastende motor kan medfra att smrjfettet
Nytt smrjfett tillsttes. kommer in i sjlva motorns inre ttning.
2. Motorer med smrjnipplar

VID SMRJNING ANVND ENDAST
Det r tillrdligt att smrja motorerna MANUELL SMRJPISTOL
SMRJINTERVALLER
TABELL 1 - KULLAGER - Serie 62/63

Smrjintervall (drifttimmar - horisontellt montage)
II-pol IV-pol VI-pol VIII-pol X-pol XII-pol Fettmngd
Serie 62
6209 18400 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 9
6211 14200 16500 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 11
6212 12100 14400 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
Serie 63
6309 15700 18100 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
6311 11500 13700 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 18
6312 9800 11900 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 21
6314 3600 4500 9700 11600 14200 16400 17300 19700 19700 20000 20000 20000 27
6316 - - 8500 10400 12800 14900 15900 18700 18700 20000 20000 20000 34
6319 - - 7000 9000 11000 13000 14000 17400 17400 18600 18600 20000 45
6322 - - 5100 7200 9200 10800 11800 15100 15100 15500 15500 19300 60
TABELL 2 - RULLAGER - Serie NU 3

Smrjintervall (drifttimmar - horisontellt montage)
II-pol IV-pol VI-pol VIII-pol X-pol XII-pol Fettmngd
NU 309 9800 13300 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
NU 311 6400 9200 19100 20000 20000 20000 20000 20000 20000 20000 20000 20000 18
NU 312 5100 7600 17200 20000 20000 20000 20000 20000 20000 20000 20000 20000 21
NU 314 1600 2500 7100 8900 11000 13100 15100 16900 16900 19300 19300 20000 27
NU 316 - - 6000 7600 9500 11600 13800 15500 15500 17800 17800 20000 34
NU 319 - - 4700 6000 7600 9800 12200 13700 13700 15700 15700 20000 45
NU 322 - - 3300 4400 5900 7800 10700 11500 11500 13400 13400 17300 60
NU 324 - - 2400 3500 5000 6600 10000 10200 10200 12100 12100 15000 72
Anmrkningar: Fr varje 15C temperaturstegring, kortas

ZZ-lager frn 6201 till 6307 behver ej smrjintervallet ned till hlften.
terinfettas eftersom deras livslngd r ca 20.000 Ovan angivna smrjintervall gller i de fall
timmar. Polyrex EM fett anvnds.
Smrjintervall enligt Tabell 1 och 2 gller vid Nr motorer anvnds vertikalt monterade
lagertemperaturer upp till 70C (fr lager upp kortas smrjintervallet ned till hlften jmfrt
till 6312 och NU312) respektive 85C (fr lager med angivna tider i tabeller ovan.
6314 och NU314 eller strre).
VI REKOMMENDERAR RESERVDELAR
ANVNDANDE AV KULLAGER FR
MOTORER SOM R Vid bestllning av reservdelar se till att ha
rtt typbeteckning och produktkod. Dessa str
DIREKTKOPPLADE TILL LASTEN.
angivna p mrkskylten.
VARNING:
FR STOR MNGD FETT KAN Uppge ven motorn serienummer som
ORSAKA VERHETTNING I anges p mrkskylten.
LAGREN OCH DRMED
FRSTRA DEM HELT.
MOTORER FR RISKFYLLDA

MILJER
Polyrex EM fett r kompatibelt med andra
fett Frutom den tidigare givna vgledningen
skall fljande iakttagas:
Polyrex EM innehller polyuretan
frtjockningsmedel och mineral olja och r STLLET FR INSTALLATIONEN AV
kompatibelt med andra fett som innehller: EN MOTOR R KUNDENS
Lithiumbaserade eller lithium polyuretan ANSVAR, DENNE ANSVARAR VEN
och mineraloljeblandningar med tillsatser som
hmmar korrosion, rost & oxidering FR MILJN DR MOTORN SKALL
INSTALLERAS.
Noteringar:
ven om Polyrex EM r kompatibelt med Motorer fr riskfyllda miljer tillverkas
andra fett enligt ovan rekommenderar vi ndock enligt specifik standard fr sdana omrden och
Er att inte blanda med andra fett. r certifierade av respektive internationella
Om du har fr avsikt att anvnda andra fett n klassningssllskap.
de vi ovan rekommenderat, kontakta Weg frst.
Vid speciella applikationer (hg eller lag 1. Installation
temperatur, hga varvtal mm) nr motorn r
specialbestlld anges typ av fett och smrjintervall Den kompletta installationen skall ske efter
p motorns mrkskylt. lokala frskrifter.
VID ANVNDANDE AV INSTALLATIONEN AV MOTORER I
STANDARDMOTORER I SPECIELLA EXPLOSIONSFARLIGA MILJER
OMRDEN ELLER TILL SPECIELLA SKALL SKE AV BEHRIG PERSONAL
APPLIKATIONER SKALL ANTINGEN OCH DET TERMISKA SKYDDET
OLJELEVERANTREN ELLER WEG SKALL MONTERAS ANTINGEN I
KONTAKTAS. SJLVA MOTORN ELLER SEPARAT .
DEMONTERING OCH MONTERING 2. Underhll

