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OPERATION &

MAINTENANCE
MANUAL
VOLUME 1 OF 2
INSTALLATION, OPERATION, MAINTENANCE,
AND MECHANICAL ACCESSORY EQUIPMENT

EQUIPMENT:

SEVEN (7) 28 m (91'-10") DIA. BioDoc


ROTARY DISTRIBUTORS
EQUIPMENT MODEL NO. RDS11S

FOR:

IQUITOS SEWERAGE IMPROVEMENT


AND EXPANSION PROJECT
IQUITOS, PERU

FURNISHED BY:

WESTECH ENGINEERING, INC.


3625 SOUTH WEST TEMPLE
SALT LAKE CITY, UTAH 84115 U.S.A.
PHONE: +1 (801) 265-1000

WESTECH NUMBER: 21233A/B


SEPTEMBER 2011

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ii

TITLE PAGE
AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL

VOLUME 1 OF 2
SEVEN (7) 28 m (91'-10") DIA. BioDoc ROTARY DISTRIBUTORS
WESTECH MODEL NO. RDS11S

FOR:

IQUITOS SEWERAGE IMPROVEMENT AND EXPANSION PROJECT


IQUITOS, PERU

USER:

CHINA INTERNATIONAL WATER & ELECTRICAL COMPANY


LIMA, PERU

CUSTOMER:

AQUA ENGINEERING & SERVICES S.A.


PANAMA CITY, PANAMA

WESTECH AGENT:

SPENA SAC
AV. ALAMEDA SUR #300
VILLA MARINA
CHORRILLOS LIMA 09, PERU
CONTACT: ROBERTO SUAREZ HARE
PHONE: (511) 254-6070 x225
FAX: (511) 254-1923
MOBILE: (511) 999-704644
E-MAIL: rsuarez@spenafish.com

MANUFACTURER:

WESTECH ENGINEERING, INC.


3625 SOUTH WEST TEMPLE
SALT LAKE CITY, UTAH 84115 U.S.A.
PHONE: +1 (801) 265-1000
FAX: +1 (801) 265-1080
24-HOUR EMERGENCY ASSISTANCE: +1 (801) 263-4093

WESTECH NUMBER: 21233A/B


SEPTEMBER 2011

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TABLE OF CONTENTS
AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL

VOLUME 1 OF 2
SECTION

PAGE

EQUIPMENT INFORMATION ................................................................................................ 1-1


GENERAL DESCRIPTION ................................................................................................. 1-5
GENERAL PRECAUTIONS ................................................................................................ 1-7
SHORTAGES, DISCREPANCIES, AND FIELD CHARGES ............................................... 1-9
INSTALLATION INSTRUCTIONS .......................................................................................... 2-1
INTRODUCTION ................................................................................................................ 2-3
INSTALL ANCHOR BOLTS ................................................................................................ 2-4
CREATE BENCHMARKS ................................................................................................... 2-6
INSTALL CENTER ASSEMBLY ......................................................................................... 2-7
INSTALL ARMS .................................................................................................................. 2-8
INSTALL TIE RODS.......................................................................................................... 2-10
ROTATIONAL LEVELING OF UNIT ................................................................................. 2-11
PRELIMINARY ARM LEVELING ...................................................................................... 2-12
INSTALL SPREADERS .................................................................................................... 2-13
BASE GROUTING ............................................................................................................ 2-14
INITIAL LUBRICATION ..................................................................................................... 2-15
ELECTRICAL INSTALLATION ......................................................................................... 2-16
RECORD OF LEVELING FORM ...................................................................................... 2-18
START-UP AND OPERATION ............................................................................................... 3-1
SAFETY INSTRUCTIONS .................................................................................................. 3-3
PRE-START-UP CHECKOUT ............................................................................................ 3-4
EQUIPMENT START-UP .................................................................................................... 3-6
DRIVEN OPERATION ........................................................................................................ 3-7
REMOTE MODE CONFIGURATION .................................................................................. 3-9
TIMER MODE SETUP ...................................................................................................... 3-10
HYDRAULIC OPERATION ............................................................................................... 3-14
PROCESS GUIDELINES .................................................................................................. 3-15
MAINTENANCE AND PARTS ................................................................................................ 4-1
GENERAL MAINTENANCE ................................................................................................ 4-3
ORIFICE AND ARM CLEANING ......................................................................................... 4-4
LUBRICATION INSTRUCTIONS ........................................................................................ 4-5
DRIVE BELT REPLACEMENT ........................................................................................... 4-7
DRIVE UNIT REMOVAL ..................................................................................................... 4-9
UPPER BEARING REPLACEMENT ................................................................................. 4-11
STABILIZING BEARING REPLACEMENT ....................................................................... 4-12
BARREL SEAL REPLACEMENT ...................................................................................... 4-13
TROUBLESHOOTING ...................................................................................................... 4-14
STORAGE AND SHUTDOWN PRECAUTIONS ............................................................... 4-15
EXPLANATION OF PARTS LIST ..................................................................................... 4-16
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TABLE OF CONTENTS
AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL

VOLUME 1 OF 2
SECTION
PAGE
ROTARY DISTRIBUTOR PARTS LIST NO. 21157 & 20748 ............................................ 4-17
ELECTRICAL PARTS LIST NO. 21873 & 21920 .............................................................. 4-27
ORDERING REPLACEMENT OR SPARE PARTS .......................................................... 4-33
RECOMMENDED SPARE PARTS LIST........................................................................... 4-35
ACCESSORY EQUIPMENT ................................................................................................... 5-1
EPOXY ANCHORS ............................................................................................................. 5-3
RECOMMENDED LUBRICANTS ....................................................................................... 5-9
MOTOR............................................................................................................................. 5-19
SPEED REDUCER ........................................................................................................... 5-49
BELT DRIVE ..................................................................................................................... 5-77
UPPER BEARING............................................................................................................. 5-83
LOWER BEARING ............................................................................................................ 5-87
ENCLOSURES ....................................................................................................................... 6-1
DRAWINGS REFERENCING ROTARY DISTRIBUTOR PARTS LISTS #21157 & 20748
D101 GENERAL ARRANGEMENT
D102 GENERAL ARRANGEMENT DETAILS
D111 GENERAL ERECTION
D112 GENERAL ERECTION DETAILS
D113 DRIVE ERECTION DETAILS
D114 TIE ROD ERECTION DETAILS
D115 ARM & ORIFICE ERECTION DETAIL
DRAWINGS REFERENCING ELECTRICAL PARTS LIST #21873
E10D CONTROL PANEL LAYOUT
E11D ELECTRICAL SCHEMATIC
E12D FIELD WIRING DIAGRAM
E13D NETWORK DIAGRAM
E14D DEVICE SETTINGS & CONFIGURATION
DRAWINGS REFERENCING ELECTRICAL PARTS LIST #21920
E15D COMMUNICATION PANEL LAYOUT
E16D ELECTRICAL SCHEMATIC

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AN EMPLOYEE-OWNED COMPANY

EQUIPMENT
INFORMATION

1-1

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1-2

FIVE YEAR WARRANTY


WesTech equipment is backed by WesTech's reputation as a quality manufacturer, and by
many years of experience in the design of reliable equipment.
Equipment manufactured or sold by WesTech Engineering, Inc., once paid for in full, is
backed by the following warranty:
For the benefit of the original user, WesTech warrants all new equipment manufactured by
WesTech Engineering, Inc. to be free from defects in material and workmanship, and will
replace or repair, F.O.B. its factories or other location designated by it, any part or parts
returned to it which WesTech's examination shall show to have failed under normal use and
service by the original user within five (5) years from shipment to the purchaser. Such
repair or replacement shall be free of charge for all items except for those items such as
resin, filter media, and the like that are consumable and normally replaced during
maintenance, with respect to which, repair or replacement shall be subject to a pro-rata
charge based upon WesTech's estimate of the percentage of normal service life realized
from the part. WesTech's obligation under this warranty is conditioned upon its receiving
prompt notice of claimed defects, which shall in no event be later than thirty (30) days
following expiration of the warranty period, and is limited to repair or replacement as
aforesaid.
THIS WARRANTY IS EXPRESSLY MADE BY WESTECH AND ACCEPTED BY PURCHASER
IN LIEU OF ALL OTHER WARRANTIES, INCLUDING WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR PARTICULAR PURPOSE, WHETHER WRITTEN, ORAL, EXPRESS,
IMPLIED, OR STATUTORY. WESTECH NEITHER ASSUMES NOR AUTHORIZES ANY OTHER
PERSON TO ASSUME FOR IT ANY OTHER LIABILITY WITH RESPECT TO ITS EQUIPMENT.
WESTECH SHALL NOT BE LIABLE FOR NORMAL WEAR AND TEAR, CORROSION, OR ANY
CONTINGENT, INCIDENTAL, OR CONSEQUENTIAL DAMAGE OR EXPENSE DUE TO
PARTIAL OR COMPLETE INOPERABILITY OF ITS EQUIPMENT FOR ANY REASON
WHATSOEVER.
This warranty shall not apply to equipment or parts thereof which have been altered or
repaired outside of a WesTech factory, or damaged by improper installation, application, or
maintenance, or subjected to misuse, abuse, neglect, accident, or incomplete adherence to
all manufacturers requirements, including, but not limited to, Operations & Maintenance
Manual guidelines & procedures.
This warranty applies only to equipment made or sold by WesTech Engineering, Inc.
WesTech Engineering, Inc. makes no warranty with respect to parts, accessories, or
components purchased by the customer from others. The warranties which apply to such
items are those offered by their respective manufacturers.
WESTECH ENGINEERING, INC.

3625 South West Temple, Salt Lake City, UT 84115

QF-00-063B

(801) 265-1000
08/18/05

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GENERAL DESCRIPTION
AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


stainless steel ring bolted to the bottom of
the rotating center well.

GENERAL DESCRIPTION
After primary screening and settling, raw
sewage or organic industrial waste usually
undergoes secondary treatment through a
biological process. One of the most widely
used methods of secondary biological
treatment is the trickling filter, where waste
effluent flows through a bed of rock, plastic,
ceramic, or wood media. Micro-organisms
attach themselves to the media and feed on
the waste contacting the media surface as
liquid trickles through the filter.
This
bacterial action lowers the oxygen demand
of the waste to levels compatible with the
receiving waters.

2.

The support cage is the rotating structural


component suspended from the thrust
bearing. It carries the weight of the center
barrel and influent, and transfers any
overturning loads to the stabilizing bearing.
The rotating center well, hanging from the
support cage, is designed to contain the
influent as it flows in from the center and
distributes it to the arms.
3.

Thrust bearing.

The thrust bearing is located at the top of


the center mast where there is no possibility
of contamination with sewage. This selfaligning spherical roller bearing carries the
weight of the rotating mechanism. The
bearing rotates in an oil bath and has a
calculated L10 life of over 30 years.

Trickling filters are considered one of the


most economical, simple, and trouble-free
system for biological treatment of organic
wastes.
An efficient and economical
method of distributing waste flow over the
surface of trickling filter beds is the
WesTech BioDoc Rotary Distributor.
Each unit is specifically designed for the
particular requirements of the installation,
and will provide years of reliable service.

4.

Stabilizing bearing.

The stabilizing bearing is a spherical roller


radial type bearing located between the
center mast and the support cage. It is
contained in a sealed housing and is
grease lubricated. It is designed for radial
loads due to eccentric or uneven loads on
the distribution arms. This bearing is also
above the high liquid level to prevent
contamination by sewage. It also has a
calculated L10 life of over 30 years.

LIST OF PRINCIPAL COMPONENTS


1.

Support cage and center well.

Center mast and base.

The mast and base are designed to support


the full operating weight of the mechanism
and any overturning loads. Ports in the
mast allow passage of flow from the center
pier through the base into the distributor
center well. Between the base and center
well is a mechanical seal assembly
designed to withstand the full hydraulic
head in the center well. The seal consists
of two stacked rubber rings, attached to the
stationary base, which seal against a

5.

Distributor arms.

The distributor arms are fabricated tapered


sections bolted to the center well. Arms
convey liquid to the spreader assemblies
located along the arm sides. The location

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GENERAL DESCRIPTION
AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


control panel contains a variable frequency
drive (VFD) capable of controlling the motor
over a 20:1 adjustment range.
Three
control modes are typically provided. Timer
mode governs speed based on a
programmable timer.
Pot model gives
speed control based on a potentiometer
knob on the control panel. Remote mode
offers control from a remote signal source,
such as the plant SCADA control system.
A separate communications panel was
provided as an interface between the plant
Profibus DP system and the Modbus RTU
system used by the VFDs.

and size of each spreader connection are


calculated to uniformly distribute flow while
maintaining the rotational velocity.
6.

Spreader assemblies.

Each spreader assembly consists of an


orifice, an o-ring gasket, and a
polycarbonate spreader bolted to pipe
connections along the arms. The diameters
of the orifices increase toward the ends of
the arms to produce a uniform flow
distribution.
Connections for these
spreader assemblies are provided on both
sides of the arm, near the outer end, to
provide a means of controlling the rotational
thrust produced by the arms.
7.

Support rods and cables.

The vertical tie rods are designed to carry


the entire weight of the arms full of water.
Horizontal cables keep the arms straight
and at the correct spacing from each other.
8.

Drive unit.

The drive unit consists of an AC motor; a


speed reducer; a cog belt drive; and a freewheeling clutch; all mounted atop the
center mast. The belt drive is designed to
transmit the full torque of the rotating
mechanism.
The free-wheeling clutch
allows the rotary distributor to coast to a
stop in the event of a power failure, thus
protecting the equipment from a sudden
deceleration overload.
The clutch also
allows hydraulic operation in the event that
the drive or controls are inoperable.
9.

Control system.

Controls provided allow each rotary


distributor to be operated independently
within the specified speed range. The
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GENERAL PRECAUTIONS
AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


GENERAL PRECAUTIONS
The packing list will be found in one of the
cartons that is shipped directly from Salt
Lake City, Utah. The list should be kept in
a readily accessible and safe place. Many
contractors prefer to keep this list in some
type of binder for protection and quick
reference.

The erection instructions enclosed are


provided to assist in the assembling and
adjustment of this mechanism. They are
suggested procedures only, and are not
intended to be substituted for the
experience of the persons assigned to the
task of erecting and assembling this
equipment. It is recommended that these
instructions be studied prior to erecting,
assembling, and adjusting.

This list is particularly useful during erection


for locating small parts and fasteners.
When coordinated with the erection
drawings,
equipment
tagging
(Item
numbers from parts list) and the
contractor's packing list becomes an
invaluable erection tool.

In the assembling of this equipment, it will


be necessary to install, adjust, and maintain
certain accessory items which are not
manufactured by WesTech Engineering,
Inc. This accessory equipment must be
stored, handled, adjusted, and maintained
in accordance with instructions provided by
the manufacturer of that equipment. This is
absolutely necessary in order to be assured
of prompt and full participation in the
warranty protection on the equipment.
WesTech Engineering, Inc. will not accept
responsibility for damage to equipment
which has not been handled in accordance
with the manufacturer's instructions.

Equipment Tags:
Each shipping piece has been tagged or
piece marked for convenience. Typically,
item number will be marked on all items.
Piece marked items received will have a
mark such as "Item 203" which may be
cross referenced through the parts list to
general erection drawings bubble number.
Receiving Material:
The equipment pieces and components
received may have been shipped from:

Packing List:
The contractor's packing list consists of a
sheet containing an itemized listing of parts.

1.

WesTech Engineering in Salt Lake


City, Utah.

2.

A fabricator, acting under WesTech


Engineering's instructions.

3.

A "buy-out" distributor, such as a


motor or reducer manufacturer.

The packing list contains:


1.

Item numbers and descriptions of the


part.

2.

Total quantity of parts shipped.

3.

Indication of direct shipment from


supplier or fabricator.

4.

Date and job number of shipment.

Since there will often be more than one


shipment to the job site, it is important to
coordinate the receiving and storage of the
items accordingly.

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GENERAL PRECAUTIONS
AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


applicable, WesTech can furnish, upon
request, a paper template for positioning
the anchor bolts. If a template has not been
furnished, remember that the location and
projection of all anchorage is critical. The
specified amount of projection and location
are shown on the general arrangement
drawings. Prior to equipment installation,
clean threads of all anchorage bolts. Add
anti-seize on projection threads prior to
threading on leveling nuts.

Upon receipt of a shipment, check packing


list against the items received and retain
this list for future reference. If certain items
are missing, make notes of this on the
shipping papers to protect all interests.
Also,
immediately
notify
WesTech
Engineering of this shortage.
IMPORTANT! WesTech must be notified of
any shortages within 72 hours of delivery.
All material has been thoroughly checked
and inspected before shipment. If the
equipment is received in bad condition or if
the packages are broken, make a bad order
notation on the shipping papers to this
effect. This notation will enable filing the
proper claims against the freight company.
Notify WesTech immediately if any parts
are found broken or damaged during
shipment.

Instruction Manual:
Keep an instruction manual in the area
where the operators can familiarize
themselves with it and have it for reference.
The manual is useless if the operator and
foremen do not have access to it.
Further Assistance:
If a problem is encountered in installing or
operating the equipment, which cannot be
solved by referring to this manual, feel free
to contact WesTech Engineering, Inc., 3625
South West Temple, Salt Lake City, Utah
84115, U.S.A.; phone (801) 265-1000; or
fax (801) 265-1080.

Please handle the equipment properly


when unloading and erecting. All cartons,
electrical equipment, and gear drives
should be stored under cover and
protection from moisture, grit, and mud.
All rolled sections must be stored on edge
or blocked up to prevent distortion. If
allowed to lay flat, these items may loose
their shape which would hinder erection
and proper alignment of equipment.

Plant Personnel Training Classes:


At the time of final check out of the
installation of the Rotary Distributor and
start-up, a WesTech representative will
conduct an instruction class.

Anchor Bolts:
If required, anchor bolts are shipped direct
to the job site upon receipt of the approved
submittals by WesTech Engineering. Notify
WesTech immediately if anchor bolts are
not received as promised.

Plant operators and maintenance personnel


are asked to attend this instruction class
usually lasting about two hours.
The synopsis covers the material in the
Installation, Operation and Maintenance
Manual as well as covering any specific
questions.

Anchor bolts must be placed accurately to


avoid future erection difficulties. Where
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SHORTAGES, DISCREPANCIES, AND FIELD CHARGES


AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


SHORTAGES, DISCREPANCIES,
FIELD CHARGES

Company policy dictates that no field


charges will be allowed without prior
approval. Written authority must be
given in the form of a WesTech
Inspection and Change Work form with
warranty tracking number. The warranty
tracking number will be issued when the
extent of such modifications and the
price for performing these modifications
have been agreed upon.

AND

Please notify WesTech Engineering, Inc.,


immediately if any apparent manufacturing
discrepancies
or
shortages
are
encountered with the equipment, since no
field charges for alterations or shortages
will be accepted unless authorized in writing
by our representative.

In general, when parts require


replacement, and we agree that
replacement is necessary, WesTech will
furnish new parts. The contractor will
remove the defective parts and install
the replacement parts at a cost agreed
upon by WesTech.

Fabricated steel parts and assemblies


furnished by WesTech Engineering, Inc. are
manufactured following best shop practices
and standards. However, some misfits and
imperfect work may arise. In such cases,
the American Institute of Steel Construction
"AISC Code of Standard Practice" dated
March 18, 2005, will apply to erection of this
equipment. The applicable section reads
as follows:
"7.14. Correction of Errors
The correction of minor misfits by
moderate amounts of reaming,
grinding, welding or cutting, and the
drawing of elements into line with
drift pins, shall be considered to be
normal erection operations. Errors
that cannot be corrected using the
foregoing means, or that require
major changes in member or
Connection configuration, shall be
promptly reported to the Owners
Designated
Representatives
for
Design and Construction and the
Fabricator by the Erector, to enable
the responsible entity to either
correct the error or approve the most
efficient and economical method of
correction to be used by others."

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1-10

AN EMPLOYEE-OWNED COMPANY

INSTALLATION
INSTRUCTIONS

2-1

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2-2

INTRODUCTION
AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


INTRODUCTION
Finally, the equipment parts lists Document
21157 & 20748 for the mechanical
equipment; and Document 21873 & 21920 for
the control panels are included in the
Maintenance and Parts section of the
manual.

The following is a standard erection


sequence for WesTechs Rotary Distributor.
This sequence is suggested only and should
not take precedence over the experience of
the erector, if due to special circumstances or
his available equipment he should decide to
vary this order or procedure. However, all
instructions should be read and considered
before beginning any installation steps.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

The center mechanism unit is a precision


machine and has been shipped fully
assembled. It is of the utmost importance that
the unit be installed level. This is necessary
for the arms to rotate freely within the tank,
without dipping, to ensure uniformity of flow
distribution, and to protect the mechanism
bearings from excessive unbalanced loading.

Introduction
Install Anchor Bolts
Create Benchmarks
Install Center Assembly
Install Arms
Install Tie Rods
Rotational Leveling of Unit
Preliminary Arm Leveling
Install Spreaders
Base Grouting
Initial Lubrication
Electrical Installation

When assembling this equipment, refer to the


enclosed erection drawings and parts list for
proper item numbers and location of
components.
The O&M page titled
"Explanation of Parts Lists" in the
Maintenance & Parts section explains the
numbering system on the drawings and parts
list.

The following drawings are included at the


back of this manual for reference during
installation:

The unit is designed for a clockwise rotation


of the arms (as viewed from above).

ROTARY DISTRIBUTOR DRAWINGS:


D101 GENERAL ARRANGEMENT
D102 GENERAL ARRANGEMENT DETAILS
D111 GENERAL ERECTION
D112 GENERAL ERECTION DETAILS
D113 DRIVE ERECTION DETAILS
D114 TIE ROD ERECTION DETAILS
D115 ARM & ORIFICE ERECTION DETAIL

IMPORTANT! It is essential that an anti-seize


compound be used on the threads of all
stainless steel fasteners to avoid galling or
seizing.

ELECTRICAL DRAWINGS:
E10D CONTROL PANEL LAYOUT
E11D ELECTRICAL SCHEMATIC
E12D FIELD WIRING DIAGRAM
E13D NETWORK DIAGRAM
E14D DEVICE SETTINGS & CONFIGURATION
E15D COMMUNICATION PANEL LAYOUT
E16D ELECTRICAL SCHEMATIC
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INSTALL ANCHOR BOLTS


AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


applicable, place the new bolts
midway between the existing bolts. It
may be helpful to make a template
using the base flange of the center
assembly.

INSTALL ANCHOR BOLTS


IMPORTANT! Correct anchor bolt location
and installation is critical for both ease of
installation and for dependable equipment
anchorage. Ensure that the bolt circle
diameter and bolt-to-bolt spacing is correct.
Make sure that anchors are installed plumb
and with proper embedment. Also make
sure that the bolt circle is centered on the
concrete center pier.
If adhesive (epoxy) anchors
provided, skip to Step #3 below.