Demontering och montering skall endast Underhll mste ske av verkstder
utfras av kvalificerad personal och endast auktoriserade av WEG.
lmpliga verktyg och metoder anvndas.
Ej WEG-auktoriserade verkstder och
Statorn skall monteras mot den inre ringen andra som fretar ngon service p motorer i
i sklden.
riskfyllda miljer ansvarar fr sdan service och
Det r viktigt att en demontering/ alla eventuella skador.
SVENSKA
montering av lagren sker under rena CERTIFIERINGEN SLOPAS OM

frhllanden fr att skra en god drift och fr att
undvika skador. Nya lager skall tas ut ur sitt DET SKER ELEKTRISKA ELLER
emballage frst nr de skall monteras. MEKANISKA MODIFIERINGAR P
EN MOTOR LOKALISERAD I EN
Innan montering av nya lager, kontrollera RISKFYLLT MILJ.
att det inte finns ngra skarpa kanter eller annan
skada p axeln. Flj dessa instruktioner vid underhll, in-
stallation eller smrjning:
Vid lagermontering, vrm de inre delarna
med lmplig utrustning och anvnd lmpliga Kontrollera att alla komponenter inte har vassa
verktyg. kanter, deformation och smuts.
Kontrollera att alla delar r i perfekt kondition. Hgre mrksstrm.
Smrj ytan p skldlagrets fsten med olja fr kad temperaturstegring.
att gra montaget lttare. Minskad motor isolation.
Anvnd endast gummi hammare vid Minskad lagerlivslngd.
montering av delarna.
Kontrollera bultarna fr korrekt tdragning. 1. Standard motorer
Montera kopplingsldan noggrannt, glappet
ska vara (mindre n 0,05 mm). Om spnningen r under 460V krvs inga filter.
Om spnningen r mellan 460V eller lgre n
TERANVND INTE SKADADE 575V krvs filter om anslutningskabeln r lngre
ELLER SLITNA DELAR. BYT UT n 20 meter.
DESSA MOT NYA ORIGINALDELAR. Om spnningen r lika med eller hgre r 575V
krvs filter oavsett lngden p kabeln.
MOTORER DRIVNA AV
F R E K V E N S O M R I K TA R E OM REKOMMENDATIONERNA INTE
FLJS, GLLER INTE GARANTIN.
Anvndandet av frekvsomr utan
utgngsfilter kan pverka motorns prestande 2. IDM Motorer (Inverter Duty Motors)
som fljer:
Lgre effektivitet. Kontrollera spnningen till den forcerade
Hgre vibrationer. kylningen.
Hgre ljudniv. Utgngs filter behvs inte.
GARANTI
WEG garanterar sina produkter mot Garantin omfattar inte demontering hos
fabrikations- och materialfel i 12 mnader frn kparen, transportkostnader, resekostnader
fabrikens fakturadatum. Auktoriserad och uppehlle fr teknikern. Garanti-service
terfrsljare eller agent begrnsas till 18 utfrs endast hos av WEG auktoriserad verkstad
mnader frn tillverkningsdatum, oberoende eller i WEG egna verkstder.
p installationsdatum och under frutsttning
att fljande r uppfyllt: Komponenter, vilkas normala livslngd, vid
normalt bruk, r kortare n garantitiden omfattas
Korrekt transport, hantering och lagring inte av garantin.
Riktig installation baserad p de
specificerade yttre frhllanden och utan Reparationer och/eller utbyte av delar som
frtande gaser. utfrs av WEG och/eller av WEG auktoriserade
Drift inom motorns kapacitet verkstad, medfr inte frlngning av
Regelbunden underhllsservice utfrs garantitiden.
Reparation och/eller utbytande av delar utfrs
av tekniker med skriftlig auktorisation av WEG. Detta anger WEGs garanti i samband med
En defekt motor eller delar drav skall finnas frsljningen och fretaget har ingen
tillgnglig fr leverantren och/eller skyldighet gentemot personer, tredje part,
verkstaden s att arten p felet kan konstateras annan utrustning eller installationer. Alla andra
och motorn repareras fordringar eller krav p ersttning tillbakavisas.
Kparen skall s snart ett fel uppstr kontakta
WEG fr att f felet godknt som ett
fabrikationsfel
PYCCKN
PYCCKN
PYCCKN
1500 1200 1000 900 750 720 600 500
( )
160 13 15700 18100 20000 20000 20000 20000 20000 20000 20000 20000 20000
180 18 11500 13700 20000 20000 20000 20000 20000 20000 20000 20000 20000
200 21 9800 11900 20000 20000 2000 20000 20000 20000 20000 20000 20000
225 27 3600 4500 9700 11600 14200 16400 17300 19700 20000 20000
250 27 3600 4500 9700 11600 14200 16400 17300 19700 20000 20000 20000
280* 27 3600 4500
280 34 8500 10400 12800 14900 15900 18700 20000 20000 20000
315* 27 3600 4500
315 45 2400 7000 9000 11000 13000 14000 17400 17400 20000 20000
355 27 3600 4500
( )
200 21 9800 11900 20000 20000 20000 20000 20000 20000 20000 20000 20000
225 27 3600 4500 9700 11600 14200 16400 17300 19700 20000 20000 20000
250 27 3600 4500 9700 11600 14200 16400 17300 19700 20000 20000 20000
280 34 3500 8500 10400 12800 14900 15900 18700 18700 20000 20000
315 60 5100 7200 9200 10800 11800 15100 15100 15500 19000
355 60 5100 7200 9200 10800 11800 15100 15100 15500 19000
PYCCKN
PYCCKN
NOTES
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22
Flkt Mxico Fans, S.A. de C.V.
Av. 2. No. 7.
Tultitln 54918, Estado de Mxico.
t: +52 (55) 5899 1330
f: +52 (55) 5899 1348
e: info@flakt.com.mx
w: www.flakt.com.mx