WARNING! The adhesive manufacturers


instructions must be followed exactly during
the following anchor bolt installation steps.
Failure to do so may cause unexpected,
catastrophic failure of the anchors which
could result in damage to equipment or
severe injury.

were

5.
If embed (hook) anchors were provided,
proceed with Steps #1 & #2.
1.

2.

Layout and secure the hook anchors


to the forms, rebar, or template, in
their proper locations. Be sure that
each anchor is at the correct spacing,
proper elevation, and is plumb.

IMPORTANT! A carbide-tipped masonry


bit must be used to drill anchor holes. The
holes must not be core drilled as the
adhesive may not bond to the smooth hole
walls. If rebar is encountered, an alternate
bit may be used just to clear the steel.
Then resume drilling with the masonry bit.

After concrete is poured, allow it to


fully set before disturbing the anchors
or releasing them from any templates
or fixtures.

For embed (hook) anchors, skip to Step


#11 below.
3.

4.

Using a masonry bit, drill holes for the


anchors. The hole diameter must be
exactly 1/16 larger than the anchor
diameter.
The depth must be as
shown on the enclosed erection
drawings for anchor embedment.

6.

Prepare the top of the center pier. If


this is a new installation, remove any
construction debris from the top of
concrete. If this is a replacement unit,
remove the existing rotary distributor
mechanism. Remove any grout from
the top of the center pier. Cut off all
existing anchors flush with the top of
concrete.

Clean out the holes using compressed


air. Thoroughly brush the walls of the
hole and blow out the holes again.

IMPORTANT! Holes must be clean for


good adhesive bond. Holes may be damp,
but leave no dust or slurry within holes.

Layout proper locations for the new


epoxy anchor bolts (item 606-607). If

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7.

Assemble the adhesive cartridge with


mixing nozzle per the manufacturers
instructions.

8.

Fill holes with adhesive to 1/2 the hole


depth.

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INSTALL ANCHOR BOLTS


AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


9.

Insert anchor studs into holes by hand


with a slow twisting motion, ensuring
that all hole and threaded-stud
surfaces are coated, and the gap is
completely filled with adhesive.

10. Hold the anchors plumb and at proper


spacing and elevation until the
adhesive is fully cured.
See the
manufacturers
instructions
for
required cure time.
11. When the anchors are fully set, clean
the exposed threads of any concrete
or adhesive residue. Coat the threads
with an anti-seize compound.
12. Install one nut and flat washer per
anchor, about 2" above the concrete.
All nuts and washers should be at the
same elevation.
13. Clear all materials from the top of the
concrete center column in preparation
for setting the center assembly on the
anchors.

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CREATE BENCHMARKS
AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


CREATE BENCHMARKS
1.

NOTE: Its helpful to align the benchmarks


with opposing anchor bolt pairs.
This
reduces the number of anchors that must
be adjusted when leveling with the
benchmarks in a later step.

Using a surveyors level, benchmark


the tank wall at four equally spaced
locations (at 90 apart) approximately
two feet above the media. These
marks will be used later to check final
level of mechanism.

2.

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Label the benchmarks A, B, C, and D


as shown on the Record of Leveling
form provided at the end of this
section.

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2-6

INSTALL CENTER ASSEMBLY


AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


INSTALL CENTER ASSEMBLY
1.

2.

3.

Before the center assembly is set into


place, check the mounting faces of the
center mast base and concrete pier.
Clean, if necessary, to allow for proper
grout installation in a later step.
Install some type of grout backstop to
be used to pack the grout solid. The
backstop material must be soft enough
that it does not inhibit leveling of the
mechanism.
Verify adjustment of the anchor bolt
washers and leveling nuts to a uniform
elevation, approximately 2" above the
concrete.

4.

Orient the center assembly with the


conduit connection coupling toward
the control panel or electrical source.

5.

Install the center assembly base on


the leveling nuts and adjust so that the
assembly is level in two directions 90
degrees apart.

6.

Install a washer and top nut on each


anchor. Snug the top nuts against
base flange, but do not fully tighten
yet.

IMPORTANT! Do not grout between center


assembly base and center pier at this time.
Grouting must be done after leveling
procedure is completed (in a later step).

WARNING! The center assembly must be


lifted either using a choker sling around the
center mast, or using shackles through the
tie rod connection holes. Avoid jarring the
assembly while handling. Keep hands clear
of the base flange until it is resting on the
anchor leveling nuts.

7.

21233A/B

Remove the shipping straps (item 135)


connecting the center mast base (item
103) to the center barrel (item 104).

REV. September 2011

2-7

INSTALL ARMS
AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


INSTALL ARMS
1.

IMPORTANT! Be sure to use anti-seize on


the threads of all stainless steel fasteners.

Place arm sections (items 109-116) on


the media in their proper positions as
shown on drawing D111 GENERAL
ERECTION. Block each arm to the
proper elevation so they can be bolted
together and to the center barrel
flange (item 104).

IMPORTANT! Do not fully tighten arm


flange bolts at this time. This will be done
after arms are leveled in a later step.
3.

IMPORTANT!
Arm sections are not
interchangeable. Identify each arm section
and make sure their locations are exactly
as shown on the erection drawings. The
figure on the following page shows a visual
check of correct placement by confirming
the nozzle spacing at flange connections.
2.

Install vent pipes (items 445-447) in


the connections on the tops of the
arms.

Using extreme care not to bend center


barrel mounting flanges, place the arm
gaskets (items 413-416) into position
and bolt the arm sections and center
barrel together.
Opposing arm
sections must be attached to center
barrel
simultaneously
to
avoid
distortion or uneven loading.

21233A/B

REV. September 2011

2-8

INSTALL ARMS

STECH _ _ _ _ _ _ _ _ _ __
AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL

r-"il

EQ.

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co.

w.

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CORRECT

'0 --1--'0--1--'0

w--I-_'O_-I-_w

TOO CLOSE A DISTANCE


BETWEEN NOZZLES

WRONG

'O-+-'O-+-'O-+'cD""So\'r\'iAN:bC"E"R'1iBET~Wfi'~CiEN;c-l-w.-+-w
NOZZLES

WRONG

21233A/B

REV. September 2011

2-9

INSTALL TIE RODS


AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


INSTALL TIE RODS
1.

2.

3.

Arms
should
remain
blocked
approximately level from the previous
step. Install vertical tie rods (items
402-412) with coupling nuts (items
609, 611, & 613), turnbuckles (items
427-429), and clevises (items 419424, 617). One jam nut (items 608,
610, & 612) must be used with each
turnbuckle and clevis. Two jam nuts
must be used with each coupling nut -one on each side.

Install horizontal tie rods or cables


(item 450). For rods, two jam nuts
must be used with each coupling nut -one on each side. Two nuts are also
used at each end of each rod or cable.
Measure from end of arm to end of
adjacent arm at centerline. Adjust
cables until all four measurements are
equal. This will ensure that each arm
is at 90 from each adjacent arm.

IMPORTANT!
Horizontal
tie
rod
adjustments must be made in two separate
groups in order to keep the arms straight.
These groups are marked 1 and 2 in the
diagram below. First, tighten all group 1
rods or cables, ensuring that arms are not
pulled out of straight. Next, tighten group 2
rods or cables, again making sure that arms
remain straight.

When connections are complete,


tighten each tie rod just until it starts to
take the weight of the arm, and
remove blocking.

IMPORTANT! All arms must be adjusted


simultaneously and tightened uniformly
around the mechanism to avoid excessive
overturning loads in the center assembly.

21233A/B

REV. September 2011

2-10

ROTATIONAL LEVELING OF UNIT


AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


A3. If the maximum difference is greater
than the allowable of 1/4" (6 mm),
raise or lower the leveling nuts on the
anchor bolts as necessary to correct.
Repeat procedure until allowable
tolerance is achieved.

ROTATIONAL LEVELING OF UNIT


The center mast of the rotary distributor
must be plumb for proper operation of the
mechanism and maximum bearing life. The
unit should rotate freely.

A4. When the unit is level to the tolerance


given above, all top anchor nuts
should be securely tightened. The,
repeat step A2 one additional time to
ensure that level has been maintained.

Leveling is achieved by adjusting the


double nuts on the anchor bolts that secure
the base flange. One of the following two
methods must be used to check for level
depending upon the distance from the
media to the top of the tank wall.

Method B
Make a copy of the Record of Leveling
Form at the end of this section, and fill in
the data as this procedure is performed.
Have a copy of the completed form
available when the WesTech field service
technician arrives for inspection and startup.

B1. Select one of the distributor arms, and


rotate it to each of the four bench
marks made previously on the tank
wall. Using a carpenter's level
extended from the arm, measure the
distance between the top of the level
and each bench mark.

IMPORTANT!
While performing the
following leveling procedures, always rotate
the distributor arms clockwise as viewed
from above.

B2. If the maximum difference is greater


than the allowable of 1/4" (6 mm),
raise or lower the leveling nuts on the
anchor bolts as necessary to correct.
Repeat procedure until allowable
tolerance is achieved.

Method A
A1. Set up a surveyor's level at a location
outside the swing of the arms (usually
above and outside of the tank wall).

B3. When the unit is level to the tolerance


given above, all top anchor nuts
should be securely tightened. Then,
repeat step B2 one additional time to
ensure that level has been maintained.

A2. Attach or hold a leveling rod to the top


of one of the arms near the outer end.
Keeping the rod in this location, slowly
rotate the arm 360 taking elevation
readings
at
least
every
90.
Determine the high and low points
over the full rotation as well as the
difference between the high and low
values.

21233A/B

REV. September 2011

2-11

PRELIMINARY ARM LEVELING


AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


PRELIMINARY ARM LEVELING
1.

that will occur when the arms fill with


water.

Measure elevations of the top of


spreader connection nozzles along
each arm -- at the innermost flange, at
each of the vertical tie rod connection
brackets and at the end of the arm.
The purpose of arm leveling is to make
sure the orifices on each arm are at
the same elevation when the unit is
operating and the arms are full of
water.

IMPORTANT! Do not measure to the top


surface of the arm. Doing so will result in
incorrect leveling because the arm height
tapers. Instead, measure along the top of
the spreader connection nozzles.
2.

3.

The elevations of the innermost


positions on each arm should be
equal. Elevations of the arm ends
should be about one inch higher than
at the innermost flanges.

4.

Adjust the elevation of each of the


measured
positions
using
the
turnbuckle on the corresponding tie
rod. Repeat the same procedure for
each arm segment.

NOTE: Dont tighten the arm flange bolts


yet.
A final arm leveling check and
adjustment must be made during start-up
(commissioning) of the unit with the arms
full of water. The arm flange bolts will be
tightened at that time.

When arms have no water a slight rise


in each arm from inner to outer ends is
desired to compensate for sagging

21233A/B

REV. September 2011

2-12

INSTALL SPREADERS
AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


INSTALL SPREADERS
1.

IMPORTANT! Care must be taken that


orifices are in their proper locations for
proper flow distribution and proper
mechanism function. Drawing D115 ARM &
ORIFICE ERECTION DETAIL and the parts
list together give the proper orifice
assembly and placement.

Attach spreaders (item 430) to arms


with proper orifice plates (items 433440) and gaskets (item 418) as shown
below and according to drawings D112
GENERAL ERECTION DETAILS &
D115 ARM & ORIFICE ERECTION
DETAIL. If provided, spreaders with
deflectors are used on the outermost
connections of each arm to keep liquid
from splashing on or over the wall. On
the outer part of each arm, spreader
connections are located on both the
front and back sides of the arm. A
seal cap must be installed on the
opposite side of the arm from each
spreader.

WARNING! Do not over-tighten spreader


fasteners or damage to the spreader will
occur. Spreader fasteners only need to be
snug tight.

21233A/B

REV. September 2011

2-13

BASE GROUTING
AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


BASE GROUTING
1.

smooth inner surface, and to ensure a


good water seal. Completely fill all
area under the base flange and taper
the grout down to the top of the
concrete pier.

When the distributor has been verified


to be properly leveled, the base should
be grouted. WesTech recommends
that a non-shrink, rapid cure grout be
used. A backstop of some kind should
be used as shown below to allow the
grout to be packed solid, to make a

2.

21233A/B

Allow the grout to fully cure before any


flow is started to the distributor.

REV. September 2011

2-14

INITIAL LUBRICATION
AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


INITIAL LUBRICATION
IMPORTANT! Refer to the Lubrication
Instructions on Page 4-5 in the
Maintenance and Parts Section for proper
types and quantities of each lubricant.
1.

The thrust bearing (item 220) located


at the top of the mast in the center
assembly is shipped without oil. The
bearing was lightly coated with grease
during
assembly
for
corrosion
protection only. After the distributor is
completely assembled, rotate the arms
clockwise until the oil level plug (item
225) is visible through an access hole
in the side of the support cage. Tie-off
the arms and remove the level plug.
Remove the oil fill plug (item 227) and
install the oil fill piping assembly (items
229, 546-550). Add oil until the level
reaches the open level plug hole.
Remove the fill piping assembly, and
replace the fill plug.

2.

The stabilizing bearing (item 219) is


located just above the barrel and is
grease lubricated. Add 10-12 shots of
grease into the fitting on the stabilizing
bearing.

3.

The motor, gear reducer, and


freewheel clutch have been factory
filled with lubricant.
No additional
lubrication is required for initial
operation. Refer to the Accessory
Equipment section of this manual for
the manufacturers instructions.

21233A/B

REV. September 2011

2-15

ELECTRICAL INSTALLATION
AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


connection near the base flange.
Additionally, WesTech provided a
short piece of flex conduit that may be
used between the rigid conduit and
motor. Wiring is must be pulled up
through this conduit for connection to
the drive motor.

ELECTRICAL INSTALLATION
IMPORTANT!
The
allowable
wiring
distance between the control panel VFD
and the distributor drive motor is limited, as
shown on WesTechs electrical drawings.
Ensure that the control panel is located
such that this distance limitation is not
exceeded.
1.

NOTE: If the trickling filter is covered by a


dome, the conduit and wiring may run along
the underside of the dome and down to the
drive motor as an alternative to routing it
through the center mechanism. Contact
WesTech for more information if this
method is preferred.

Install each control panel in the


specified or desired location near the
trickling filter. Position it such that all
lights and operators can be easily
seen and reached. Also, ensure that
the door can be fully opened for
maintenance access.

3.

WARNING! Do not install a disconnect


switch in the wiring between the VFD and
motor
without
contacting
WesTech.
Incorrect use of a disconnect switch may
cause damage to the VFD and/or drive
mechanism.

WARNING! Ensure that the motor is wired


for the correct voltage according to
WesTechs electrical drawings.
Also
ensure that the motor and control panel are
properly grounded.
See the enclosed
motor instructions for additional information
on wiring leads.

IMPORTANT! Field power wiring from the


VFD to the rotary distributor must be in a
separate steel conduit isolated 12" from all
other conduits and wiring. However, note
that only a single conduit is provided within
the rotary distributor center mechanism due
to limited internal space. If instrumentation
wiring is required, the separate conduits
must join at the base of the rotary
distributor.
Instrumentation and control
wiring should be of shielded cable with only
one end of the shield grounded.
2.

Make certain that all conduit


connections and joints are tight to
prevent water from entering the motor
housing or running back to the control
panel.

Install power, control, and ground


wiring between the control panel and
drive motor. Notice that there is a
permanent conduit installed in the
center mechanism of the rotary
distributor with a threaded conduit

21233A/B

4.

Connect supply power to the control


panels.

5.

Install the communication panel in the


desired location, and wire between the
panel and the plant SCADA system.

6.

Run communication wire from the


communication panel to the first
control panel.
However, do not
connect
the
wires
to
the
communication panel terminal block
yet.

REV. September 2011

2-16

ELECTRICAL INSTALLATION
AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


operation.
See enclosed drawing
E14D
DEVICE
SETTINGS
&
CONFIGURATION for a chart of
preset memory locations in the LUFP7
Gateway.

IMPORTANT! The plant SCADA system


with Profibus DP controller must be fully
configured and have established and
functional communication with the LUFP7
Gateway in the communication panel
before the Gateway is connected to the
Rotary
Distributor
Control
Panels.
Otherwise invalid data will be written to
each VFD causing the Timer mode to
function incorrectly.
7.

10. After SCADA communication is


established and programming is
complete, connect the control wiring,
which was left un-terminated in step
#6 above, to the terminal block in the
communication panel.

Run wire to each additional control


panel in a chain. Install the required
termination resistor-capacitor devices
at the ends of the wiring chain.

11. Complete any other interconnecting


wiring required. Review all electrical
work and confirm proper installation.

IMPORTANT! The Modbus RTU protocol


used between the communication panel
and each rotary distributor control panel is
based on RS-485. This requires resistorcapacitor termination devices on each end
of the communication bus to ensure data
signal integrity. These termination devices
have been provided for installation at the
beginning and end panels in the wiring
chain. Ensure that these termination
devices are properly located and installed.
Reference
enclosed
drawing
E13D
NETWORK DIAGRAM and Altivar 312
Modbus Communication Manual, page 10,
for more info.
8.

Power the communication panel and


establish communication with the plant
SCADA system.

9.

Program the Profibus DP controller to


send the appropriate sequence of
control
words
and
frequency
references to operate the control panel
VFDs while in Remote mode. Also set
preset speed values SP2 through SP8
in the LUFP7 Gateway for each control
panel VFD to use with Timer mode

21233A/B

REV. September 2011

2-17

RECORD OF LEVELING FORM


AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


Project: Iquitos, Peru

WesTech Project No. 21233A/B

Unit No. / Designation

Date

Checked By

Company

INSTRUCTIONS: Select one arm to use for the leveling process. Rotate the distributor, stopping this arm at each of
the four benchmarks on the tank wall. Measure the vertical distance from a point on the arm to each of the
benchmarks. Record the measurements in the table below. Calculate the maximum difference by subtracting the
smallest measurement from the largest. Compare the maximum difference to the allowable difference given below.
If the maximum difference is greater than the allowable, adjust the anchor nuts and then re-measure at each
benchmark. Repeat until the maximum difference is less than or equal to the allowable. Finally, tighten all anchor
nuts (above and below the base flange) and take a final reading to verify the unit is level.

Allowable difference between arm measurements = 1/4" (6 mm)

Benchmark
A

Benchmark
B

Benchmark
C

Benchmark
D

Maximum
Difference

1st Reading
Adjustment
Adjustment
Final Reading

21233A/B

REV. September 2011

2-18

AN EMPLOYEE-OWNED COMPANY

START-UP AND
OPERATION

3-1

This page intentionally left blank.

3-2

SAFETY INSTRUCTIONS
AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


equipment. Keep hands and clothing
away from moving parts.

SAFETY INSTRUCTIONS
WARNING! All of the following safety
instructions must be followed at all times to
avoid personal injury or death as well as
equipment damage.
1.

It is essential to understand that the


WesTech Rotary Distributor is capable
of producing and storing a huge
amount of rotational energy, even
though it's typically a slow-moving
mechanism. Just as the arms take
time to go from zero to full speed; it
may take just as long or longer to slow
to a stop. Never stand or place any
object in the path of the rotating arms.
Never walk on the arms while they are
moving.

6.

Place "Warning" signs in the area of


moving parts and hazardous locations.

7.

Never permit people who have been


drinking alcohol, using drugs, or are
otherwise
impaired
to
operate,
maintain, or repair equipment.

8.

Inspect equipment frequently for loose


bolts or malfunctioning components.
Any problems found should be fixed as
soon as safely possible.

9.

Ensure that all guards, handrails, and


other safety devices are in place and
functioning before operating this
equipment.

2.

Only operators and maintenance


workers who have been trained in
safety procedures should be allowed
to work on or around this equipment.
Give access only to authorized
personnel.

3.

To prevent personal injury, the


mechanism and accessories must be
stopped before performing any
maintenance or adjustments. Lockout
electrical power and wastewater flow
before beginning any inspection or
maintenance procedures.

11. Do not work on or around the


equipment during lightning storms.

4.

Tie-off one or more arms during


maintenance to prevent unexpected
distributor movement due to wind
gusts, residual flow from the arms, etc.

13. Ladders, platforms, railings, and other


working surfaces may become icy or
slippery. Exercise caution at all times
to avoid slipping or falling.

5.

Exercise caution around moving parts.


Do not wear loose clothing, hair, or
jewelry when working on or around the

14. Exercise appropriate cautions when


working around wastewater. Wash
thoroughly after coming in contact with
sewage.

10. Verify that all electrical components


are always properly grounded. Do not
operate the equipment if there is any
evidence of damaged or incorrect
electrical wiring.

12. Never attempt to stop the unit by


pushing or pulling on the arms.
Always allow the distributor to coast to
a stop.

21233A/B

REV. September 2011

3-3

PRE-START-UP CHECKOUT
AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


according to the initial lubrication
instructions in the previous section.

PRE-START-UP CHECKOUT
NOTE: Refer to the Installation Instructions
and Enclosures sections of this manual for
additional information.
1.

Verify that all components of the


Rotary
Distributor
have
been
completely and properly assembled
according to the enclosed installation
instructions and assembly drawings.

2.

Verify that the center assembly is


installed plumb, and that each arm has
been uniformly leveled.

3.

Make sure that all fasteners except


arm flange bolts have been properly
tightened.
Confirm that shop
assembled
fasteners
have
not
loosened during shipment or handling.

4.

5.

6.

7.

8.

Make sure that all construction


materials,
equipment,
personnel,
uneven media, and other potential
obstructions are removed from the
path of the arms.

9.

Push the arms around for a full


clockwise revolution to verify that the
unit rotates freely. Ensure that proper
clearance is maintained between the
arms and the media, grating, and any
other obstructions present in the
trickling filter.

WARNING!
The distributor arms only
rotate freely in the clockwise direction. This
is because the drive clutch disengages the
motor and gear reducer, preventing them
from back-driving. Do not attempt to rotate
the arms counter-clockwise or damage to
the mechanism may occur.

Check to see that all anchor nuts on


the base mounting flange have been
tightened, and that grouting has been
completed.

10. Verify that the orifices and spreaders


are installed exactly as shown on the
assembly drawings. This means that
each orifice diameter is correct, and
each of the outer spreaders is installed
on the proper side of the arm.

Verify that installation of the controls is


complete, and that all electrical wiring
is complete and correct. Ensure that
the voltage supply to the control panel
is correct per WesTechs electrical
drawings.

11. Set the control panel Off/On switch to


their OFF position. Apply power to
the control panel.

Confirm that the belt drive is properly


aligned and tensioned. See the Drive
Belt Replacement section beginning
on page 4-7 for requirements.

12. Confirm
that
the
programmed
parameters in the VFD are correct
according to the table on drawing
E11D ELECTRICAL SCHEMATIC. In
particular, the acceleration and
deceleration rates, and motor overload
parameters must be correctly set.

Verify that the upper distributor


bearing has been filled with the proper
type and quantity of oil, and that the
lower bearing has been greased

21233A/B

REV. September 2011

3-4

PRE-START-UP CHECKOUT
AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


17. With each arm full of water, use a
surveyors level to take measurements
at the top of a nozzle near each
vertical tie rod connection on each
arm. Verify that the nozzles are level
along the full length of each arm to
inch (6 mm). Adjust vertical tie rods as
required. After leveling, snug all arm
flange bolts but dont over-tighten.

13. Open all flush gates at the ends of the


arms. Start flow to the distributor.
Allow the arms to flush for several
minutes to ensure that any debris in
the distributor or influent piping exits
the arms without clogging orifices.
Then stop flow and close the flush
gates.
14. Set flow to the minimum design rate so
that only the primary arms are full and
discharging water.

18. Use a surveyors level to check the


elevation at the tip of each arm and
verify they are equal to inch. If an
adjustment is required, slightly loosen
the arm flange bolts and repeat step
18. When leveling is complete, ensure
that tie rod jam nuts have been
tightened against the turnbuckles and
clevises.

15. Verify that the distributor does not tend


to rotate either forward or backward
with the drive off. Adjust primary arm
spreader and seal cap pairs between
front and back sides as necessary to
balance the thrust for zero speed.

19. Remove tie off rope(s).

NOTE: Spreaders at the outer end of an


arm have more effect on the net hydraulic
thrust than the inner spreaders do. Swap
outer spreaders and caps to make larger
changes in thrust and speed. Switching
inner spreaders and caps will yield smaller
changes in speed.

Additional Pre-Start Recommendations


20. If spare parts were provided, these
should be labeled and properly stored.
21. A copy of this Operation &
Maintenance manual should be made
available to both operations and
maintenance personnel.

IMPORTANT! Only switch spreader


assemblies and seal caps in pairs that are
directly in line with each other. Also, when
a spreader assembly and seal cap are
switched, the corresponding pair on the arm
180 opposite should also be switched if
possible.

When these procedures have been


completed the distributor should be ready
for start-up.

16. Increase flow to maximum so that the


secondary arms are full. Verify again
that the hydraulic thrust is neutralized
and the arms do not tend to rotate.
Adjust only secondary arm spreader
and seal cap pairs between front and
back sides as required.

21233A/B

REV. September 2011

3-5

EQUIPMENT START-UP
AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


EQUIPMENT START-UP
1.

Stop flow to the distributor if it is still


flowing from previous pre-startup
checks.

2.

Ensure that all tools and equipment


have been removed from the filter so
the arms are free to rotate.

3.

On the control panel, turn the


potentiometer knob counter-clockwise
to the lowest setting. Turn the selector
switch to the POT position, and turn
the Off/On switch to ON. Confirm
proper motor rotation by watching to
see that the distributor arms begin to
turn clockwise very slowly. Monitor
the distributor mechanism for any
unusual motion or sounds.

IMPORTANT! The VFD is programmed


with a slow acceleration rate to avoid
overloading the drive.
When starting,
stopping, and selecting different speeds, it
may take several minutes for the unit to
complete each speed change.
IMPORTANT! If the arms do not begin to
turn, the motor may be rotating backwards.
This can be checked by removing the belt
guard cover and carefully observing the
free-wheel clutch and belt drive while the
motor is operating. If the drive turns the
wrong way, switch two of the motor power
leads at the VFD output terminals.
4.

5.

If the communication panel is


connected to an operable remote
control source such as a plant SCADA
system, this can be tested now. Turn
the selector switch to the REMOTE
position and use the remote source to
vary the distributor speed over the
available range. When finished, turn
the selector back to the POT setting.

6.

Decrease the speed back to the


slowest setting, and start flow to the
distributor.

7.

Run the equipment through the


available speed range again to verify
proper operation.

8.

Set an operating schedule in the


control panel timer according to the
Timer
Mode
Setup
procedure
beginning on page 3-10. Change the
mode selector to TIMER and confirm
proper operation.

9.

Set
the
selector
switch
and
potentiometer knob to the desired
positions to begin normal operation.

The unit is now ready for continuous driven


operation.

Turn the potentiometer knob clockwise


to increase the speed to maximum.
Continue to observe the equipment,
allowing the distributor to reach
maximum speed and to run there for
several minutes.

21233A/B

REV. September 2011

3-6

DRIVEN OPERATION
AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


make Timer mode speed changes, refer
to the Timer Mode Settings procedure on
page 3-10.

DRIVEN OPERATION
The WesTech BioDoc Rotary Distributor
is designed to continuously distribute
wastewater over trickling filter media. The
drive mechanism on top of the center
assembly controls the rotational speed of
the distributor. Using the controls provided,
the speed that produces optimal filter
performance can be maintained.

The following table gives distributor arm


speeds as a function of VFD output
frequency:
VFD Frequency
Hz.
5
10
20
30
40
50
60
70
80
90
100
110
120

On the distributor control panel, the


Remote/Pot/Timer switch selects one of
three available modes of speed control, as
follows:
When the selector switch is in the
REMOTE position, operating speed is
based on signal received from a remote
source such as a plant SCADA system.
With the switch in the POT position, speed
is set by the potentiometer knob on the
control panel.

Distributor Speed
rev/min
min/rev
0.01
70.0
0.03
35.0
0.06
17.5
0.09
11.7
0.11
8.8
0.14
7.0
0.17
5.9
0.20
5.0
0.23
4.4
0.26
3.9
0.29
3.5
0.31
3.2
0.34
2.9

IMPORTANT! The VFD is programmed


with a slow acceleration rate to avoid
overloading the drive.
When starting,
stopping, and selecting different speeds, it
may take several minutes for the unit to
complete each speed change.

The TIMER switch position bases speed


control on settings programmed in the VFD
and programmable timer within the control
panel.
Starting the Drive

Stopping the Drive

To start the drive, turn the On/Off selector


switch to the ON position. The drive will
then slowly accelerate the distributor arms
to the proper speed according to the
selected operating mode.

To stop the drive, turn the On/Off selector


switch to the OFF position. The drive will
stop quickly, and the distributor arms will
independently coast to a stop.

Changing the Speed

Before performing maintenance on the


distributor, the drive should be stopped as
described above. When the VFD output
has reached 0 Hz and the arms have
stopped turning, the control panel
disconnect switch should be placed in the

To change the operating speed in


REMOTE mode, the signal must be varied
by the remote source. In POT mode,
simply turn the potentiometer knob on the
control panel to the desired setting. To
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DRIVEN OPERATION
AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


OFF position to lock out power to the
panel. When maintenance is complete,
turn the disconnect switch back to the ON
position before switching the panel On/Off
switch to ON.
WARNING!
Do not attempt to do
maintenance or other work on the rotary
distributor while the drive is operating.
Power must be locked out and the
mechanism must be secured from rotating
while servicing the equipment.
Drive Faults
A fault alarm light is located on the front of
the control panel. If the light illuminates, it
indicates a fault or problem with the VFD or
an overload of the drive. Identify the fault
by looking at the VFD display, and refer to
the VFD instructions enclosed. Fault status
is also communicated to the plant SCADA
system through the Profibus communication
network.
To clear a fault and reset the VFD, switch
the control panel circuit breaker to the off
position for a few seconds and then back
on again. Make sure that the problem is
corrected before reactivating the drive.

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3-8

REMOTE MODE CONFIGURATION


AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


For example, the Control Word (CMD) and
Frequency Reference (LFr) parameters are
used to operate each VFD. The following
sequence of commands is sent to the
appropriate Write registers of each VFD to
control motor operation:
1. Set CMD = 16#0006 This sets the
VFD to Ready to Switch On state.
2. Set CMD = 16#000F This enables
operation and the motor begins to
run.
3. Set LFr = value of VFD output
frequency reference where 1 = 0.1
Hz. Resend values as necessary to
vary the speed during normal
operation.
4. Set CMD = 16#0000 This sets the
VFD to Disable Voltage state and
stops the motor.

REMOTE MODE CONFIGURATION


The BioDoc Rotary Distributor control
panels each contain a VFD which can be
operated remotely via a Modbus RTU
communication network.
The provided
communication panel contains an LUFP7
Gateway to interface the Modbus RTU
protocol with the plant Profibus DP
controller. Each VFD is configured with a
unique Modbus address, allowing the
gateway to send commands to and receive
status from each VFD through predefined
registers. This memory map is shown on
WesTech
drawing
E14D
DEVICE
SETTINGS & CONFIGURATION enclosed.

The registers for 2nd Preset Speed


through 8th Preset Speed are not used for
Remote mode operation. Instead, they are
available to allow remote adjustment of the
preset speeds used in Timer mode
operation. See the following section for
additional details on using this operational
mode.
The Read-type registers available give VFD
status information and cannot be written to.
The definition of each register is given in
the Altivar 312 Communication Variables
Manual, starting on page 19. All registers
are two bits in size. Additional Read-type
variables can be monitored if they are
properly configured in the LUFP7 Gateway
using spare lines in the memory locations
chart on drawing E14D DEVICE SETTINGS
& CONFIGURATION.

When programming the plant SCADA


and/or Profibus controller system, be aware
of each parameter function and the proper
memory (register) address locations. Refer
to the enclosed Altivar 312 Communication
Variables Manual for details of each bit of
all parameters used.

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3-9

TIMER MODE SETUP


AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


TIMER MODE SETUP
The available speed range in the VFD is 6
Hz to 120 Hz. This gives a distributor arm
speed range of 60 min/rev to 3 min/rev.

Timer
mode
gives
the
distributor
mechanism the capability of being
automatically operated at up to seven
different speeds over a 24-hour period.
This gives the operator the ability to vary
speed in accordance with diurnal changes
in flow and waste strength. Also, one of the
seven speeds is typically set very slow to
give a daily flush of the filter media.

The duration of each speed preset can be 1


minute to 24 hours long.
For example, as shown on the enclosed
electrical drawings, the control panel was
factory set with the following program:
Speed #1: 60 Hz from 00:00 to 05:00
Speed #2: 8 Hz from 05:00 to 06:00 (flush)
Speed #3: 60 Hz from 06:00 to 00:00
Speeds #4 through #7: Unused

IMPORTANT! WesTech recommends that


a flushing step always be present in the
program. This helps avoid excess biomass
build-up which in turn reduces problems
with seasonal sloughing, odors, and flies.

Unused speeds in the VFD are set to a


nominal value of 60 Hz. Unused settings in
the Timer are set to start at time 00:00,
and stop at 00:01.

Timer mode setup involves making settings


in two different components: the variable
frequency
drive
(VFD),
and
the
programmable relay (timer). The following
table shows the correlation between the
settings in the two devices.
Speed

Timer Address

VFD Parameter

#1
#2
#3
#4
#5
#6
#7

@0
@1
@2
@3
@4
@5
@6

SP2
SP3
SP4
SP5
SP6
SP7
SP8

The timer mode program can be modified at


anytime
to
optimize
trickling
filter
performance. Following are procedures on
how to make the necessary settings.
WARNING! Timer mode settings must be
made within the control panel while the
power is on. To avoid risk of shock or
electrocution, only qualified personnel
should access the panel to make the
changes. Keep fingers and tools clear of all
wiring and terminations. Touch only the
buttons / control surfaces of the VFD and
timer.

IMPORTANT! For the timer mode to


properly function there must be at least one
and a maximum of seven speeds set, each
with a start and stop time. There must be
no gaps or overlaps in the program. The
program must start and end at midnight
(0:00) so that all the set points together
span a full 24-hour day.

IMPORTANT! Stop the distributor drive by


turning the control panel On/Off switch to
the OFF position before changing any
VFD or timer settings. However, power to
the control panel must remain on.

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3-10

TIMER MODE SETUP


AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


VFD Speed Settings

6.

Speed settings are input into the Altivar 312


VFD parameters, SP2 SP8, in terms of
output frequency (Hz).

Press ENT to access the speed preset


parameter. The current value will be
displayed.

7.

Rotate the jog dial to change the


speed preset value. The permissible
range is 6 Hz to 120 Hz.

8.

Press ENT to store the new speed


preset value. The display will flash
when the value is stored.

9.

To set additional speed values, repeat


steps 5-8 above.

10. When finished, press ESC one or


more times to exit the parameters and
menus.
Timer Settings
1.

Start and stop times are set in the Omron


ZEN Programmable Relay as shown below.

The Altivar 312 VFD is operated using


two controls. The large jog dial on the
front is rotated left or right to change a
selection or setting. The jog dial is
pressed to make a selection (ENT).
The ESC button is pressed to cancel
or back up one step in a menu.

2.

With the VFD displaying rdY, press


ENT to access the VFD menus.

3.

Rotate the jog dial to cycle through the


menus until FUn- is displayed.

4.

Press ENT to access the Application


Functions submenu.

5.

Rotate the jog dial to cycle through the


parameters until the desired speed
preset parameter is displayed (SP2
through SP8). See the table of speeds
and corresponding VFD parameters
above.

NOTE: All times are set in 24-hour format.

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TIMER MODE SETUP


AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


1.

13. Press OK to save the Start Time.

From the run screen, press OK to


access the main menu.

2.

Put the ZEN in Stop Mode by pressing


the DOWN arrow to select STOP.

3.

Press OK. The menu will now show


RUN instead of STOP.

4.

Press the DOWN arrow to select


PARAMETER.

14. Press the RIGHT arrow to select the


Off (Stop) Time.
15. Again use the LEFT and RIGHT
arrows to move between hour and
minute digits of the Stop Time. Use
the UP and DOWN arrows to change
the numbers.
16. Press OK to save the Stop Time.

5.

6.

Press OK. The timer address @0


will be shown in the upper-left corner
with the square cursor flashing over
the 0.

17. To set times for additional speed set


points, press the RIGHT arrow to put
the cursor on the timer address, and
repeat steps 6-16.

Press OK again. The 0 will begin to


flash, indicating that it can be
changed.

18. Press ESC to return to the main menu.


19. Press the UP arrow to select RUN.

7.

8.

9.

Press the UP arrow to display the


timer address you wish to adjust. See
the table of speeds and timer
addresses above.

20. Press OK to put the ZEN in Run Mode.


21. Press ESC to return to the run screen.

Press OK. The square cursor will


again flash over the timer number.

Setting the Current Date & Time


To set the current date and time in the
Omron Zen Programmable Relay, use the
following procedure:

Press the RIGHT arrow 2 times to put


the cursor on the active days of the
week. Verify that SU-SU is shown,
meaning Sunday to Sunday (all days).

1.

From the run screen, press OK to


access the main menu.

2.

Press the DOWN arrow 3 times to


SET CLOCK.

3.

Press OK twice to display the current


time.

4.

Press OK again to edit the current


time. The last digit of the date will
begin flashing.

10. Press the RIGHT arrow 2 more times


to select the On (Start) Time.
11. Press OK to begin editing the Start
Time.
12. Use the LEFT and RIGHT arrows to
move between hour and minute digits
of the Start Time. Use the UP and
DOWN arrows to change the numbers.

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TIMER MODE SETUP


AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL

5.

Use the UP and DOWN arrows to


change the numbers. Use the LEFT
and RIGHT arrows to move between
the hour, minute, and date digits.

NOTE: The day of week will automatically


change as the date is set.
6.

Press OK twice to confirm and


complete the date and time setting.

7.

Press ESC twice to return to the run


screen.

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3-13

HYDRAULIC OPERATION
AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


HYDRAULIC OPERATION
NOTE: Spreaders at the outer end of an
arm have more effect on the net hydraulic
thrust than the inner spreaders do. Swap
outer spreaders and caps to make larger
changes in thrust and speed. Switching
inner spreaders and caps will yield smaller
changes in speed.

If power is unavailable, or if the controls


and drive unit are not functioning, the
distributor may be hydraulically operated.
This means that the arms are set to rotate
using thrust produced by the water
discharging from the orifices. Follow these
steps to operate a distributor hydraulically.
1.

Stop flow to the rotary distributor, and


use a permanent marker to label the
outer end of each arm with Arm #1,
Arm #2, Arm #3, and Arm #4.

2.

Using these labels, write down


whether each spreader is on the front
or back of the arm at each location on
each arm.

IMPORTANT! Only switch spreader


assemblies and seal caps in pairs that are
directly in line with each other. Also, when
a spreader assembly and seal cap are
switched, the corresponding pair on the
opposite arm should also be switched if
possible.
IMPORTANT! The drive mechanism
includes a freewheel clutch to protect the
equipment from the shock loads of sudden
shutdowns. It also prevents the drive from
braking or slowing the mechanism. As a
result, if the distributor is set to operate
hydraulically, the drive will not be able to
control the rotational speed. The spreader
arrangement must be reconfigured for
neutral thrust (zero speed) before resuming
driven operation.

IMPORTANT!
Before switching any
spreaders and seal caps, make careful note
of their original positions so they can be
restored when driven operation is resumed.
3.

4.

5.

Switch several of the outermost


spreader assemblies from the front
side of each arm to the rear side, and
cap the front side connections with the
displaced seal caps.

6.

Restart flow to the distributor at the


minimum rate.
Confirm that the
distributor rotates clockwise at an
acceptable operating speed. Increase
flow to maximum and again confirm
that the distributor rotates clockwise at
an acceptable rate.

The rotary distributor may now be


operated hydraulically until the drive
unit and controls are ready for
operation.

To resume driven operation, stop flow to


the distributor, reconfigure the spreader
assemblies as recorded in step 2 above.
Then the drive unit and distributor flow can
be restarted.

If necessary, repeat steps 1 through 3,


switching spreader assembly and seal
cap pairs between front and back on
the arms to adjust to the desired
operating speed.

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PROCESS GUIDELINES
AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


of odors and nuisance organisms. Too
much flushing will diminish trickling filter
performance since flow passes through the
media at a rate faster than it can be treated.
The proper flushing speed, frequency, and
duration for this plant must be determined
by the operators based on testing and
process results.

PROCESS GUIDELINES
Optimum operational speed of a rotary
distributor is a function of wastewater flow
and loading.
Studies have found that
slower rotation often yields better treatment
results. This is because the media is more
completely wetted through its entire depth,
and because excess biomass can be
flushed away which helps keep media
surface area at a maximum.

Finally, as part of operating this equipment,


ensure that a schedule is developed for
performing maintenance, both according to
this manual, and for any other observed
needs. Equipment that is well maintained
will give better performance and thus better
tricking filter process results.

Initially the Rotary Distributor should be


operated at approximately 3 - 5 minutes per
revolution. This should be continued until
the biological film on the media (biomass)
has fully formed. The length of time this
takes will vary depending on local climate
and weather conditions as well as
wastewater content. Typical plants require
3 - 6 weeks for full biological growth when
media is new or hasn't been recently used.
After there has been sufficient biological
growth, the rotary distributor speed may be
adjusted to optimize trickling filter
performance. Operating speeds may be
calculated based on typical wastewater
flow, loading, seasonal temperatures, etc.
WesTech
can
assist
with
these
calculations, if desired.
Periodic flushing of the media is an
important part of maximizing trickling filter
performance. This is done by slowing the
distributor arms, typically to 30-60 minutes
per revolution, on a daily basis during times
of low flow and loading. The slow speed is
maintained for 1-2 revolutions of the arms.
Its important to note that too little flushing
will allow excessive amounts of biological
growth to build up on the media. This can
result in poor flow through the media and
sloughing of biomass.
Also, excessive
biomass buildup often results in complaints
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3-16

AN EMPLOYEE-OWNED COMPANY

MAINTENANCE
AND PARTS

4-1

This page intentionally left blank.

4-2

GENERAL MAINTENANCE
AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


GENERAL MAINTENANCE

IMPORTANT! Rapid wear or damage to the


belt could be a sign of other problems with
the rotary distributor. If such belt damage is
discovered, a thorough examination of the
full distributor mechanism should be made.

WARNING! The safety instructions given


in the Equipment Information section of this
manual must be followed at all times when
maintenance work is being done on the
equipment.

4.

Seals and gaskets check. The barrel


seal and all arm gaskets should be
inspected at least annually for
cracking,
leaking,
or
other
deterioration. These must be replaced
as necessary.

5.

Anchors and fasteners check.


anchors and fasteners should
annually verified as tight.
corroding
fasteners
should
replaced.

6.

Tie rod and support cable check.


Annually, all tie rods and support
cables should be checked for proper
tensioning and load sharing. Arms
should also be rechecked for level if
any tie rod adjustments are required.
See the Installation Instructions
section for leveling procedures.

7.

Coating / corrosion check.


Each
distributor should be taken out of
service and fully drained at least
annually to check for any surface
coating deterioration or corrosion. If
found, these should be repaired as
soon as possible.

IMPORTANT!
The unit must not be
operational during any maintenance or
service work.
Try to schedule any
extensive work on cool or cloudy days to
protect biological growth from drying out.
NOTE: Refer to the Enclosures, Accessory
Equipment, and Installation Instructions
sections of this manual for equipment
drawings and additional information.
WesTech Rotary Distributors are designed
to have minimal maintenance requirements.
Below is a general list of the necessary
periodic maintenance items:
1.

Orifice cleaning and arm flushing.


Follow the Orifice & Arm Cleaning
procedure on the following page.

2.

Bearing lubrication. See the enclosed


Lubrication Instructions on page 4-5.

3.

Drive component maintenance. Refer


to the Lubrication Instructions on page
4-5 for gear reducer and drive clutch
lubrication requirements. Drive belt
tension and sprocket alignment should
also be verified regularly according to
the Drive Belt Replacement procedure
on page 4-7. At that time the belt
should also be examined for cracking,
splitting, missing teeth, or other signs
that it should be replaced.

21233A/B

All
be
Any
be

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4-3

ORIFICE AND ARM CLEANING


AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


ORIFICE AND ARM CLEANING
Trickling filter influent usually contains
material that has a tendency to restrict or
clog the orifices. As a result, periodic
orifice cleaning is required. The more
material in the influent, the more often the
orifices will require cleaning. Individual
plants must determine how and when to
clean the arms and spreaders of their rotary
distributors. A suggested orifice cleaning
procedure is as follows:
1.

Shut off flow to the distributor. Allow


the arms to stop.

2.

Open the flush gate on each arm and


allow the arm to drain.

3.

Inspect each orifice. Use a brush to


clean any obstructing material from the
orifices. If possible, draw the material
out through the orifices and collect it
for disposal. Otherwise, push it back
into the arm.

4.

Clean the vent pipes on the top of


each arm. Ensure that they are fully
open so excess air can exit the arms.