Mo 0431 0 Sopladores Flakt

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IAHMX - 9544 - HA - EN - 01 - MO-0431-0-1906 Instalation, Operation

Cliente: Petro-Chem Mexicana & Maintenance Manual

Flkt Mxico Fans. S.A. de C.V.

Flkt Mxico Fans

Telephone: +52 (55) 5899-1330

1.3 Description of fan.

Flkt Mxico Fans

1=0 2=45 3=90 4=135

5=180 6=225 7=270 8=315

Self-limiting power grease-lubricated, depending on the fan

For gas transportation in

moderate dust content.

characteristics (not for

higher dust content or Fig.1.2 Counter Clockwise Rotation (CCW).

f=5 (180 ) f=6 (225 ) f=7 (270 ) f=8 (315 )

Fig.1.3 Flkt Mexico angles for inlet box

Fig.1.7 Inlet Vane control (only for fan sizes

1.4 Condition of delivery.

Flkt Mexico Fans, S.A. de C.V.

Any missing, broken or damaged

If the fan is not to be put in use

When a crane or hoist is used in

Mounting and bolting down.

Weight Q of the foundation below 50,000

Flkt Mxico Fans

2.4 Impeller assembly

Once the motor has been perfectly

Once the equipment has been operating for

Flkt Mxico Fans

Fig. 2.7 Impeller clearance.

Fig. 2.8 Adapter Sleeve.

Flkt Mxico Fans

Test the anchoring of the bearing

Scarce air quantity or pressure:

Flkt Mxico Fans

Always wipe the grease nipples

4.2 Impeller If the bearing housings are exposed to

repairs are made to the impeller, it is Lubrication interval

The bearing housings must be handled

Pay special attention to the bearings, which

To grease the bearings, follow the

Flkt Mxico Fans

Flkt Mxico Fans

Carefully read the complete instructions prior to starting work.

4. Position the housing base on the support surface. Fit the

6. Mount the bearing on the shaft - either directly on a

stepped shaft or using an adapter sleeve.

10. For locating bearing arrangements and bearing

11. Carefully align the housing base. Vertical markings at the

16. Check alignment and fully tighten the attachment bolts in

The instructions are valid for SKF bearings only.

Arrange for a clean working place.

Review the actual drawing and study the bearing arrangement.

Make sure that shaft or housing is properly supported during dismounting.

Loosen the nut a few turns but leave it on the sleeve.

Use a dead blow hammer and strike firmly in the centre.

Bearings mounted so that it is impossible to use a hammer and

The instructions are valid for SKF bearings only.

The bearings should be left in their original packages until

The dimensional and form accuracy of all components which

The diameter of cylindrical shaft seatings is usually checked

The diameter of cylindrical housing seatings is usually checked

Wipe the preservative from the bore and outside diameter of

Wipe the preservative from the surfaces of the sleeve.