5.

Start flow to the distributor, and allow


the arms to flush for several minutes
with the flush gates open.

6.

Close the flush gates and observe the


spreaders on each arm for uniform
water distribution. If any orifices still
appear clogged, repeat the above
procedure, re-cleaning the problem
orifice(s).

NOTE: If a clog is severe, removal of the


spreader assembly may be necessary to
fully clean the orifice.
7.

21233A/B

When all spreaders are giving proper


water distribution, check that all flush
gates are securely closed, and return
the distributor to normal service.

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4-4

LUBRICATION INSTRUCTIONS
AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


LUBRICATION INSTRUCTIONS
Item

Location

Type of Lubrication

Frequency

Amount

Upper Bearing

Mobilgear SHC 634 Oil, or equal

Check and drain


condensate monthly;
change every 6 months

22 oz.
(650 ml)

Lower Bearing

Mobilith SHC PM Grease, or equal

Add monthly

10-12
shots

Gear Reducer

NLGI No. 2 Grease


Shell Alvania Grease 2, or equal

No periodic lubrication
required; overhaul every
2 years

19 oz.
(540 g)

Freewheel
Clutch

NLGI No. 1 non-EP Grease


Mobilith AW1, or equal

No periodic lubrication
required; purge with
new grease during Gear
Reducer overhaul

8-10
shots

Teflon tape to prevent moisture from


entering bearing housing.

ITEM LUBRICATION DETAILS:


1.

Upper Bearing Fully drain and refill


upper bearing with oil as outlined
above. Check the collected oil for
condensate which may indicate a seal
failure or the need to change the oil
more frequently. To change the oil,
rotate the distributor until oil drain plug
(item 225) is accessible through hole
in the upper part of the support cage
(item 106).
See drawing D111
GENERAL ERECTION. Remove the
drain and level/vent plugs, and catch
the oil in a small can or bucket. An
extension pipe can be threaded in the
drain hole to make oil collection easier.
After draining, replace drain plug and
remove fill plug (item 227). Install oil
fill piping (items 229, 546-550) and
add new oil until level reaches oil level
plug. Remove fill piping and replace
fill plug, ensuring that threads are
sealed with pipe thread compound or

WARNING! Do not allow the distributor


arms to rotate while the oil fill piping is
installed, or damage to the equipment will
result.
IMPORTANT!
If an equivalent to the
specified oil is needed, check that it has the
following characteristics:
a. The oil must be ISO 460 grade.
b. The oil must have EP additives for low
speed, heavy load bearing applications.
c. The oil must have effective demulsifying
agents to help avoid forming condensate
emulsions.
d. WesTech recommends that the oil be
synthetic type as this will flow more
readily during cold weather oil changes,
but this is not mandatory.
2.

21233A/B

Lower Bearing Add grease to the


lower bearing as described above.
For best results, rotate the arms 90
REV. September 2011

4-5

LUBRICATION INSTRUCTIONS
AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


between every 2-3 shots.
When
greasing the lower bearing, inspect the
bearing housing and covers for signs
of corrosion or damage. Check that
the sealant on the split covers (items
205 & 206) is intact to prevent
moisture entry into the bearing
housing.
3.

Gear Reducer Overhaul of the


reducer consists of disassembly,
cleaning all old grease from the
internal components, and repacking
with new grease. There are three
cavities that must be repacked. See
the
enclosed
manufacturers
information for additional details.

4.

Freewheel Clutch Add grease to


the clutch at the same time as reducer
overhaul as described above. The
clutch may have grease fittings or plug
screws installed in one or more
lubrication ports on the O.D. of the
clutch.
If plugs are installed,
temporarily replace one with a
standard grease zirk fitting. Purge the
clutch with new grease, remove the
zirk fitting, and replace the plug.

IMPORTANT! Grease added to the


freewheel clutch must not contain any
extreme pressure (EP) or other slippery
additives such as molybdenum disulfide,
sulfur phosphate, or graphite.
These
materials will cause the clutch to slip under
load.

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4-6

DRIVE BELT REPLACEMENT


AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


DRIVE BELT REPLACEMENT
1.

Remove the drive belt guard (item


510).

2.

Loosen the four drive support bolts


(item 537) and the belt drive
tensioning bolt (item 532). Slide the
reducer mounting plate (item 509) to
decrease the sprocket spacing and
loosen the belt (item 529). Remove
the belt.

3.

Inspect the sprockets for signs of


wear, damage, or corrosion. Verify
that all sprocket fasteners are properly
tightened.

4.

Install a new drive belt on the


sprockets.

5.

Use the belt drive tensioning bolt to


increase sprocket spacing until the
new belt is fairly tight. Make sure that
the belt cogs are fully seated in the
sprocket grooves.

IMPORTANT! Belt drive misalignment is


one of the most common causes of
premature belt failure.
A belt can be
destroyed in a matter of days or hours due
to misalignment. Belt alignment needs to
be checked in both parallel and angular
planes each time the belt is installed.
6.

Check the belt tension by pressing a


tension tester against the belt midway
between sprockets. See the diagram
on the following page. The belt is
properly tensioned when it takes the
proper amount of force to deflect the
belt by the amount indicated below.
Adjust the reducer mounting plate nut
until the tension is correct.

NEW BELT APPLIED FORCE: 42-46 lb.


USED BELT APPLIED FORCE: 32-35 lb.
BELT DEFLECTION DISTANCE: 0.24 in.

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4-7

DRIVE BELT REPLACEMENT


AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


7.

Tighten the four drive support bolts


securely.

8.

Next check the alignment of the


sprockets.
Use a ruler or other
straight-edge across the faces of both
sprockets. Ideally, the straight-edge
will contact at four points - one on
each side of each sprocket. Adjust as
required to minimize parallel and
angular misalignment.
See the
diagram below.

9.

Recheck the sprocket alignment and


make any final adjustments needed.
Repeat the tension and alignment
checks, if necessary.

10. Tighten the eight belt drive adjustment


nuts securely and replace the belt
guard cover.

21233A/B

REV. September 2011

4-8

DRIVE UNIT REMOVAL


AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


from the reducer mounting plate (item
509).

DRIVE UNIT REMOVAL


If an overhaul or other maintenance work is
required for the drive unit or either of the
rotary distributor bearings, the drive unit will
need to be removed. See the enclosed
manufacturers instructions for additional
details on maintenance or overhaul of
components. See drawing D113 DRIVE
ERECTION DETAILS for reference.

8.

Remove the reducer mounting plate


from the drive support by removing
four bolts (item 537).

9.

Loosen the setscrews (item 534) in the


drive support, and lift it off of the
bearing seat shaft (item 507).

NOTE: If its necessary to operate the


trickling filter while work is being done on
the removed drive unit, the distributor can
be run hydraulically. See the Hydraulic
Operation procedure on page 3-14. While
the drive is removed, grease and wrap all
exposed machined surfaces to protect them
from corrosion.

IMPORTANT: Do not lose the bearing seat


key (item 520) when removing the drive
support.

1.

First, lockout power to the control


panel and drive motor.

2.

Tie off a distributor arm to prevent the


arms from turning.

3.

Disconnect the electrical wiring in the


motor terminal box. Remove flexible
conduit (item 513) from between motor
and rigid conduit upper end (item 511).

WARNING: The bearing seat seal (item


234) must be kept in place to prevent
moisture or contaminants from entering the
upper bearing cavity. Do not remove this
seal unless either it will be immediately
replaced, or disassembly will continue to
remove one of the two distributor bearings.

4.

Cut silicon sealant from around set


collar (item 530) and remove collar
from rigid conduit.

5.

Remove drive belt according to Drive


Belt Replacement procedure given on
page 4-7.

6.

Remove the top cap (item 512) from


the top of the drive support (item 508).

7.

Unfasten the four bolts (item 539) to


remove the gear reducer and motor

10. Check to ensure that the bearing seat


seal (item 234) is in good condition
and is in proper position to seal
against the top cover (item 107).

REASSEMBLY:
11. Clean the mating surfaces of the drive
support (item 508) and the bearing
seat shaft (item 507). Apply a small
amount of grease or anti-seize
compound to these surfaces to ease
assembly.
12. Reassembly the drive components in
reverse order of the removal sequence
given above.
13. Ensure that the belt drive is properly
aligned and tensioned per the Drive
Belt Replacement procedure.

21233A/B

REV. September 2011

4-9

DRIVE UNIT REMOVAL


AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL

14. Apply new silicon sealant to the set


collar (item 530) both where it contacts
the electrical conduit (item 511), and
where it sits on the top cap (item 512).
15. Reconnect electrical conduit and
wiring.
Before sealing or taping
electrical connections, bump the drive
motor to confirm proper rotation
direction. If rotation is found to be
backwards, switch two of the motor
power leads to change direction.

21233A/B

REV. September 2011

4-10

UPPER BEARING REPLACEMENT


AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


UPPER BEARING REPLACEMENT
See drawing D113 DRIVE ERECTION
DETAILS for further reference.
1.

Stop the rotary distributor arms with


access hole at the top of the support
cage (item 106) aligned with the upper
bearing oil drain valve (item 225).
Lockout flow and power to the filter.

2.

Complete steps 1 9 of the Drive Unit


Removal procedure on page 4-9.

3.

Drain upper bearing oil by removing


the oil drain plug (item 225) and
connecting a drain pipe. Then remove
the oil level/vent plug (item 225) and
collect oil in a clean can or bucket.

Remove upper bearing excluder seal


(item 234).

5.

Place blocks or jacks between the


concrete center pier and the distributor
center barrel (item 104). Position the
blocks to be in line with the arm
connections. Adjust the jacks or use
wooden wedges together with blocking
so the rotating mechanism will be
uniformly supported without dropping.

6.

Remove the old bearing (item 220)


from the bearing seat (item 507) and
top cover. Remove any remaining oil.
Inspect bearing and replace if
necessary. Clean and check tightness
of bolts (item 323) connecting the
bearing seat to center mast (item 103).

8.

Remove the existing bearing seat seal


(item 233) from the bearing seat.

IMPORTANT!
Cleanliness is essential
while installing the new bearing. Keep the
bearing
and
housing
free
from
contamination.
9.

NOTE: If the upper bearing is being


replaced due to failure, an analysis of the
oil may be advisable to help determine the
cause of failure and to prevent future
problems.
4.

7.

Install the lower race of the new


bearing in the bearing seat.

10. Install a new bearing seat seal on the


bearing seat.
11. Install the upper race and rollers on
the top cover. Use a center punch to
peen the edge of the centering
shoulder so the bearing won't easily
come off. Set the top cover and
bearing in place.
12. Install a new upper bearing excluder
seal.
13. Replace oil drain plug, and refill the
upper bearing housing with oil
according
to
the
Lubrication
Instructions (page 4-5) until it starts to
come out of the oil level hole. Then
replace oil level plug.

Remove bolts (item 305) uniformly


from top cover (item 107) and allow
the rotating mechanism to settle on the
jacks or blocking. Match mark the top
cover and support cage for proper
reassembly orientation. Remove the
top cover with belt drive sprocket.

14. Reinstall and uniformly tighten top


cover fasteners.
15. Remove supporting blocking.

21233A/B

REV. September 2011

4-11

STABILIZING BEARING REPLACEMENT


AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


STABILIZING BEARING REPLACEMENT
See drawing D112 GENERAL ERECTION
DETAILS for further reference.
1.

2.

3.

8.

Remove blocking from under bearing


and insert the bearing into the
housing.

Complete steps 1 through 6 described


in the Upper Bearing Replacement
procedure (page 4-11).

9.

Replace bearing backup ring & glue a


new felt seal to the top of the backup
ring.

Remove lower bearing split cover


(item 205) and the felt seal strip (item
235) from the top of the bearing
backup ring. Clean all silicon sealant
from the bearing split cover and glue
from the backup ring.

10. Reinstall
bearing
split
cover.
Completely seal all seams with silicon
sealant to prevent water from entering
bearing.
11. Complete steps 10 through 15 of the
Upper
Bearing
Replacement
procedure to finish the reassembly.

Remove the backup ring (item 204)


from the top of the stabilizing bearing
housing (item 203).

12. Underneath the barrel, examine the


gap between the barrel and center
mast. Confirm that it is uniform all the
way around. If not, loosen the bolts
(item 314) connecting the stabilizing
bearing housing to the support cage.
Shift the housing until the gap is
uniform all the way around and
retighten the bolts.

IMPORTANT! It is critical that the center


barrel and support cage not move with
respect to the center mast while the bearing
is removed.
Ensure that the rotating
structure is securely braced.
4.

Remove the bearing from the mast


(item 103) by tapping with a hardwood
dowel or a brass rod to clear the
housing and then slide the bearing up
the mast.

13. Using the grease fittings on the side of


the bearing housing, pump several
shots of grease into the bearing to
ensure that all lubricant channels are
purged of air.

IMPORTANT! Do not disturb the bolts


(item 314) holding the housing to the
support cage.
5.

Clean old grease out of the bottom of


the bearing housing.

6.

Lower a new bearing onto the center


mast and onto blocking just above the
stabilizing bearing housing.

7.

Pack both sides of the new bearing


with the proper type of grease.

21233A/B

REV. September 2011

4-12

BARREL SEAL REPLACEMENT


AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


BARREL SEAL REPLACEMENT

5.

Inspect old stainless steel seal plate.


Top of seal plate must be flat and
smooth. Clean or polish if necessary.

6.

Make a single cut (if not provided)


between two closely spaced holes in
each of the new barrel seal rings.
Place the rings around the mast and
glue the cuts back together.

Refer to drawing D112 GENERAL


ERECTION DETAILS for further reference.
1.

Clean the center barrel (item 104) with


a high pressure hose inside, outside,
and underneath.

2.

Remove the fasteners (item 319) from


the seal back-up ring (item 123).

3.

Remove the weight guides (item 129),


the backup ring (item 123), and the
weight rings (item 143).

4.

Cut and remove the old barrel seal


rings (item 208).

IMPORTANT: The split in the seal ring


must be glued with "Super Glue" or other
cyanoacrylate adhesive and allowed to fully
set before dropping the seal ring into place.
Note that split on second seal should not be
located directly over that of the first seal.
The rings must lay flat without wrinkles or
gaps between them.

IMPORTANT: The seal plate should be


replaced only if extensively worn or
damaged. The old seal plate must be cut
for removal, and replacements come in two
pieces. If a new plate is required, call
WesTech for detailed installation and
leveling instructions.

7.

21233A/B

Reinstall the weight rings, backup ring,


weight guides, and fasteners.

REV. September 2011

4-13

TROUBLESHOOTING
AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


TROUBLESHOOTING
SYMPTOMS OR
PROBLEMS

POSSIBLE
MALFUNCTIONS

CORRECTIVE ACTION

Non-uniform flow over media


or low spreader flow.

Obstructed flow in some of


the spreaders.

Clean orifices and flush


arms. Schedule for regular
maintenance.

Visible oil around outside of


center mast pipe under
upper bearing.

Oil leakage or overflow from


upper bearing housing.
Overflow can be caused by
condensate accumulation in
bearing housing.

Drain condensate from


housing. Ensure oil level is
correct. If oil is leaking from
around drain plugs or sight
glass, tighten or reseal
threads.

Distributor not operating level Clogged arm vent pipes.


or non-uniform flow over
media.

Clean obstructions from vent


pipes. Schedule for regular
maintenance.

Popping or grinding noise in


bearing.

Bearing failure.

Inspect bearing. Replace as


required.

Leakage from flush gate,


barrel seal, or seal gasket.

Worn or damaged gaskets or


seals, or particles trapped
between sealing surfaces.

Inspect, clean or replace as


required.

Belt not tracking or short belt


life.

Drive sheaves misaligned or


belt not tensioned properly.

Check for proper sheave


alignment, and adjust as
necessary. Adjust tension.

Belt makes a loud snapping


sound.

Belt tension is too loose, belt


is damaged, or drive is
overloaded.

Inspect belt for damage.


Replace or adjust tension as
required.

Distributor doesnt turn when


drive is activated.

Locked-out or loss of
electrical power, disconnect
switch open, VFD drive fault,
broken drive belt, motor
failure, or motor rotating the
wrong direction.

Check for possible


malfunctions. Confirm
proper direction of motor
rotation. Refer to VFD drive
portion of this manual for
explanation of drive faults.
Replace belt or drive motor if
required.

21233A/B

REV. September 2011

4-14

STORAGE AND SHUTDOWN PRECAUTIONS


AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


Check for condensate and drain any
accumulation from all bearing cavities and
lubricant reservoirs.

STORAGE AND SHUTDOWN


PRECAUTIONS
BEFORE INSTALLATION:
Generally it is preferable to store
mechanical items indoors in a dry, well
ventilated enclosure with a constant as
possible temperature.
The equipment
should be adequately supported to prevent
distortion and undue stresses. It should be
at least six inches off the floor. Crates
should be resealed after delivery inspection
to protect contents. See the Short-term and
Long-term Storage sections below for
additional info.

At least once a month, re-lubricate all items


that are grease lubricated, and grease
exterior surfaces of all seals. Spin rotating
components to redistribute lubricant within
bearings and seals. Inspect all of the
equipment for signs of corrosion and take
corrective steps as required.
IMPORTANT! Shipping straps must be
removed from the center assembly before
rotating the bearings. However, these must
be reinstalled before assembly.

INSTALLED EQUIPMENT:
To shutdown the rotary distributors, stop
flow to the unit. Open flush gates and allow
arms to drain. Leave flush gates open until
unit is ready to start-up again.

LONG-TERM STORAGE / SHUTDOWN:


In addition to those steps shown under
"Short-Term", the following steps should be
taken whether storage is indoors or
outdoors.

IMPORTANT: Stopping flow for an


extended amount of time will cause the
biological growth on the media to dry out
and die. If this happens, new growth will
have to form on the media over a period of
days or weeks before the trickling filter will
yield effective wastewater treatment again.

Remove all flush gates from arms, tag them


with identifying info, and store in a safe
location. Tie off one or more arms to
prevent the wind from spinning the
distributor. Add grease and check/change
oil according to the enclosed Lubrication
Instructions.

Whether stored indoors or outdoors, the


appropriate steps outlined in the following
paragraphs should be taken:
"Short-Term" is from 30 to 120 days,
"Long-Term" is 120 days or more.

Tarps or coverings can be used to protect


the equipment, but should be arranged to
allow ventilation.
Machined parts and
threaded items should be coated with a
waterproof grease or rust inhibitor. Prevent
water accumulation in the center barrel
where it could freeze and cause ice buildup on the seal.

SHORT-TERM STORAGE / SHUTDOWN:


The following instructions also apply if there
is to be a period of time between installation
and start-up, or between start-up and the
equipment being put on-line. These steps
are required to protect against corrosion,
contamination, or other possible equipment
deterioration.

Keep the equipment area clean and free of


trash or debris. Take measures to protect
equipment
from
insect
or
rodent
infestations.

21233A/B

REV. September 2011

4-15

EXPLANATION OF PARTS LIST


AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


EXPLANATION OF PARTS LIST

PART NUMBERS:
Part numbers identify drawing numbers for
shop drawings.
Part numbers have a
drawing number followed by a letter. The
first letter of the drawing number indicates
the size of the drawing. The last letter of
the part number distinguishes parts
associated with that drawing.

ITEM NUMBERS:
Item numbers identify a part shown on an
erection or assembly drawing.
Item
numbers are in circles on the drawing with
an arrow pointing to the part. On the parts
list, item numbers are found in the left most
columns of the list. Item numbers are three
digit numbers. The first digit is the parts list
page number where the part is listed, and
the second and third digits are the line
number of the page where the part is listed.

OTHER:
Also listed are part names, materials,
quantities required per assembly and per
order, and weights of parts.

21233A/B

REV. September 2011

4-16

AN EMPLOYEE-OWNED COMPANY

ROTARY
DISTRIBUTOR
PARTS LIST NO.
21157 & 20748

4-17

This page intentionally left blank.

4-18

Document No.
Drawing No.

Dwg
Rev

Description

No. of Pages

Quantity per
Order

Weight

Line
Rev

21157

EQUIPMENT & SPECIFICATION INDEX

20748

BioDoc ROTARY DISTRIBUTOR

D101

GENERAL ARRANGEMENT

D102

GENERAL ARRANGEMENT DETAILS

D111

GENERAL ERECTION

D112

GENERAL ERECTION DETAILS

D113

DRIVE ERECTION DETAILS

D114

TIE ROD ERECTION DETAILS

D115

ARM & ORIFICE ERECTION DETAILS

48,643

REFERENCE DRAWINGS:

REFERENCE SPECIFICATIONS:

P24Z-024A

WESTECH STANDARD SPECIFICATIONS

A60B-001A

FABRICATION AREA CLEANING REQUIREMENTS - GRADE "D"

04/06/11

JEC

SRH

LRS

Date

Proj. By

Proj. Chkd.

Proj. Aprvd.

Date

Std. By

Std. Chkd.

Std. Aprvd.

PARTS LIST INDEX PAGE

QF-00-052

Printed by- ECARNLEY

Assembly Description

Total Weight

48643

lbs

INDEX PAGE
Type

Size

RDS11S

28m DIA

Document Number

Job Number

P/L Page No.

Rev.

21157

21233A

INDEX

Printed on- September 14, 2011 3:52 PM

12/19/03

Item
No.

Part Number
Drawing Number

101 D111

Dwg
Rev

Electrical
Location

Description of Parts

Material

Weight Qty Qty


Line
Per
Per Per
Rev
Order Assy Order

GENERAL ERECTION

103 D120A

CENTER MAST

304SS

4,956

104 D121A

CENTER BARREL

304SS

6,531

105 D122A

WEIR PLATE

304SS

420

14

106 D123A

BARREL SUPPORT CAGE

304SS

2,667

107 D124A

TOP COVER

304SS

826

109 D131A

PRIMARY ARM #1 (INNER)

304SS

2,898

110 D132A

PRIMARY ARM #1 (OUTER)

304SS

2,492

111 D134A

PRIMARY ARM #2 (INNER)

304SS

2,891

112 D135A

PRIMARY ARM #2(OUTER)

304SS

2,492

113 D137A

SECONDARY ARM #1 (INNER)

304SS

4,088

114 D138A

SECONDARY ARM #1(OUTER)

304SS

2,996

115 D140A

SECONDARY ARM #2 (INNER)

304SS

4,081

116 D141A

SECONDARY ARM #2(OUTER)

304SS

2,996

118 D169A

LADDER SUPPORT BRACE

304SS

56

14

119 D129A

LADDER

304SS

448

120 D128A

PLATFORM MOUNT

304SS

91

121 D127A

PLATFORM MOUNT-OPPOSITE

304SS

91

122 D126A

PLATFORM FLOOR

304SS

707

123 D153A

SEAL BACKUP RING

304SS

70

14

124 D154A

SEAL PLATE

304SS

203

125 D143A

FLUSH GATE

304SS

308

28

126 D143B

FLUSH GATE HANDLE

304SS

56

28

WEIGHT GUIDE

304SS

56

131 A155A

SHIM 1/32" THK. (ACTUAL QTY AS REQ'D)

ALUM

28

132 A155B

SHIM 1/16" THK. (ACTUAL QTY AS REQ'D)

ALUM

28

133 A155C

SHIM 1/8" THK. (ACTUAL QTY AS REQ'D)

ALUM

28

SHIPPING STRAP

304SS

28

28

VERTICAL TIE ROD SUPPORT

304SS

560

28

NAME PLATE

ALUM

SEAL WEIGHT

304SS

56

28

102

108

117

127
128
129 A152A
130

134
135 B148A
136
137
138 D147A
139
140 D160A
141
142
143 D151A
144
145
146
147
148
149
150

03/10/11

JEC

SRH

LRS

Date

Proj. By

Proj. Chkd.

Proj. Aprvd.

Date

Std. By

Std. Chkd.

Std. Aprvd.

EQUIPMENT PARTS LIST

QF-00-051

Printed by- ECARNLEY

Total Weight

Assembly Description

43015

this Page/ lbs

BioDoc ROTARY DISTRIBUTOR


Type

Size

RDS11S

28m DIA

Document Number

Job Number

P/L Page No.

Rev.

20748

21233A

Printed on-July 8, 2011

10:18 AM

12/19/03

Item
No.

Part Number
Drawing Number

Dwg
Rev

201

Electrical
Location

Description of Parts

Material

Weight Qty Qty


Line
Per
Per Per
Rev
Order Assy Order

SHOP ASSEMBLY BUYOUTS:

202
203 RD-B456

MIDDLE BEARING HOUSING

204 RD-B457

BEARING BACK-UP RING, SPLIT

CALUM

63

ALUM

205 RD-B458

BEARING SPLIT COVER, TOP (8" PIPE)

CALUM

35

206 RD-B459

BEARING SPLIT COVER, BOTTOM (8" PIPE)

CALUM

35

208 A172A

BARREL SEAL

BUNA

14

14

209 A173A

SEAL PLATE GASKET

CC NEOP

FLUSH GATE GASKET

NEOP

28

28

207

210 A174A
211
212
213
214
215
216
217
218
219 ----------

SPHERICAL ROLLER BEARING

STL

210

220 ----------

SPHERICAL ROLLER THRUST BEARING

STL

84

304SS

14

PLUG, 3/8" NPT, ALLEN HEAD

BRS

14

PLUG, 3/8" NPT, HEX HEAD

BRS

BREATHER

BRS

BALL VALVE, 3/8", CHROME PLATED

BRS

221
222
223 ----------

GREASE FITTING, 1/8" PTF-SAE SPEC. EXT. SHORT, SS, STRAIGHT

224
225 ---------226

227 ---------228 A182A

229 MBV-38
230
231 ----------

ANTI-SLIP GRIT TAPE, 2" WIDE x 30 ' ROLL

232
233 ----------

V-RING SEAL

NBR

234 ----------

EXCLUDER SEAL

NBR

235 MS-0054A

FELT STRIP, 1/4" x 1/2" MED GRAY x 4 FT LG.

FELT

14

SS

236
237
238
239 A161A

SPECIFICATION NAMEPLATE

240
241
242
243
244
245
246
247
248
249
250

03/10/11

JEC

SRH

LRS

Date

Proj. By

Proj. Chkd.

Proj. Aprvd.

Date

Std. By

Std. Chkd.

Std. Aprvd.

EQUIPMENT PARTS LIST

QF-00-051

Printed by- ECARNLEY

Total Weight

Assembly Description

483

this Page/ lbs

BioDoc ROTARY DISTRIBUTOR


Type

Size

RDS11S

28m DIA

Document Number

Job Number

P/L Page No.

Rev.

20748

21233A

Printed on-July 8, 2011

10:18 AM

12/19/03

Item
No.

Part Number
Drawing Number

301

Dwg
Rev

Electrical
Location

Description of Parts

Material

Weight Qty Qty


Line
Per
Per Per
Rev
Order Assy Order

*******SHOP ASSEMBLY FASTENERS:*******

302
303 ---------///

----------

305 ---------///

----------

307 ---------///

---------

309 ---------///

----------

///
----------

314 ---------///

304SS

42

HEX NUT 1/2" (platform floor to platform mount)

304SS

42

CAPSCREW HEX HD 3/4" X 2 3/4"

304SS

56

HEX NUT 3/4" (top cover to support cage)

304SS

56

CAPSCREW HEX HD 3/4" x 2 1/2"

304SS

56

HEX NUT, 3/4" (barrel to support cage)

304SS

56

CAPSCREW HEX HD 1/2" x 1 1/2"

304SS

12

84

HEX NUT 1/2" W/ HVY FW (ladder to barrel, & platform to platform mount)

304SS

12

84

CAPSCREW HEX HD 1/2" x 2 3/4"

304SS

28

NUT 1/2" (flush gate to arm)

304SS

56

CAPSCREW HEX HD 1/2" X 2"

304SS

56

HEX NUT W/ LW 1/2" (bearing housing to support cage)

304SS

56

CAPSCREW HEX HD 1/2" X 2 1/4" (seal plate to barrel)

304SS

12

84

(ladder support brace to platform) (platform mount to cage)

312 ---------///

CAPSCREW, HEX SOCKET FLAT HEAD 1/2" x 1 1/2" LG.

----------

316 ---------///

----------

NYLOCK NUT, 1/2"

304SS

12

84

///

----------

FLAT WASHER 1/2" (seal plate to barrel)

304SS

12

84

CAPSCREW HEX HD 3/8" x 2"

304SS

14

98

NYLOCK NUT 3/8" (backup ring to mast)

304SS

14

98

CAPSCREW HEX HD 3/8" X 1 3/4"

304SS

28

NUT 3/8" (split cover)

304SS

28

323 ----------

CAPSCREW SOCKET HD, 1/2" X 1 1/2"

304SS

42

324 ----------

CAPSCREW HEX HD 5/8" X 1 1/2"

304SS

56

HEX NUT 5/8" (shipping strap)

304SS

56

FLAT MACH PHILLIPS SCREW #12-24NC x 5/8" LG.

304SS

12

84

304SS

56

CAPSCREW HEX HD 1/2" X 1 1/2" LG.

304SS

10

70

HEX NUT 1/2" W/ FW

304SS

10

70

CAPSCREW HEX HD 3/4" X 5 1/2"

304SS

28

NYLOCK 3/4"

304SS

28

319 ---------///

---------

321 ---------///

///

----------

----------

326 ---------///

(split bearing backup ring)

328 ----------

SOCKET SETSCREW, CUP PT 1/4" x 1/2" LG. ALLEN HEAD

///

(split bearing cover)

330 ---------///

----------

332 ---------///

----------

0
(weir-barrel)

(vertical tie rod support to arm)

334 ----------

ANTI-SEIZE, 16oz., BRUSH-TOP CAN

335 ----------

CAPSCREW HEX HD 1/4" X 3/4"

304SS

28

HEX NUT 1/4" W/ FW (nameplate)

304SS

28

POP RIVET, 5/32" x 0.215" GRIP

SS

28

POP RIVET WASHER (nameplate)

SS

28

///

----------

337 ---------///

----------

339
340
341
342
343
344
345
346
347
348
359
350

03/10/11

JEC

SRH

LRS

Date

Proj. By

Proj. Chkd.

Proj. Aprvd.

Date

Std. By

Std. Chkd.

Std. Aprvd.

EQUIPMENT PARTS LIST

QF-00-051

Printed by- ECARNLEY

this Page/ lbs

Total Weight

Assembly Description

BioDoc ROTARY DISTRIBUTOR


Type

Size

RDS11S

28m DIA

Document Number

Job Number

P/L Page No.

Rev.

20748

21233A

Printed on-July 8, 2011

10:18 AM

12/19/03

Item
No.

Part Number
Drawing Number

Dwg
Rev

401

Electrical
Location

Description of Parts

Material

Weight Qty Qty


Line
Per
Per Per
Rev
Order Assy Order

FIELD ASSEMBLY PARTS:

402 D145A

SUPPORT ROD (1/2" x 2'-9 1/2")

304SS

140

28

403 D145B

SUPPORT ROD (1/2" x -1'-2 1/2")

304SS

56

14

404 D145C

SUPPORT ROD (1/2" x 1'-4")

304SS

56

14

405 D145D

SUPPORT ROD (5/8" x 1'-2 1/2")

304SS

70

14

406 D145E

SUPPORT ROD (3/4" x 1'-2")

304SS

70

14

408 A146A

TIE ROD (1/2"x 10'-0")

304SS

392

56

409 A146B

TIE ROD (1/2 x 2'-0 1/2")

304SS

28

28

410 A146C

TIE ROD (5/8 x 12'-0")

304SS

364

28

411 A146D

TIE ROD (3/4 x 12'-0")

304SS

504

28

412 A146E

TIE ROD (1/2" x 12'-0")

304SS

448

56

413 A176A

PRIMARY ARM GASKET-INNER

CC NEOP

14

414 A177A

PRIMARY ARM GASKET-OUTER

CC NEOP

14

415 A178A

SECONDARY ARM GASKET-INNER

CC NEOP

14

416 A179A

SECONDARY ARM GASKET-OUTER

CC NEOP

14

418 RD-0005A

GASKET - SPREADER 2"

CC NEOP

106

742

419 RD-724

CLEVIS, #2, 1/2" -13NC, RIGHT HAND THREAD.

316SS

112

16

112

420 RD-725

CLEVIS, #2, 5/8"-11NC, RIGHT HAND THREAD.

316SS

14

14

421 RD-728

CLEVIS, #2 1/2, 3/4" -10NC, RIGHT HAND THREAD.

316SS

28

14

423 RD-740

3/4" CLEVIS PIN, 3 1/2" LG.

304SS

424 RD-CLP-1

1" CLEVIS PIN

304SS

426 ----------

SEAL CAP, 2"

427 RD-722

TURNBUCKLE, 3/4"-10NC x 6"

428 RD-721

TURNBUCKLE, 5/8"-11NC x 6"

429 RD-720

TURNBUCKLE, 1/2"-13NC x 6"

430 RD-371

SPREADER 2", POLYCARBONATE

433 RD-0035D

434 RD-0035E

435 RD-0035F

407

417

422
14

98

14

14

PVC

70

36

252

316SS

28

14

316SS

14

14

316SS

84

12

84

PC

106

742

ORIFICE, 1" ID x 2 3/8" OD, 1/8" THK

ACRY

10

70

ORIFICE, 1-1/8" ID x 2 3/8" OD, 1/8" THK

ACRY

42

ORIFICE, 1-1/4" ID x 2 3/8" OD, 1/8" THK

ACRY

56

436 RD-0035G

ORIFICE, 1-3/8" ID x 2 3/8" OD, 1/8" THK

ACRY

17

119

437 RD-0035H

ORIFICE, 1-1/2" ID x 2 3/8" OD, 1/8" THK

ACRY

10

70

438 RD-0035J

ORIFICE, 1-5/8" ID x 2 3/8" OD, 1/8" THK

ACRY

15

105

439 RD-0035K

ORIFICE, 1-3/4" ID x 2 3/8" OD, 1/8" THK

ACRY

28

440 RD-0035L

ORIFICE, 1-7/8" ID x 2 3/8" OD, 1/8" THK

ACRY

28

445 ----------

2" SCH 40 NIPPLE x 24" LG. (T.B.E.)

304SS

56

446 ----------

ELL 90 DEG 2" SCH 80, SOC x FIPT (FOR VENT PIPE)

PVC

56

447 ----------

ST ELL 45 DEG 2" SCH 80, SPIG x SOC

PVC

56

56

425

431
432

441
442
443
444
(VENT PIPE)

448
449
450 B168A

HORIZONTAL SUPPORT CABLE (1/4" x 40'-0")

03/10/11

JEC

SRH

LRS

Date

Proj. By

Proj. Chkd.

Proj. Aprvd.

Date

Std. By

Std. Chkd.

Std. Aprvd.

EQUIPMENT PARTS LIST

QF-00-051

Printed by- ECARNLEY

Assembly Description

304SS

280

Total Weight

2772

this Page/ lbs

BioDoc ROTARY DISTRIBUTOR


Type

Size

RDS11S

28m DIA

Document Number

Job Number

P/L Page No.

Rev.

20748

21233A

Printed on-July 8, 2011

10:18 AM

12/19/03

Item
No.

Part Number
Drawing Number

Dwg
Rev

501

Electrical
Location

Description of Parts

Material

Weight Qty Qty


Line
Per
Per Per
Rev
Order Assy Order

DRIVE ASSEMBLY:

502
503
504
505 A180A

CLUTCH WASHER

304SS

506 A181A

SPACER

304SS

507 D183A

BEARING SEAT (& DRIVE MOUNT)

304SS

301

508 C184A

DRIVE SUPPORT

304SS

399

509 C185A

REDUCER MOUNTING PLATE

304SS

266

510 D186A

BELT GUARD

304SS

119

511 A187A

ELECTRICAL CONDUIT

304SS

70

512 A188A

TOP CAP

304SS

14

513 B189A

FLEX CONDUIT 1/2"

14

514 A190A

CYCLO REDUCER

497

MOTOR

224

515
516
517
518 A191A
519
520 ---------

KEY, 3/8" SQ. X 3" LG

304SS

521 ---------

FEATHER KEY, 3/8" X 7/8" X 2 1/4" LG, FULL RADIUS ENDS

304SS

DRIVER CLUTCH SPROCKET

ZP CI

49

525 A193A

DRIVEN SPROCKET

ZP CI

287

526 A194A

DRIVEN SPROCKET BUSHING

ZP CI

35

527 A195A

FREEWHEEL CLUTCH

NP STL

84

14

522
523 A192A
524

528
529 ----------

BELT

530 ----------

SET COLLAR

ALUM

531

****DRIVE SHOP ASSEMBLY FASTENERS****

ALL THREAD - 1/2", 4 1/4" LG.

304SS

HEX NUT 1/2"

304SS

14

534 ----------

SET SCREW, CUP PT. 3/8" x 3/4" LG. SQUARE HEAD (drive support)

304SS

14

535 ----------

CAPSCREW HEX HD 3/8" X 1" (motor to reducer)

304SS

28

CAPSCREW HEX HD 1/2" X 2"

304SS

28

304SS

28

CAPSCREW HEX HD 1/2" X 2 1/4"

304SS

28

HEX NUT 1/2" W/ FW

(reducer to mounting plate)

304SS

28

541 ----------

SOCKET FLAT HEAD CAP SCREW 5/16-24NF x 3/4" LG. (sprocket to clutch

304SS

42

542 ----------

CAPSCREW HEX HD 3/8" X 1"

304SS

56

HEX NUT 3/8" (guard)

304SS

56

CAPSCREW HEX HD 5/16" X 2 1/4" (clutch to reducer shaft)

304SS

546 ---------

ELBOW 90 DEG 3/8" NPT THREADED

304SS

547 ----------

REDUCING COUPLING 1 1/2" NPT x 3/8" NPT THREADED

304SS

548 ----------

PLUG 1 1/2" NPT THREADED

PVC

549 ----------

NIPPLE, SCH 40, 3/8" MNPT x 1 1/2" LG THREADED

304SS

14

550 ----------

NIPPLE, SCH 40, 3/8" MNPT x 4" LG THREADED

304SS

532 ---------///

----------

536
537 ---------///

----------

NUT W/ HEAVY AW FW 1/2"

539 ---------///

///

----------

----------

544 ----------

(drive support to mounting plate)

545

03/10/11

JEC

SRH

LRS

Date

Proj. By

Proj. Chkd.

Proj. Aprvd.

Date

Std. By

Std. Chkd.

Std. Aprvd.

EQUIPMENT PARTS LIST

QF-00-051

Printed by- ECARNLEY

Total Weight

Assembly Description

2373

this Page/ lbs

BioDoc ROTARY DISTRIBUTOR


Type

Size

RDS11S

28m DIA

Document Number

Job Number

P/L Page No.

Rev.

20748

21233A

Printed on-July 8, 2011

10:18 AM

12/19/03

Item
No.

Part Number
Drawing Number

Dwg
Rev

601

Electrical
Location

Description of Parts

Material

Weight Qty Qty


Line
Per
Per Per
Rev
Order Assy Order

******FIELD ASSEMBLY FASTENERS:******

602
603
604 ----------

CAPSCREW HEX HD 5/8" X 2"

304SS

88

616

HEX NUT 5/8" (arm flanges)

304SS

88

616

606 ---------

EPOXY ANCHOR, 3/4" x 11 1/4" LG. (6 3/4" EMBED), RED HEAD A7

304SS

56

607 ---------

HEX NUT 3/4" W/ HEAVY FW (mast anchors)

304SS

16

112

608 ----------

HEX NUT 5/8" (tie rods)

304SS

56

609 ----------

HEX COUPLING NUT, 5/8" (tie rods)

304SS

14

610 ----------

HEX NUT 1/2" (tie rods)

304SS

36

252

611 ----------

HEX COUPLING NUT, 1/2" (tie rods)

304SS

28

612 ----------

HEX NUT 3/4" (tie rods)

304SS

56

613 ----------

HEX COUPLING NUT, 3/4" (tie rods)

304SS

14

614 ----------

SETSCREW, SQUARE HEAD CUP POINT, 3/8 x 5/8" (spreaders)

304SS

106

742

COTTER PIN, 1/8" DIA. x 1 3/4" LG.

304SS

32

224

---

///

----------

615
616
617 ---------618 ----------

ANTI-SEIZE, 8 OZ, FOR STAINLESS

619
620
621
622
623
624
625
626
627
628
629
630
631
632
633
634
635
636
637
638
639
640
641
642
643
644
645
646
647
648
649
650

03/10/11

JEC

SRH

LRS

Date

Proj. By

Proj. Chkd.

Proj. Aprvd.

Date

Std. By

Std. Chkd.

Std. Aprvd.

EQUIPMENT PARTS LIST

QF-00-051

Printed by- ECARNLEY

this Page/ lbs

Total Weight

Assembly Description

BioDoc ROTARY DISTRIBUTOR


Type

Size

RDS11S

28m DIA

Document Number

Job Number

P/L Page No.

Rev.

20748

21233A

Printed on-July 8, 2011

10:18 AM

12/19/03

Item
No.

Part Number
Drawing Number

Dwg
Rev

701

Electrical
Location

Description of Parts

Material

Weight Qty Qty


Line
Per
Per Per
Rev
Order Assy Order

SPARES:

702
703 RD-0005A

GASKET - SPREADER 2" (SPARE FOR ITEM 418, DOC. 20748)

CC NEOP

112

112

704 RD-371

SPREADER 2", POLYCARBONATE (SPARE FOR ITEM 430, DOC. 20748)

PC

112

112

706 RD-0003D

ORIFICE, 1" ID x 2 3/8" OD, 1/8" THK 1/8" THK (SPARE FOR ITEM 433, DO

ACRY

14

14

707 RD-0003E

ORIFICE, 1-1/8" ID x 2 3/8" OD, 1/8" THK 1/8" THK (SPARE FOR ITEM 434,

ACRY

708 RD-0003F

ORIFICE, 1-1/4" ID x 2 3/8" OD, 1/8" THK 1/8" THK (SPARE FOR ITEM 435,

ACRY

14

14

709 RD-0003G

ORIFICE, 1-3/8" ID x 2 3/8" OD, 1/8" THK 1/8" THK (SPARE FOR ITEM 436,

ACRY

21

21

710 RD-0003H

ORIFICE, 1-1/2" ID x 2 3/8" OD, 1/8" THK 1/8" THK (SPARE FOR ITEM 437,

ACRY

14

14

711 RD-0003J

ORIFICE, 1-5/8" ID x 2 3/8" OD, 1/8" THK 1/8" THK (SPARE FOR ITEM 438,

ACRY

14

14

712 RD-0003K

ORIFICE, 1-3/4" ID x 2 3/8" OD, 1/8" THK 1/8" THK (SPARE FOR ITEM 439,

ACRY

713 RD-0003L

ORIFICE, 1-7/8" ID x 2 3/8" OD, 1/8" THK 1/8" THK (SPARE FOR ITEM 440,

ACRY

705

714
715
716 ----------

MOBILGEAR SHC 634, 1 QT. (UPPER BEARING OIL)

717 ----------

MOBILTH SHC PM 460, 12.5 OZ. CARTRIDGE (LOWER BEARING GREAS

718
719
720
721
722
723
724
725
726
727
728
729
730
731
732
743
734
735
736
737
738
739
740
741
742
743
744
745
746
747
748
749
750

03/10/11

JEC

SRH

LRS

Date

Proj. By

Proj. Chkd.

Proj. Aprvd.

Date

Std. By

Std. Chkd.

Std. Aprvd.

EQUIPMENT PARTS LIST

QF-00-051

Printed by- ECARNLEY

this Page/ lbs

Total Weight

Assembly Description

BioDoc ROTARY DISTRIBUTOR


Type

Size

RDS11S

28m DIA

Document Number

Job Number

P/L Page No.

Rev.

20748

21233A

Printed on-July 8, 2011

10:18 AM

12/19/03

AN EMPLOYEE-OWNED COMPANY

ELECTRICAL
PARTS LIST NO.
21873 & 21920

4-27

This page intentionally left blank.

4-28

Part Number
Drawing Number

Item
No.
101

Dwg
Rev

Electrical
Location

Description of Parts

Material

Weight Qty
Qty
Line
Per
Per
Per
Rev
Order Assy Order

E10D

ROTARY DISTRIBUTOR CONTROL PANEL LAYOUT

102 E11D

ELECTRICAL SCHEMATIC

103 E12D

FIELD WIRING DIAGRAM

104 E13D

NETWORK DIAGRAM

105 E14D

DEVICE SETTINGS AND CONFIGURATION

106
107

----

WIRE, DUCT, BITS, FASTENERS, ETC

~---------

304SS

455

STL

140

WINDOW KIT, 5 X 3

304SS

MOUNTING FOOT KIT, SS

304SS

108 CSD302412SS

ENCLOSURE, TYPE 4X

109 CP3024

BACK PANEL, 28.2 X 22.2

110 APWK53NFSS
111

CMFKSS

112
113 ZB5AD3

SELECTOR SWITCH, 3 POSITION, MAINTAINED BODY, W/O CONTACT

114 ZBE101

CONTACT BLOCK, 1 N.O.

115 ZBE102

CONTACT BLOCK, 1 N.C.

116 ZB5AZ009

COLLAR, BODY/MOUNTING

118 ZBVG4

MODULE, RED LIGHT, 120 VAC

119 ZB5AV043

PILOT LIGHT HEAD, RED

120 ZB5AZ009

COLLAR, BODY/MOUNTING

---------

28

-------

117

121
122 ZBVG3

MODULE, GREEN LlGHT,120 VAC

123 ZB5AV033

PILOT LIGHT HEAD, GREEN

124 ZB5AZ009

COLLAR, BODY/MOUNTING

-------

126 ZBVG5

MODULE, AMBER LIGHT, 120VAC

---

127 ZB5AV053

PILOT LIGHT HEAD, AMBER

---

128 ZB5AZ009

COLLAR, BODY/MOUNTING

---

130 ZB5AD2

SELECTOR SWITCH, 2 POSITION, MAINTAINED BODY, W/O CONTACT

---

131 ZBE101

CONTACT BLOCK, 1 N.O.

132 ZB5AZ009

COLLAR, BODY/MOUNTING

125

129
7

-----

---

-------

-----

14

21

133
134 EHD3015

BREAKER, MAIN, 15 AMP 3 PHASE, 480VAC

MB

135 HM1R12X

DISCONNECT, THROUGH DOOR, 4X

MB

136
137 ZB5AD922

OPERATOR, POTENIOMETER 22mm OPERATOR ONLY!

138 RV4NAYSJ103A

BODY, POTENTIOMETER 22MM 10K OHM

139 ZB5AZ009

COLLAR, BODY/MOUNTING

140
141

TIME DELAY FUSE, 1 1/2 AMP

FNQ-R-11/2

F1,2

142 FNQ-R-3 2/10

TIME DELAY FUSE, 3 2110 AMP

143 LP-CC-6

FUSE, 6 AMP LOW PEAK, TIME DELAY

FB1

144 FH8-2PC30-L

FUSE HOLDER, 2 POLE, 30A CC

F1,2

145 FH8-1PC30L

FUSE HOLDER, 1 POLE, 30A CC

F3

146 FH8-3PC30-L

FUSE HOLDER, 3 POLE, 30A CC

FB1

148 ATV312H037N4

1/2 HP VFD, 3 PHASE, 480VAC & 380VAC

VFD

149 KDRA6L

LINE REACTOR 0.5 HP

150 NV-RJ45A

RJ45 TO TERMINAL BLOCK ADAPTER

F3

-------

147

LR

06/15/11

BAJ

PES

NRT

Date

Proj. By

Proj. Chkd.

Proj. Aprvd.

Date

Std. By

Std. Chkd.

Std. Aprvd.

EQUIPMENT PARTS LIST

EsTECH
QF-00-051

Printed by-BJEPPSEN

RJ45

-------

Irotal Weight

Assembly Description

28

630

this Pagel Ibsi

- ---

--

BIODOC CONTROL PANEL


Type

--

----

RDS11S

Size

RD-3-3

Document Number

Job Number

P/L Page No.

Rev.

21873

212338

Printed on-August 25, 2011

7:35 AM

12/19/03

Item
No.

Part Number
Drawing Number

Dwg
Rev

Electrical
Location

Description of Parts

Material

Weight Qty Qty


Line
Per
Per Per
Rev
Order Assy Order

201
202 ZEN10C1ARAV2

RELAY, PROGRAMMABLE, 120 VAC 121N / 8 OUT

PR

BAITERY BACKUP, RELAY, PROGRAMMABLE,

PR

-----

203 ZEN-BAT01

204
205 RH2B-ULAC120V

RELAY, TWO POLE, 120VAC W/INDICATION LIGHT

CR2-3

---

14

206 SH2B-05C

FINGERSAFE RELAY BASE, DOUBLE POLE

CR2-3

---

14

207
208 RH3B-ULAC120V

RELAY, THREE POLE, 120VAC W/INDICATION LIGHT

CR1

---

209 SH3B-05C

FINGERSAFE RELAY BASE, THREE POLE

CR1

---

TB1,2

28

196

28

21

35

210

212 0800886

TERMINAL BLOCK, END BRACKET UT4

TB1,2,3

213 3047028

TERMINAL BLOCK, 6.2mm, END COVER, GRAY

TB1,2,3

-------

214 0442079

TERMINAL BLOCK, GROUND SCREW TYPE, USLKG6N

GND

---

215 1051003

TERMINAL MARKERS

60

420

216 3046142

DISC TYPE TERMINAL BLOCK UT4

TB3

---

14

TRANSFORMER, 250VA, 260/480/120,50/60HZ

CPT

----

211

3044102

TERMINAL BLOCK, 6mm UT4

TB1,2,3

217
218 AE06-0250
219
220

***** TB3 TERMINATION PLUG *****

221 3036796

COMPONENT PLUG, TERMINAL BLOCK ADAPTER UT4

222 CF1/4C121J

120 OHM RESISROR, 5% TOL, 1/4 WAIT

R1

---

223 SA105A102FAB

1 nF (1000 pF) CERAMIC CAPACITOR, 1% TOL, 50 VOLT

C1

---

TB3

224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249

I1I L ,

250

/"

~~T

Proj. By

Jp~'
Proj. Chkd.

Proj. Aprvd.

Std. By

Std. Chkd.

Std. Aprvd.

06/15/11

BAJ

Date

Date

EQUIPMENT PARTS LIST

WEsTECH
QF-00-051

Printed by-BJEPPSEN

ITotal Weight

Assembly Description

this Page/lbsl

BIODOC CONTROL PANEL


Type

Size

RDS11S

RD-3-3

Document Number

Job Number

P/L Page No.

Rev.

21873

212338

Printed on-June 27. 2011

2:50 PM

12/19/03

Item
No.

Part Number
Drawing Number

Dwg
Rev

Electrical
Location

Description of Parts

Material

Weight Qty Qty


Line
Per
Per Per
Rev
Order Assy Order

301
302
303
304 NP-2X3W

NAMEPLATE:

MAIN DISCONNECT

ACRY

NAMEPLATE:

ROTARY DISTRIBUTOR PANEL 01

ACRY

305
306 NP-2X3W

307

ROTARY DISTRIBUTOR PANEL 02

308

ROTARY DISTRIBUTOR PANEL 03

309

ROTARY DISTRIBUTOR PANEL 04

310

ROTARY DISTRIBUTOR PANEL 05

311

ROTARY DISTRIBUTOR PANEL 06

312

ROTARY DISTRIBUTOR PANEL 07

313
314 LP-T22W

LEGEND:

REMOTE/POTITIMER

ACRY

LEGEND:

VFD RUN

ACRY

LEGEND:

POTENTIOMETER DIAL PLATE

ACRY

LEGEND:

VFDSTOPPED

ACRY

LEGEND

OFF/ON

ACRY

LEGEND:

VFD FAULT

ACRY

315
316 LP-T22W
317
318 LP-T22W
319
320 LP-T22W
321
322 LP-T22W
323
324 LP-T22R
325
326
327 NP-3X4Y

NAMEPLATE

ROTARY DISTRIBUTOR MUST BE

328

AT A COMPLETE STOP BEFORE

329

TURNING OFF MAIN DISCONNECT

330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349

f:2,

350

PES

~RT

06/15/11

BAJ

Date

Proj. By

Proj. Chkd.

Proj. Aprvd.

Date

Std. By

Std. Chkd.

Std. Aprvd.

EQUIPMENT PARTS LIST

WEsTECH
QF-00-OS1

Printed by-BJEPPSEN

this Page/lbsl

Irotat Weight

Assembly Description

BIODOC CONTROL PANEL


Type

Size

RD-3-3

RDS11S
Document Number

Job Number

P/L Page No.

Rev.

21873

212338

Printed on-June 27, 2011

2:17 PM

12/19/03

Item
No.

Part Number
Drawing Number

Dwg
Rev

Electrical
Location

Description of Parts

Material

Weight Qty
Qty
line
Per
Per
Per
Rev
Order Assy Order

101 E15D

COMMUNICATION PANEL LAYOUT

102 E16D

ELECTRICAL SCHEMATIC

103
104
105
106
107

----------

WIRE, DUCT, BITS, FASTENERS, ETC

----

108
109
110
111 CSD16126SS

ENCLOSURE, TYPE 4X, WALL MOUNT

PANEL

304SS

15

112 CP1612

BACK PANEL, 14.2 X 10.2

PANEL

STL

113 CMFK

MOUNTING FOOT KIT

PANEL

STL

---

114
115
POWER SUPPLY, 24VDC, 1.3 AMP MINI-PS-100-240AC/24DC/1.3

116 2866446

PS

STL

117
PROFIBUS SPLITTER, DSUB9 ADAPTER SUBCON-PLUS-PROFIBUS/SC

118 2708232

SPLITTER
304SS

119
120 LUFP7

PROFIBUS/MODBUS GATEWAY

121 NV-RJ45A

RJ45 TO TERMINALS ADAPTER NVT

GATEWAY

STL

RJ45

SS

---

-----

-------

16

16

36

36

122

---

123
124
125
1 AMP CIRCUIT BREAKER

126 0916604
127
128 FH8-1PC30L

FUSE HOLDER, 1 POLE, 30A CC

F1

129 FNQ-R-3

TIME DELAY FUSE, 3 AMP

F1

130
131 3044102

TERMINAL BLOCK, 6mm UT4

132 3047028

TERMINAL BLOCK, 6.2mm, END COVER, GRAY

TB1

133 3046142

DISC TYPE TERMINAL BLOCK UT4-TG

TB2

134 3036796

COMPONENT PLUG, TERMINAL BLOCK ADAPTER UT4

TB2

135 0800886

TERMINAL BLOCK, END BRACKET UT4

TB1,2

136 1051003

TERMINAL BLOCK, SPRING, 6mm, BLANK MARKER STRIP ZB6 UT4

TB1,2

137 0442079

TERMINAL BLOCK, GROUND

138 3046142

DISC TYPE TERMINAL BLOCK

TB1,2

GND
TB3

----------

139
140

***** TB3 TERMINATION PLUG *****

141 3036796

COMPONENT PLUG, TERMINAL BLOCK ADAPTER UT4

142 CF1/4C121J

120 OHM RESISROR, 5% TOL, 1/4 WATT

R1

143 GP210

1 nF (1000 pF) CERAMIC CAPACITOR, 10% TOL,1k VOLT

C1

TB3

-----

144
145
146
NAMEPLATE

147 NP-2X3W

ACRY

PROFIBUS/MODBUS COMMUNICATION PANEL

148

149
150

06/23/11

BAJ

PES

NRT

Date

Proj. By

Proj. Chkd.

Proj. Aprvd.

Date

Std. By

Std. Chkd.

Std. Aprvd.

EQUIPMENT PARTS LIST

QF-00-051

Printed by-BJEPPSEN

19

this Page/lbs

- -

COMMUNICATION PANEL
Type

Size

RDS11S

21920
Printed on-August 25. 2011

------

RD-3-3

Document Number

EsTECH

Irotal Weight

Assembly Descriptio ll

8:03 AM

Job Number

P/L Page No.

212338

Rev.

A
1211 9/03

ORDERING REPLACEMENT OR SPARE PARTS


AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


ORDERING REPLACEMENT OR SPARE
PARTS

or a return phone call to confirm that your


order has been received.

Spare or replacement parts may be ordered


from the Parts Department at:

Spare parts may also be ordered directly


from our web page www.westech-inc.com.
Simply go to the web page, click on
Products, then click on Replacement Parts,
fill out the online form, and a WesTech
representative will process your order and
follow up with an Order Acknowledgement,
or a return phone call to confirm that your
order has been received.

WESTECH ENGINEERING, INC.


3625 SOUTH WEST TEMPLE
SALT LAKE CITY, UTAH 84115
U.S.A.
PHONE: +1(801) 265-1000 or -1007
FAX: +1(801) 265-1080
24-HR EMERGENCY: +1(801) 263-4093
E-MAIL ADDRESS:
parts@westech-inc.com
WEB ADDRESS:
www.westech-inc.com

For convenience, a Recommended Spares


Parts List is provided in this manual. This
is a guide for the appropriate level of spares
to keep on-hand to minimize lost time due
to unscheduled breakdowns.

If you would like to talk directly to a spare


parts representative during normal business
hours of 6:00 am to 5:00 pm MST, dial
+1(801)265-1007, Ext. 172 or 173 from a
touch tone phone and a WesTech
representative will take your order.

Should you require further assistance in


determining which spare parts are
appropriate for your particular situation,
please contact WesTechs Spare Parts
Department.

If you would like to fax your order, send the


request to +1(801)265-1080. A WesTech
representative will process your order and
follow
up
with
a
faxed
Order
Acknowledgement, or a return phone call to
confirm that your order has been received.
To use the 24-hour emergency number, dial
+1(801)263-4093. An answering service
will take information about the equipment,
the nature of the emergency, and your
contact info.
They will then notify a
WesTech employee who will return your
call within one hour.
If you would like to e-mail a spare parts
order, simply e-mail your request to us at
parts@westech-inc.com and a WesTech
representative will process your order and
follow up with an Order Acknowledgement,
21233A/B

REV. September 2011

4-33

ORDERING REPLACEMENT OR SPARE PARTS


AN EMPLOYEE-OWNED COMPANY

OPERATION AND MAINTENANCE MANUAL


To avoid unnecessary delays in obtaining
the correct spare or replacement parts for
your equipment, be sure to give the
following information with each order.
1.

Identify equipment using the WesTech


Job number. Your equipment is
identified as follows:
WesTech Job No.: 21233A/B
Equipment Type:
SEVEN (7) 28 m (91'-10") DIA.
BioDoc ROTARY DISTRIBUTORS
Customer/Project Name:
IQUITOS, PERU

2.

Identify the part by name and give the


number of the drawing on which this
part or assembly appears.

3.

Identify the part number.

4.

Identify the size and include all


pertinent
dimensions
(such
as
diameter, length, thickness, bore,
pitch, etc.) whenever possible.

5.

If parts being ordered are electrical in


nature, give all pertinent data such as:
voltage, amperage, wattage, cycles,
speed, power factor, or other
information given on the parts
nameplate or included in the parts
brochure.

6.

Submit your written purchase order or


request for a quotation, both signing
and printing your full name so that
WesTech will know whom to contact
should further clarification of the
inquiry be necessary. ALL VERBAL
ORDERS MUST BE VERIFIED IN
WRITING.

7.

Give a return address and a shipping


address.

8.

Give a preferred method of shipping:


UPS, truck freight, rail freight, air
express, etc.

9.

Show the quantity desired.

10. Provide
instructions
invoicing.

for

proper

11. All spare or repair parts orders are


subject to a $100.00 minimum order
charge.
An item number identifies a part shown on
an assembly drawing.
(See sample
segments of an assembly drawing and
parts list on page 4-16.) Item numbers
enclosed in circles are shown on the
drawing with arrows pointing to each part.
On the parts list, item numbers are found in
the leftmost columns of the Parts List. Item
numbers are three-digit numbers. The first
digit is the parts list page number where the
part is listed. The second and third digits
are the line number on the page where the
part is listed.

21233A/B

REV. September 2011

4-34

Page

""EsTECH
3665 SOUTH WEST TEMPLE, SALT LAKE CITY, UT 84115

Recommended
Spare Parts List

Phone +1(801) 2651000 I Fax +1(801) 2651080


24 Hour Emergency Assistance +1(801) 263-4093
EMail: parts@westechinc.com

21233A

September 12, 2011

90 da s

Prepared by: SHAYMORE


Pa ment Terms: Net 30 Da s

In order to increase the life of your equipment, and avoid costly downtime, Westech recommends that you maintain your equipment
at regular intervals. To do this, Westech recommends, at a minimum, that you have the below mentioned items on hand at all times.
Lona lead items that could sianificantlv minimize downtime as well as normal maintenance and wear items are included in this list.

Item
Number

Drawing
Number

Item
Description

Recommended
Quanitity

Parts List No: 20748


14.00

208

A172A

BARREL SEAL

209

A173A

SEAL PLATE GASKET

7.00

SPHERICAL ROLLER BEARING

7.00

219
220

SPHERICAL ROLLER THRUST BEARING

7.00

233

VRINGSEAL

7.00

234

EXCLUDER SEAL

7.00

MS0054A

FELT STRIP, 1/4" x 1/2" MED GRAY

14.00

413

A176A

PRIMARY ARM GASKETINNER

14.00

414

A177A

PRIMARY ARM GASKETOUTER

14.00

415

A178A

SECONDARY ARM GASKETINNER

14.00

416

A179A

SECONDARY ARM GASKETOUTER

418

RD0005A

GASKET SPREADER 2"

235

14.00
742.00

SEAL CAP, 2"

252.00

430

RD371

SPREADER 2", POLYCARBONATE

742.00

433

RD0035D

ORIFICE, 1" ID x 2 3/8" OD,

70.00

434

RD0035E

ORIFICE, 11/8" ID x 2 3/8" OD,

42.00

435

RD0035F

ORIFICE, 11/4" ID x 2 3/8" OD,

56.00

436

RD0035G

ORIFICE, 13/8" ID x 2 3/8" OD,

119.00

437

RD0035H

ORIFICE, 11/2" ID x 23/8" OD,

70.00

438

RD0035J

ORIFICE, 15/8" ID x 2 3/8" OD,

105.00

426

439

RD0035K

ORIFICE, 13/4" ID x 2 3/8" OD,

28.00

440

RD0035L

ORIFICE, 17/8" ID x 23/8" OD,

28.00

514

A190A

CYCLO REDUCER

7.00

518

A191A

MOTOR

7.00

523

A192A

DRIVER CLUTCH SPROCKET

7.00

525

A193A

DRIVEN SPROCKET

7.00

526

A194A

DRIVEN SPROCKET BUSHING

7.00

527

A195A

FREEWHEEL CLUTCH

7.00

BELT

7.00

7.00

529

Parts List No: 21873


115

ZBE102

CONTACT BLOCK, 1 N.C.

134

EHD3015

BREAKER, MAIN, 15AMP

7.00
14.00

141

FNQR11/2

TIME DELAY FUSE, 11/2 AMP

142

FNQR3 2/10

TIME DELAY FUSE, 3 2/10 AMP

143

LPCC6

FUSE,6AMP

21.00

206

SH2B05C

FINGERSAFE RELAY BASE,

14.00

7.00

Page

""EsTECH
3665 SOUTH WEST TEMPLE, SALT LAKE CITY, UT 84115

Recommended
Spare Parts List

Phone +1(801) 265-1000 I Fax +1(801) 265-1080


24 Hour Emergency Assistance +1(801) 263-4093
E-Mail: parts@westech-inc.com

Westech Job No.: 21233B


Pro osal Valid for: 90 da s

Date Prepared: September 12, 2011


FOB Shi Pt. w/Frt: Pre a & Add

Prepared by:
Pa ment Terms:

In order to increase the life of your equipment, and avoid costly downtime, Westech recommends that you maintain your equipment
at regular intervals. To do this, Westech recommends, at a minimum, that you have the below mentioned items on hand at all times.
Lona lead items that could sianificantlv minimize downtime as well as normal maintenance and wear items are included in this list.

Item
Number

Drawing
Number

Item
Description

Recommended
Quanitity

209

SH3B-05C

FINGERSAFE RELAY BASE,

7.00

210

SH1B-05C

FINGERSAFE RELAY BASE,

7.00

TIME DELAY FUSE, 3 AMP

1.00

Parts List No: 21920


129

FNQ-R-3

Please call, for current price and availibility.

Municipal Recommended Spare Parts List

AN EMPLOYEE-OWNED COMPANY

ACCESSORY
EQUIPMENT

5-1

This page intentionally left blank.

5-2

AN EMPLOYEE-OWNED COMPANY

EPOXY ANCHORS

5-3

This page intentionally left blank.

5-4

Submittal Information

ADHESIVE ANCHORING SPECIALISTS

INSTALLATION STEPS

A7 Adhesive

Solid Base Material

1.

Drill 1/16" oversize diameter holes for 1/4"1/2"


diameter threaded rods and #3 rebar. Drill 1/8" oversize diameter holes for 5/8"1-1/4" diameter threaded
rods, #4 rebar, grout filled blocks and brick pinning.
Clean out hole from bottom with forced air. Complete
hole preparation with brush and repeat cleaning with
forced air (leave no dust or slurry).

2.

When starting new cartridge or new nozzle, dispense


and discard enough adhesive until uniform light grey
color is achieved. Insert the nozzle into the bottom of
the hole and fill to 1/2 the hole depth.

3.

Insert rod slowly by hand into the bottom of the hole


with a slow twisting motion. This insures adhesive fills
voids and crevices and uniformly coats the anchor rod.

4.

See table for working times and curing times. After


the suggested cure time is met, install and tighten
fixture into place.

Fast Dispensing, Fast


Curing Acrylic Adhesive
ADHESIVE ANCHORING SYSTEMS

Fast Dispensing,
Fast Curing Acrylic
35 Minute Cure Time at 60F
Fast Dispensing at all Temperatures
Multi-Patented Formula
ICBO Evaluation Report No. 5560

The acrylic resin and hardening agent are completely mixed as


they are simultaneously dispensed from the dual cartridge
through a static mixing nozzle, directly into the anchor hole. A7
can be used with threaded rod or rebar (for fastening to
hollow base materials, see pages 30 and 33).

Multi-Patented Formula
Miami-Dade County Product Control Approved

Contents: 825 ml (28 fl. oz.)


Part No: A7-28

ADVANTAGES
 All weather formula

 No drip, no sag, easy clean up

 Fast & easy dispensing, even 28-oz.


cartridges can be hand dispensed
 Fast curing time, 35 minutes
at 60F

 Not mix ratio sensitive


 NSF 61 Approved

 Rods are easier to insert into the


hole with A7 compared with other
adhesives
 Works in damp holes and
underwater applications

 Requires less adhesivecan be


used in 1/16" oversized or 1/8"
oversized holes

 One formula for both hollow


and solid base materials

Curing Times
BASE MATERIAL
BASE MATERIAL
(F/C)
TEMPERATURE (F/C)
100/ 38
80/ 27
60/ 16
40/ 4
20/ -7
0/ -18

WORKING
WORKING
TIME

FULL
FULL
CURE TIME

TIME

CURE TIME

5 minutes
5.5 minutes
7 minutes
15 minutes
35 minutes
4 hours

25 minutes
30 minutes
35 minutes
75 minutes
6 hours
24 hours

APPROVALS/LISTINGS
Meets ASTM C881-02, Type IV, Grade 3,
Class A, B, and C; with the exception of gel time and
epoxy content
ICC Evaluation Service, Inc. #ER-5560
Miami-Dade County #06-0425.02
City of Los Angeles RR#25379
DOT Approvals
Florida Building Code
NSF Standard 61 Certified for Drinking Water Components

10/09

1-800-899-7890

www.itwredhead.com

Submittal Information

ADHESIVE ANCHORING SPECIALISTS

A728 fl. oz. Ordering Information


PART NUMBER

BOX QTy

28 Fluid Ounce Cartridge A7

PART NUMBER

DESCRIPTION

ADHESIVE ANCHORING SYSTEMS

Multi-Patented Formula

Miami-Dade County Product Control Approved

ICBO Evaluation Report No. 5560

Fast Dispensing,
Fast Curing Acrylic

Contents: 825 ml (28 fl. oz.)


Part No: A7-28

35 Minute Cure Time at 60F


Fast Dispensing at all Temperatures
Multi-Patented Formula

DESCRIPTION

A7-28

E55

Mixing Nozzle for A7-28 and G5-22 Cartridge


Nozzle diameter fits 3/8 to 5/8 holes.
(overall length of nozzle 14")

RH7010

BOX QTy

EPCON DRIVE Cordless, battery powered


dispensing tool for the A7-28 Cartridge

24

E25-6

6-Foot Straight Tubing


(can cut to proper size)
(.39 in I.D. x .43 in. O.D.)

A200

Pneumatic Dispenser for A7-28 Cartridge

Largest hand dispensable cartridge


still easy to dispense

A102

Hand Dispenser for A7-28 Cartridge

Plunger Repair Kit


Available for A102 Dispenser
Part No. A102RKIT

ESTIMATING TABLE

Number of Anchoring Installations per Cartridge*


Using Reinforcing Bar with A7 Adhesive in Solid Concrete

A7
28 Fluid Ounce Cartridge
REBAR

#3
#4
#5
#6
#7
#8
#9
# 10
# 11

DRILL
HOLE DIA.
INCHES

1
(25.4)

2
(50.8)

3
(76.2)

4
(101.6)

5
(127.0)

6
(152.4)

7/16
5/8
3/4
7/8
1
1-1/8
1-1/4
1-1/2
1-3/4

662.5
373.0
286.1
231.0
213.4
177.3
102.8
84.1
51.4

331.3
186.5
143.0
115.5
106.7
88.6
51.4
42.0
25.7

220.8
124.3
95.4
77.0
71.1
59.1
34.3
28.0
17.1

165.6
93.2
71.5
57.7
53.3
44.3
25.7
21.0
12.8

132.5
74.6
57.2
46.2
42.7
35.5
20.6
16.8
10.3

110.4
62.2
47.7
38.5
35.6
29.5
17.1
14.0
8.6

EMBEDMENT DEPTH IN INCHES (mm)


7
8
9
(177.8)
(203.2)
(228.6)

94.6
53.3
40.9
33.3
30.5
25.3
14.7
12.0
7.3

82.8
46.6
35.8
28.8
26.7
22.2
12.8
10.5
6.4

73.6
41.4
31.8
25.7
23.7
19.7
11.4
9.3
5.7

10
(254.0)

11
(279.4)

12
(304.8)

13
(330.2)

14
(355.6)

15
(381.0)

66.3
37.3
28.6
23.1
21.3
17.7
10.3
8.4
5.1

60.2
33.9
26.0
21.0
19.4
16.1
9.3
7.6
4.7

55.2
31.1
23.8
19.2
17.8
14.8
8.6
7.0
4.3

51.0
28.7
22.0
17.8
16.4
13.6
7.9
6.5
4.0

47.3
26.6
20.4
16.5
15.2
12.7
7.3
6.0
3.7

44.2
24.9
19.1
15.4
14.2
11.8
6.9
5.6
3.4

* The number of anchoring installations is based upon calculations of hole volumes using ANSI tolerance carbide tipped drill bits, the nominal areas of the reinforcing bars and the stress areas of the threaded rods. These estimates do not account for waste.

ESTIMATING TABLE

CLAMPING FORCE PROvIDED ON PAGE 10

A7
28 Fluid Ounce Cartridge
ROD
In. (mm)

1/4
3/8
1/2
5/8

(6.4)
(9.5)
(12.7)
(15.9)

3/4 (19.1)
7/8 (22.2)
1 (25.4)
1-1/4 (31.8)

Number of Anchoring Installations per Cartridge*


Using Threaded Rod with A7 Adhesive in Solid Concrete

DRILL
HOLE DIA.
INCHES

1
(25.4)

2
(50.8)

3
(76.2)

4
(101.6)

5
(127.0)

5/16
7/16
9/16
11/16
3/4
13/16
7/8
15/16
1
1 -1/16
1 -1/8
1 -5/16
1 -3/8

915.5
530.0
381.4
273.6
195.6
192.9
154.4
185.1
128.0
158.3
105.2
101.3
80.0

457.7
265.0
190.7
136.8
97.8
96.5
77.2
92.6
64.0
79.2
52.6
50.7
40.0

305.2
176.7
127.1
91.2
65.1
64.3
51.5
61.7
42.8
52.8
35.2
33.8
26.6

228.9
132.5
95.4
68.4
48.8
48.2
38.6
46.3
32.0
39.6
26.3
25.3
20.0

183.1
106.0
76.3
54.7
39.0
38.6
30.9
37.0
25.6
31.7
21.1
20.3
15.9

EMBEDMENT DEPTH IN INCHES (mm)


6
7
8
9
10
(152.4) (177.8)
(203.2) (228.6)
(254.0)

152.8
88.3
63.6
45.6
32.5
32.2
25.7
30.9
21.4
26.4
17.6
16.9
13.3

130.8
75.7
54.5
39.1
27.9
27.6
22.1
26.8
18.3
22.6
15.0
14.5
11.4

114.4
66.3
47.7
34.2
24.4
24.1
19.3
23.1
16.0
19.8
13.2
12.7
10.0

101.7
58.9
42.4
30.4
21.7
21.4
17.2
20.6
14.2
17.6
11.7
11.3
8.9

91.5
53.0
38.1
27.4
19.5
19.3
15.4
18.5
12.8
15.8
10.5
10.1
8.0

11
(279.4)

83.2
48.2
34.7
24.9
17.7
17.5
14.0
16.8
11.6
14.4
9.6
9.2
7.2

12
(304.8)

76.3
44.2
31.8
22.8
16.3
16.1
12.9
15.4
10.7
13.2
8.8
8.4
6.6

13
(330.2)

70.4
40.8
29.3
21.0
15.0
14.8
11.9
14.2
9.9
12.2
8.1
7.8
6.1

14
(355.6)

15
(381.0)

65.4
37.9
27.2
19.5
13.9
13.8
11.0
13.2
9.2
11.3
7.6
7.2
5.7

61.0
35.3
25.4
18.2
13.0
12.9
10.3
12.3
8.5
10.6
7.0
6.8
5.3

* The number of anchoring installations is based upon calculations of hole volumes using ANSI tolerance carbide tipped drill bits, the nominal areas of the reinforcing bars and the stress areas of the threaded rods. These estimates do not account for waste.

10/09

1-800-899-7890

www.itwredhead.com

Submittal Information

ADHESIVE ANCHORING SPECIALISTS

PERFORMANCE TABLE

Average Ultimate Tension and Shear Loads1,2,3


Acrylic Adhesive for Threaded Rod Installed in Solid Concrete

A7

2000 PSI (13.8 MPa) CONCRETE


ULTIMATE
ULTIMATE
TENSION
SHEAR
Lbs. (kN)
Lbs. (kN)
--------5,852
(26.0)
5,220
(23.2)
7,729
(34.4)
5,220
(23.2)

4000 PSI (27.6 MPa) CONCRETE


ULTIMATE
ULTIMATE
TENSION
SHEAR
Lbs. (kN)
Lbs. (kN)
3,734
(16.6)
4,126
(18.3)
10,977
(48.8)
5,220
(23.2)
11,661
(51.9)
5,220
(23.2)

THREADED
ROD DIA.
In. (mm)

DRILL HOLE
DIAMETER
In. (mm)

MAX. CLAMPING FORCE


AFTER PROPER CURE
Ft.-Lbs. (Nm)

3/8

(9.5)

7/16

(11.1)

13 - 18

(17-24)

1-1/2
3-3/8
4-1/2

(38.1)
(85.7)
(114.3)

1/2

(12.7)

9/16

(14.3)

22 - 25

(29-33)

2
4-1/2
6

(50.8)
(114.3)
(152.4)

--10,798
14,210

--(48.0)
(63.2)

--8,029
8,029

--(35.7)
(35.7)

6,022
17,162
17,372

(26.8)
(76.3)
(77.3)

8,029
8,029
8,029

(35.7)
(35.7)
(35.7)

5/8

(15.9)

11/16

(17.5)

55 - 80

(74-108)

2-1/2
5-5/8
7-1/2

(63.5)
(142.9)
(190.5)

--16,417
18,747

--(73.0)
(83.4)

--15,967
15,967

--(71.0)
(71.0)

7,330
26,504
29,381

(32.6)
(117.9)
(130.7)

11,256
15,967
15,967

(50.1)
(71.0)
(71.0)

106 - 160

(143-216)

3
6-3/4
9

(76.2)
(171.5)
(228.6)

--18,618
23,934

--(82.8)
(106.5)

--20,126
20,126

--(89.5)
(89.5)

8,634
29,727
37,728

(38.4)
(132.2)
(167.8)

20,126
20,126
20,126

(89.5)
(89.5)
(89.5)

185 - 250

(250-338)

3-1/2
7-7/8
10-1/2

(88.9)
(200.0)
(266.7)

----36,881

----(164.1)

--29,866
29,866

--(132.9)
(132.9)

13,650
44,915
48,321

(60.7)
(199.8)
(215.0)

20,920
29,866
29,866

(92.9)
(132.9)
(132.9)

or
3/4
3/4

(19.1)

(19.1)

13/16

(20.6)
or

7/8
7/8

(22.2)

(22.2)

15/16

(23.8)
or

1
1

(25.4)

EMBEDMENT
IN CONCRETE
In. (mm)

(25.4)

1-1/16 (27.0)
or
1-1/8 (28.6)

276 - 330

(374-447)

4
9
12

(101.6)
(228.6)
(304.8)

--32,215
46,064

--(143.3)
(143.3)

--37,538
37,538

--(167.0)
(167.0)

16,266
48,209
63,950

(72.2)
(214.5)
(284.5)

33,152
37,538
37,538

(147.5)
(167.0)
(167.0)

1-1/4 (31.8)

1-5/16 (33.3)
or
1-3/8 (34.9)

370 - 660

(501-894)

5
11-1/4
15

(127.0)
(285.8)
(381.0)

--45,962
62,208

--(204.5)
(276.7)

--58,412
58,412

--(259.8)
(259.8)

21,838
56,715
84,385

(97.1)
(252.3)
(375.4)

33,152
58,412
58,412

(147.5)
(259.8)
(259.8)

1 Allowable working loads for the single installations under static loading should not exceed 25% capacity or the allowable load of the anchor rod.
2 Ultimate load values in 2000 and 4000 psi stone aggregate concrete. Ultimate loads are indicated for the embedment shown in the Embedment in Concrete column. Performance values are based on the use of high strength threaded rod
(ASTM A193 Gr. B7). The use of lower strength rods will result in lower ultimate tension and shear loads.
3 Linear interpolation may be used for intermediate spacing and edge distances (see pages 14-15).

Allowable Tension Loads1 for Threaded Rod Installed in


Acrylic Adhesive Solid Concrete

A7

THREADED
ROD DIA.
In. (mm)

DRILL HOLE
DIAMETER
In. (mm)

3/8

(9.5)

7/16

(11.1)

1/2

(12.7)

9/16

(14.3)

5/8

(15.9)

11/16
or
3/4

(17.5)
(19.1)

3/4

(19.1)

13/16

(20.6)

MIN.
EMBEDMENT
DEPTH
In. (mm)

ALLOWABLE TENSION LOAD BASED


ON ADHESIvE BOND STRENGTH
2000 PSI (13.8 MPa)
4000 PSI (27.6 MPa)
CONCRETE
CONCRETE
Lbs. (kN)
Lbs. (kN)
----934
(4.2)
1,460
(6.5)
2,740
(12.2)

ALLOWABLE TENSION LOAD BASED


ON STEEL STRENGTH
ASTM A307
ASTM A193 GR. B7
(SAE 1018)
(SAE 4140)
Lbs. (kN)
Lbs. (kN)
2,080
(9.3)
4,340
(19.3)
2,080
(9.3)
4,340
(19.3)

ASTM F593
AISI 304 SS
Lbs. (kN)
3,995
(17.8)
3,995
(17.8)

1-1/2
3-3/8

(38.1)
(85.7)

4-1/2

(114.3)

1,930

(8.6)

2,915

(13.0)

2,080

(9.3)

4,340

(19.3)

3,995

(17.8)

2
4-1/2
6

(50.8)
(114.3)
(152.4)

--2,700
3,550

--(12.0)
(15.8)

1,505
4,290
4,340

(6.7)
(19.1)
(19.3)

3,730
3,730
3,730

(16.6)
(16.6)
(16.6)

7,780
7,780
7,780

(34.6)
(34.6)
(34.6)

7,155
7,155
7,155

(31.8)
(31.8)
(31.8)

2-1/2
5-5/8
7-1/2

(63.5)
(142.9)
(190.5)

--4,100
4,685

--(18.3)
(20.8)

1,832
6,625
7,345

(8.2)
(29.5)
(32.7)

5,870
5,870
5,870

(26.1)
(26.1)
(26.1)

12,230
12,230
12,230

(54.4)
(54.4)
(54.4)

11,250
11,250
11,250

(50.0)
(50.0)
(50.0)

(76.2)
(171.5)
(228.6)

--4,655
5,980

--(20.7)
(26.6)

2,158
7,430
9,430

(9.6)
(33.1)
(42.0)

8,490
8,490
8,490

(37.8)
(37.8)
(37.8)

17,690
17,690
17,690

(78.7)
(78.7)
(78.7)

14,860
14,860
14,860

(66.1)
(66.1)
(66.1)

(22.2)

3
6-3/4
9

(22.2)

15/16 (23.8)
or
1
(25.4)

3-1/2
7-7/8
10-1/2

(88.9)
(200.0)
(266.7)

---9,220

---(41.0)

3,413
11,230
12,080

(15.2)
(49.9)
(53.7)

11,600
11,600
11,600

(51.6)
(51.6)
(51.6)

25,510
25,510
25,510

(113.5)
(113.5)
(113.5)

20,835
20,835
20,834

(92.7)
(92.7)
(92.7)

(25.4)

1-1/16
or
1-1/8

4
9
12

(101.6)
(228.6)
(304.8)

--8,050
11,515

--(35.8)
(51.2)

4,067
12,050
15,985

(18.1)
(53.6)
(71.1)

15,180
15,180
15,180

(67.5)
(67.5)
(67.5)

31,620
31,620
31,620

(140.7)
(140.7)
(140.7)

26,560
26,560
26,560

(118.1)
(118.1)
(118.1)

1-1/4

(31.8)

1-5/16 (33.3)
or
1-3/8 (34.9)

5
11-1/4
15

(127.0)
(285.8)
(381.0)

--11,490
15,550

--(51.1)
(69.2)

5,460
14,175
21,095

(24.3)
(63.1)
(93.8)

23,800
23,800
23,800

(105.9)
(105.9)
(105.9)

49,580
49,580
49,580

(220.6)
(220.6)
(220.6)

34,670
34,670
34,670

(154.2)
(154.2)
(154.2)

or
7/8
7/8

(27.0)
(28.6)

1 Use lower value of either bond or steel strength for allowable tensile load.

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Submittal Information

ADHESIVE ANCHORING SPECIALISTS

DRILL HOLE DIAMETERS


PROvIDED ON PAGES 6-8

PERFORMANCE TABLE

Allowable Shear Loads1 for Threaded Rod Installed in


Acrylic Adhesive Solid Concrete

A7

THREADED
ROD DIA
In. (mm)

DRILL HOLE
DIAMETER
In. (mm)

3/8

(9.5)

7/16

(11.1)

1/2

(12.7)

9/16

(14.3)

5/8

(15.9)

3/4

(19.1)

7/8

(22.2)

(25.4)

1-1/4

11/16
or 3/4
13/16
or 7/8
15/16
or 1
1-1/16
or 1-1/8
1-5/16
or 1-3/8

(31.8)

(17.5)
(19.1)
(20.6)
(22.2)
(23.8)
(25.4)
(27.0)
(28.6)
(33.3)
(34.9)

MIN.
EMBEDMENT
DEPTH
In. (mm)
1-1/2
3-3/8
2
4-1/2
2-1/2
5-5/8
3
6-3/4
3-1/2
7-7/8
4
9
5
11-1/4

(38.1)
(85.7)
(50.8)
(114.3)
(63.5)
(142.9)
(76.2)
(171.5)
(88.9)
(200.0)
(101.6)
(228.6)
(127.0)
(285.8)

ALLOWABLE SHEAR LOAD BASED


ON CONCRETE STRENGTH
2000 PSI (13.8 MPa)
4000 PSI (27.6 MPa)
CONCRETE
CONCRETE
Lbs. (kN)
Lbs. (kN)
--1,305
--2,005
--3,990
--5,030
--7,465
--9,385
--14,600

--(5.8)
--(8.9)
--(17.8)
--(22.4)
--(33.2)
--(41.7)
--(64.9)

1,031
1,305
2,005
2,005
2,814
3,990
5,030
5,030
5,230
7,465
8,288
9,385
8,288
14,600

(4.6)
(5.8)
(8.9)
(8.9)
(12.5)
(17.8)
(22.4)
(22.4)
(23.3)
(33.2)
(36.9)
(41.7)
(36.9)
(64.9)

ALLOWABLE SHEAR LOAD BASED


ON STEEL STRENGTH
ASTM A307
ASTM A193 GR. B7
ASTM F593
(SAE 1018)
(SAE 4140)
AISI 304 SS
Lbs. (kN)
Lbs. (kN)
Lbs. (kN)
1,040
1,040
1,870
1,870
2,940
2,940
4,250
4,250
5,800
5,800
7,590
7,590
11,900
11,900

(4.6)
(4.6)
(8.3)
(8.3)
(13.1)
(13.1)
(18.9)
(18.9)
(25.8)
(25.8)
(33.8)
(33.8)
(52.9)
(52.9)

2,170
2,170
3,895
3,895
6,125
6,125
8,855
8,855
12,760
12,760
15,810
15,810
24,790
24,790

(9.7)
(9.7)
(17.3)
(17.3)
(27.2)
(27.2)
(39.4)
(39.4)
(56.8)
(56.8)
(70.3)
(70.3)
(100.3)
(100.3)

1,995
1,995
3,585
3,585
5,635
5,635
7,440
7,440
10,730
10,730
13,285
13,285
18,840
18,840

(8.9)
(8.9)
(15.9)
(15.9)
(25.1)
(25.1)
(33.1)
(33.1)
(47.7)
(47.7)
(59.1)
(59.1)
(83.8)
(83.8)

1 Use lower value of either concrete or steel strength for allowable shear load.

Average Ultimate Tension and Shear Loads1,2 for


Acrylic Adhesive Threaded Rod Installed in Grout Filled Concrete Block

A7

THREADED
ROD DIA.
In. (mm)

DRILL HOLE
DIAMETER
In. (mm)

EMBEDMENT
DEPTH
In. (mm)

ANCHOR
LOCATION

ULTIMATE
TENSION
Lbs. (kN)

ULTIMATE
SHEAR
Lbs. (kN)

1/2

(12.7)

5/8

(15.9)

4-1/4

(108.0)

GROUTED CELL

5,170

(23.0)

8,500

5/8

(15.9)

3/4

(19.1)

(127.0)

GROUTED CELL

6,320

(28.1)

10,850

(37.8)
(48.3)

3/4

(19.1)

7/8

(22.2)

6-5/8

(168.3)

GROUTED CELL

10,910

(48.5)

17,075

(76.0)

1 Allowable working loads for the single installations should not exceed 25% (an industry standard) capacity or the allowable load of the anchor rod. Loads based upon testing with ASTM A193, Grade B7 rods.
2 The tabulated values are for anchors installed at minimum 12 inch edge distance and minimum 8 inch spacing.

A7

Average Ultimate Tension and Shear Loads1 for Threaded Rod Installed
Acrylic Adhesive in Grouted 2 Brick Masonry Constructed of Solid Red Brick Units
THREADED
ROD DIA.
In. (mm)

DRILL HOLE
DIAMETER
In. (mm)

1/4

(6.4)

3/8

(9.5)

3/8

(9.5)

1/2

(12.7)

1/2

(12.7)

5/8

(15.9)

EMBEDMENT
DEPTH
In. (mm)
3-1/2
6
3-1/2
6
3-1/2
6

ANCHOR
LOCATION

(88.9)
(152.4)
(88.9)
(152.4)
(88.9)
(152.4)

CENTER OF
BRICK FACE
CENTER OF
BRICK FACE
CENTER OF
BRICK FACE

ULTIMATE
TENSION
Lbs. (kN)
2,130
3,575
2,130
8,875
2,130
12,155

(9.5)
(15.9)
(9.5)
(39.5)
(9.5)
(54.1)

ULTIMATE
SHEAR
Lbs. (kN)
1,165
1,550
4,150
6,950
3,090
7,910

(5.2)
(6.9)
(18.5)
(30.9)
(13.7)
(35.2)

1 Allowable working loads for the single installations should not exceed 25% (an industry standard) capacity or the allowable load of the anchor rod. Loads based upon testing with ASTM A193, Grade B7 rods.
2 Void between brick wythes was grouted solid; therefore the use of screens was not necessary.

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AN EMPLOYEE-OWNED COMPANY

RECOMMENDED
LUBRICANTS

5-9

This page intentionally left blank.

5-10

IQUITOS 21233A - PL #20748

UPPER BEARING

Mobilgear SHC Series


Gear Oils
Product Description
The Mobilgear SHC Series lubricants are supreme performance heavy-duty gear oils primarily designed for all
kinds of enclosed gearing as well as plain and rolling element bearings. They are designed to provide outstanding
service in terms of equipment protection, oil life, and problem-free operation enabling increased customer
productivity. These scientifically engineered synthetic lubricants areformulated from synthetic base fluids that
have exceptional oxidation and thermal properties and excellent low temperature fluidity. The combination of a
naturally high viscosity index and a unique additive system enables these products to provide outstanding
performance under severe high and low temperature operating conditions. The nature of the syntheticbase fluids
also contributes to the products' excellent low temperature performance. They have outstanding EP properties
and resistance to shock loading. The syntheticbase stocks have inherently low traction properties that result in
low fluid friction in the load zone of non-conforming surfaces such as gears and rolling element bearings. Reduced
fluid friction produces lower operating temperatures and improved gear efficiency.
The Mobilgear SHC Series covers a very wide viscosity range, from ISO VG 150 to 6800. Accordingly, they find
application in a wide range of enclosed gear applications, as well as plain and rolling element bearings. Because
of the very high viscosities available, this family can meet the lubrication needs of very slow speed and high
load/high temperature gears and bearings; they are ideal for situations in which conventional products operate
in the boundary regime. They may be situations where a lubricant bath or recirulation system are used to apply
the oil.
Mobilgear SHC Series lubricants are the products of choice for many OEMs and customers world-wide based
on their wide application range and superb performance in tough situations.

Features and Benefits


The Mobilgear SHC Series of lubricants is a leading member of the MobilSHC brand of products that are
world-renowned for their innovation and performance. These scientifically engineered synthetic lubricants
symbolize the continuing commitment to using advanced technology to provide outstanding lubricant products.
The Mobilgear SHC Series of lubricants providebenefits not possible with mineral stocks, particularly under
extreme high and low temperature operating conditions,and deliverperformance features and customer benefits.
Our formulation scientists have used a proprietary additive combination that fortifies the base fluidsto provide
excellent EP and anti-wear performance, even in shock load situations. The resulting finished products have
shown exceptional performance in OEM evaluations, customer field tests and commercial use. The higher
viscosity grades are particularly effective in low-speed, high load, high temperature situations and provide
excellent gear and bearing protection, longer oil life and excellent all-round service compared with conventional
products.
Specific features and potential benefits for the Mobilgear SHC Series of lubricants include:
Features
Outstanding load-carrying and antiwear properties

1 of 3

Advantages and Potential Benefits


Extended gear life and reduced maintenance costs

IQUITOS 21233A - PL #20748

Features
Advantages and Potential Benefits
Very high viscosity grades available, without reduction Provides excellent EHL film protection of gears and
of properties or performance capability
bearings even at slow speeds, high loads and high
temperatures
Can be used to convert all-loss systems to circulation
Can replace grease in some applications resulting in
plant product consolidation
High viscosity index
Trouble-free operation over a wide temperature range
particularly at extremely low temperatures.
Low traction properties
Improved gear efficiency and lower operating
temperatures lead to lower operating costs
Outstanding thermal/oxidation resistance and long
Reduced lubricant consumption, reduced product and
product life
change-out costs
Light colour
Minimises need for gear cleaning prior to inspections,
reducing maintenance costs

Applications
Application Considerations: While the Mobilgear SHC Series are compatible with mineral oil based products,
admixture may detract from their performance. Consequently it is recommended that before changing a system
to one of the Mobilgear SHC Series, it should be thoroughly cleaned out and flushed to achieve the maximum
performance benefits. Mobilgear SHC Series oils are recommended for all types of enclosed steel-on-steel gear
drives. They are suitable for both circulation and splash lubrication systems. The range of viscosity choices in
the Mobilgear SHC Series from ISO 150 to ISO 6800, provides the right lubrication option for low temperature
applications where pour points of -46C are required to high temperature applications where operating
temperatures of 121C are encountered. They are particularly recommended for gear sets operating under
heavy or shock loads and low speeds where boundary lubrication may prevail. For clarity, applications for this
product family are described for two viscosity ranges, as follows:

Mobilgear SHC 150 to 1500 - Industrial enclosed spur, helical and bevel gear drives, especially heavy-duty
applications especially those found in mining, chemical processing, metals and paper sectors.
Mobilgear SHC 150 to 1500 - Industrial gearing for conveyers, agitators, dryers, extruders, fans, mixers,
presses, pulpers, pumps (including oil well pumps), screens, extruders and other heavy duty applications
Mobilgear SHC 150 to 1500 - Marine gearing including main propulsion, centrifuges, deck machinery such
as winches, windlasses, cranes, turning gears, pumps, elevators and rudder carriers
Mobilgear SHC 3200 and 6800 - Industrial enclosed spur, helical and bevel gears, especially slow speed,
and/or high load units
Mobilgear SHC 3200 and 6800 - Plain and rolling element bearings, especially in slow speed, and/or high
load applications
Mobilgear SHC 3200 and 6800 - Railroad DC Traction Motor drives
Mobilgear SHC 3200 and 6800 - Certain open gear applications such as oiling pinions or specially designed
circulation systems

Typical Properties
Mobilgear SHC
150
ISO Viscosity Grade 150

2 of 3

220
220

320
320

460
460

680
680

1000
1000

1500
1500

3200
3200

6800
--

IQUITOS 21233A - PL #20748

Mobilgear SHC
Viscosity, ASTM D
445
cSt @ 40 C
cSt @ 100 C
Viscosity Index,
ASTM D 2270
Pour Point, C,
ASTM D 97
Density @15.6 C
kg/l, ASTM D 4052
Flash Point, C,
ASTM D 92
Timken OK Load
4-Ball EP Teat,
ASTM D 2783:
Weld load, Kg
Load Wear Index,
Kgf
FZG test, DIN
51354, Failure
Stage
Copper Corrosion,
ASTM D130, 3 hrs
@ 100 C
Demulsibility, EP
Oils, ASTM D
2711-2,Free water,
ml
Foaming
Characteristics,
ASTM D 892,Seq. I,
II, III,
Tendency/Stability,
ml/ml
Rust Protection,
ASTM D 665, Sea
Water

150

220

320

460

680

1000

1500

3200

6800

150
19.5
150

220
26
150

320
35
155

460
46
155

680
62
160

1000
81
160

1500
106
160

3025
171
160

8100
350
170

-45

-36

-33

-27

-27

-24

-18

-9

-6

0.86

0.87

0.88

0.87

0.89

0.87

0.88

0.89

0.90

222

232

238

245

256

60

60

60

60

60

60

60

60

60

250
48

250
48

250
48

250
48

250
48

250
48

250
48

250
48

250
48

13+

13+

13+

13+

13+

13+

13+

13+

13+

1B

1B

1B

1B

1B

1B

1B

1B

1B

85

85

85

85

85

85

85

85

85

0/0, 0/0, 0/0, 0/0, 0/0, 0/0, 0/0, 0/0, 0/0, 0/0, 0/0, 0/0, 0/0, 0/0, 0/0, 0/0, 0/0, 0/0,
0/0
0/0
0/0
0/0
0/0
0/0
0/0
0/0
0/0

Pass

Pass

Pass

Pass

Pass

Pass

Pass

Pass

Pass

Health and Safety


Based on available information, this product is not expected to produce adverse effects on health when used
for the intended application and the recommendations provided in the Material Safety Data Sheet (MSDS) are
followed. MSDS's are available upon request through your sales contract office, or via the Internet. This product
should not be used for purposes other than its intended use. If disposing of used product, take care to protect
the environment.
The Mobil logotype, the Pegasus design and Mobilgear SHC are trademarks of Exxon Mobil Corporation, or
one of its subsidiaries.

ExxonMobil Lubricants & Specialties


All products may not be available locally. For more information, contact your local sales office or visit www.exxonmobil.com.
ExxonMobil is comprised of numerous affiliates and subsidiaries, many with names that include Esso, Mobil, or ExxonMobil. Nothing in this document is intended to override or
supersede the corporate separateness of local entities. Responsibility for local action and accountability remains with the local ExxonMobil affiliate entities. Due to continual product
research and development, the information contained herein is subject to change without notification. Typical Properties may vary slightly.
2007 Exxon Mobil Corporation. All rights reserved.

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21233A IQUITOS - PL #20748

LOWER BEARING GREASE

Mobilith SHC PM Series


Grease
Product Description
Mobilith SHC PM greases are supreme performance products designed specifically for severe paper machine
applications, including extreme temperature environments and exposure to different qualities of water. Mobilith
SHC PM greases combine the unique features of a synthetic base fluid with those of a high quality lithium
complex thickener. The wax-free nature of the synthetic base fluid provides excellent low temperature pumpability
and low starting and running torque compared to non-synthetic oil products of the same viscosity. The high
viscosity index of the synthetic base fluid ensures excellent film protection at high temperatures. The lithium
complex thickener contributes excellent adhesion, structural stability and resistance to water. These properties
are complemented by a special additive system to provide rust and corrosion resistance, wear protection,
thermal/oxidative resistance and to enhance water resistance properties. Mobilith SHC PM 220 and Mobilith
SHC PM 460 are both NLGI grade 1.5 with base fluids of ISO VG 220 and 460, respectively.
Mobilith SHC PM greases are designed for use in the most critical rolling element bearing applications in paper
machines. They provide outstanding protection against rust and typical acid and alkali water corrosion, making
them ideal for the wet end of the paper machine. The low volatility and excellent oxidation stability of the PAO
base stock ensures excellent service at high temperatures typical of dry end conditions.
The Mobilith SHC PM series has become the technology of choice for many paper mill operators, worldwide.
Their reputation is based on exceptional quality, reliability and the proven performance benefits they deliver.

Features and Benefits


The Mobil SHC brand of oils and greases are recognized and appreciated around the world for their innovation
and outstanding performance. The Mobilith SHC series symbolizes ExxonMobil's continued commitment to
using advanced technology to provide outstanding products. A key factor in the development of Mobilith SHC
PM greases was the close contacts between our scientists and application specialists with key paper machine
designers to ensure that our product offerings would provide exceptional performance in this continually evolving,
and increasingly severe, equipment area.
Our work with equipment builders has helped confirm the results from our own laboratory tests showing the
exceptional performance of the Mobilith SHC PM greases. These benefits include excellent resistance to acidic
and alkaline water, enhanced bearing protection and bearing life, wide temperature range of application, and
longer grease life.
To combat high thermal exposure our product formulation scientists chose proprietary synthetic base oils for
Mobilith SHC PM grease because of their exceptional thermal and oxidative resistance. Our scientists developed
a state-of-the-art lithium complex thickener technology and used specific additives to enhance Mobilith SHC
PM greases to meet the needs of modern and future paper machines. Mobilith SHC PM greases offer the
following features and benefits:

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21233A IQUITOS - PL #20748

Features
Outstanding high temperature and low temperature
performance

Advantages and Potential Benefits


Wide application temperature range, from -40C to 180C
with excellent protection at high temperatures and low
torque, easy start-up at low temperatures
Excellent protection against wear, rust and corrosion, Reduced downtime and maintenance costs because of
including acidic water
reduced wear, rust and corrosion even in acidic and
alkaline water environments
Excellent structural stability and oxidation resistance Extended service life with longer intervals between
relubrication and improved bearing life
Excellent wear protection under heavy loads, slow
Outstanding protection of slow speed, heavily loaded
speeds, and high temperatures
bearings, with extended bearing life
Outstanding structural stability in the presence of water Retains excellent grease performance in hostile aqueous
environments
Low volatility
Helps resist viscosity increase at high temperatures to
maximize relubrication intervals and bearing life

Applications
Application Considerations: While Mobilith SHC PM greases are compatible with most mineral oil based products,
admixture may detract from their performance. Consequently it is recommended that before changing a system
to one of the Mobilith SHC PM greases, it should be thoroughly cleaned out to achieve the maximum performance
benefits. If dismantling the system for cleaning before changeover isn't feasible, then thorough purging and
increased relubrication intervals are strongly recommended. Contact your local ExxonMobil Lube Engineer for
consultation on this approach.
Mobilith SHC PM greases are recommended for critical rolling element bearing applications in paper machines.
Included among these are:

Wet end paper machine bearings.


Highly loaded press section bearings.
High-temperature felt roll and calendar stack bearings.

Typical Properties
Mobilith SHC
NLGI Grade
Thickener Type
Color, Visual
Penetration, Worked, 25 C, ASTM D 217
Dropping Point. C, ASTM D 2265
Viscosity of Oil, ASTM D 445, cSt @ 40 C
4-Ball Wear, ASTMD 2266, Scar, mm
4-Ball Weld Load, ASTM D 2596, kg
Timken OK Load, ASTM D 2509, lbs
Roll Stability, ASTM D 1831, % Change
Water Washout, ASTM D 1264, 79 C, % Loss

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PM 220
1.5
Lithium Complex
Off-White
305
275
220
0.5
250
65
-5 to +5
2

PM 460
1.5
Lithium Complex
Off-White
305
275
460
0.5
250
65
-5 to +5
3

21233A IQUITOS - PL #20748

Mobilith SHC
Rust Test, ASTM D 1743, Rating
Copper Corrosion, ASTM D 4048, Rating
EMCOR Rust Test, ASTM D 6138, Distilled Water,
Rating
EMCOR Rust Test, ASTMD 6138, Acid Water pH 4.5,
Rating
EMCOR Rust Test, ASTM D 6138, Alkaline Water pH
12.0, Rating
Oil Separation, ASTM D 1742, 0.25 psi, 24 hours @
25 C, % Wt. Loss

PM 220
PASS
1A
0/0

PM 460
PASS
1A
0/0

0/0

0/0

0/0

0/0

Health and Safety


Based on available information, this product is not expected to produce adverse effects on health when used
for the intended application and the recommendations provided in the Material Safety Data Sheet (MSDS) are
followed. MSDS's are available upon request through your sales contract office, or via the Internet. This product
should not be used for purposes other than its intended use. If disposing of used product, take care to protect
the environment.
The Mobil logotype, the Pegasus design are trademarks of Exxon Mobil Corporation, or one of its subsidiaries.

ExxonMobil Lubricants & Specialties


All products may not be available locally. For more information, contact your local sales office or visit www.exxonmobil.com.
ExxonMobil is comprised of numerous affiliates and subsidiaries, many with names that include Esso, Mobil, or ExxonMobil. Nothing in this document is intended to override or
supersede the corporate separateness of local entities. Responsibility for local action and accountability remains with the local ExxonMobil affiliate entities. Due to continual product
research and development, the information contained herein is subject to change without notification. Typical Properties may vary slightly.
2007 Exxon Mobil Corporation. All rights reserved.

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AN EMPLOYEE-OWNED COMPANY

MOTOR

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21233A IQUITOS - PL #20748

Integral Horsepower
AC Induction Motors

Installation & Operating Manual

2/09

MN400

21233A IQUITOS - PL #20748

Any trademarks used in this manual are the property of their respective owners.

21233A IQUITOS - PL #20748

Table of Contents
Section 1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal From Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 2
Installation & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Doweling & Bolting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conduit Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
First Time Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coupled Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Jogging and Repeated Starts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 3
Maintenance & Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relubrication & Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Type of Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relubrication Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relubrication Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suggested bearing and winding RTD setting guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MN400

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Table of Contents i

21233A IQUITOS - PL #20748

Section 1
General Information

ii Table of Contents

MN400

21233A IQUITOS - PL #20748

Section 1
General Information
Overview

Important:

This manual contains general procedures that apply to Baldor Motor products. Be sure to read and
understand the Safety Notice statements in this manual. For your protection, do not install, operate or
attempt to perform maintenance procedures until you understand the Warning and Caution statements.
A Warning statement indicates a possible unsafe condition that can cause harm to personnel.
A Caution statement indicates a condition that can cause damage to equipment.
This instruction manual is not intended to include a comprehensive listing of all details for all
procedures required for installation, operation and maintenance. This manual describes general
guidelines that apply to most of the motor products shipped by Baldor. If you have a question
about a procedure or are uncertain about any detail, Do Not Proceed. Please contact your Baldor
distributor for more information or clarification.
Before you install, operate or perform maintenance, become familiar with the following:
S
NEMA Publication MG-2, Safety Standard for Construction and guide
for Selection, Installation and Use of Electric Motors and Generators.
S
The National Electrical Code
S
Local codes and Practices

Limited Warranty
www.baldor.com/support/warranty_standard.asp

Safety Notice: This equipment contains high voltage! Electrical shock can cause serious or fatal injury. Only qualified

WARNING:
WARNING:
WARNING:
WARNING:
WARNING:

WARNING:
WARNING:
WARNING:
WARNING:
WARNING:
WARNING:

MN400

personnel should attempt installation, operation and maintenance of electrical equipment.


Be sure that you are completely familiar with NEMA publication MG-2, safety standards for construction and
guide for selection, installation and use of electric motors and generators, the National Electrical Code and
local codes and practices. Unsafe installation or use can cause conditions that lead to serious or fatal injury.
Only qualified personnel should attempt the installation, operation and maintenance of this equipment.
Do not touch electrical connections before you first ensure that power has been disconnected.
Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt the
installation, operation and maintenance of this equipment.
Disconnect all electrical power from the motor windings and accessory devices before
disassembly of the motor. Electrical shock can cause serious or fatal injury.
Be sure the system is properly grounded before applying power. Do not apply AC power before
you ensure that all grounding instructions have been followed. Electrical shock can cause
serious or fatal injury. National Electrical Code and Local codes must be carefully followed.
Avoid extended exposure to machinery with high noise levels. Be sure to wear ear protective
devices to reduce harmful effects to your hearing.
Surface temperatures of motor enclosures may reach temperatures which can cause discomfort
or injury to personnel accidentally coming into contact with hot surfaces. When installing,
protection should be provided by the user to protect against accidental contact with hot surfaces.
Failure to observe this precaution could result in bodily injury.
This equipment may be connected to other machinery that has rotating parts or parts that are
driven by this equipment. Improper use can cause serious or fatal injury. Only qualified
personnel should attempt to install operate or maintain this equipment.
Do not by-pass or disable protective devices or safety guards. Safety features are designed to
prevent damage to personnel or equipment. These devices can only provide protection if they
remain operative.
Avoid the use of automatic reset devices if the automatic restarting of equipment can be
hazardous to personnel or equipment.
Be sure the load is properly coupled to the motor shaft before applying power. The shaft key
must be fully captive by the load device. Improper coupling can cause harm to personnel or
equipment if the load decouples from the shaft during operation.
Use proper care and procedures that are safe during handling, lifting, installing, operating and
maintaining operations. Improper methods may cause muscle strain or other harm.
Thermostat contacts automatically reset when the motor has slightly cooled down. To prevent
injury or damage, the control circuit should be designed so that automatic starting of the motor is
not possible when the thermostat resets.

General Information 1-1

21233A IQUITOS - PL #20748


Section 1
General Information

Safety Notice Continued


WARNING:
UL Listed motors must only be serviced by UL Approved Authorized Baldor Service Centers if
these motors are to be returned to a hazardous and/or explosive atmosphere.
WARNING:
Pacemaker danger Magnetic and electromagnetic fields in the vicinity of current carrying
carrying conductors and permanent magnet motors can result result in a serious health hazard to
persons with cardiac pacemakers, metal implants, and hearing aids. To avoid risk, stay way from
the area surrounding a permanent magnet motor.
WARNING:
Before performing any motor maintenance procedure, be sure that the equipment connected to
the motor shaft cannot cause shaft rotation. If the load can cause shaft rotation, disconnect the
load from the motor shaft before maintenance is performed. Unexpected mechanical rotation of
the motor parts can cause injury or motor damage.
WARNING:
Use only UL/CSA listed explosion proof motors in the presence of flammable or combustible
vapors or dust.
WARNING:
Motors that are to be used in flammable and/or explosive atmospheres must display the UL label
on the nameplate along with CSA listed logo. Specific service conditions for these motors are
defined in NFPA 70 (NEC) Article 500.
WARNING:
Guards must be installed for rotating parts such as couplings, pulleys, external fans, and unused
shaft extensions, should be permanently guarded to prevent accidental contact by personnel.
Accidental contact with body parts or clothing can cause serious or fatal injury.
Caution:
To prevent premature equipment failure or damage, only qualified maintenance personnel should
perform maintenance.
Caution:
Do not overlubricate motor as this may cause premature bearing failure.
Caution:
Do not over tension belts. Excess tension may damage the motor or driven equipment.
Caution:
Do not lift the motor and its driven load by the motor lifting hardware. The motor lifting hardware
is adequate for lifting only the motor. Disconnect the load (gears, pumps, compressors, or other
driven equipment) from the motor shaft before lifting the motor.
Caution:
If eye bolts are used for lifting a motor, be sure they are securely tightened. The lifting direction
should not exceed a 20 angle from the shank of the eye bolt or lifting lug. Excessive lifting
angles can cause damage.
Caution:
To prevent equipment damage, be sure that the electrical service is not capable of delivering more
than the maximum motor rated amps listed on the rating plate.
Caution:
If a HI POT test (High Potential Insulation test) must be performed, follow the precautions and
procedure in NEMA MG1 and MG2 standards to avoid equipment damage.
If you have any questions or are uncertain about any statement or procedure, or if you require additional
information please contact your Baldor distributor or an Authorized Baldor Service Center.
Receiving
Each Baldor Electric Motor is thoroughly tested at the factory and carefully packaged for shipment. When
you receive your motor, there are several things you should do immediately.
1. Observe the condition of the shipping container and report any damage immediately to the
commercial carrier that delivered your motor.
2. Verify that the part number of the motor you received is the same as the part number listed on your
purchase order.
Handling
The motor should be lifted using the lifting lugs or eye bolts provided.
Caution:
Do not lift the motor and its driven load by the motor lifting hardware. The motor lifting hardware
is adequate for lifting only the motor. Disconnect the load (gears, pumps, compressors, or other
driven equipment) from the motor shaft before lifting the motor.
1. Use the lugs or eye bolts provided to lift the motor. Never attempt to lift the motor and additional
equipment connected to the motor by this method. The lugs or eye bolts provided are designed to lift
only the motor. Never lift the motor by the motor shaft or the hood of a WPII motor.
2. To avoid condensation inside the motor, do not unpack until the motor has reached room temperature.
(Room temperature is the temperature of the room in which it will be installed).
The packing provides insulation from temperature changes during transportation.
3. When lifting a WPII (Weather Proof Type 2) motor, do not lift the motor by inserting lifting lugs into
holes on top of the cooling hood. These lugs are to be used for hood removal only.
A spreader bar should be used to lift the motor by the cast lifting lugs located on the motor frame.

1-2 General Information

MN400

21233A IQUITOS - PL #20748

4. If the motor must be mounted to a plate with the driven equipment such as pump, compressor etc.,
it may not be possible to lift the motor alone. For this case, the assembly should be lifted by a sling
around the mounting base. The entire assembly can be lifted as an assembly for installation.
Do not lift the assembly using the motor lugs or eye bolts provided. Lugs or eye bolts are designed to
lift motor only. If the load is unbalanced (as with couplings or additional attachments) additional slings
or other means must be used to prevent tipping. In any event, the load must be secure before lifting.
If the load is unbalanced (as with couplings or additional attachments) additional slings or other
means must be used to prevent tipping. In any event, the load must be secure before lifting.
Storage
Storage requirements for motors and generators that will not be placed in service for at least six months
from date of shipment.
Improper motor storage will result in seriously reduced reliability and failure. An electric motor that does
not experience regular usage while being exposed to normally humid atmospheric conditions is likely to
develop rust in the bearings or rust particles from surrounding surfaces may contaminate the bearings.
The electrical insulation may absorb an excessive amount of moisture leading to the motor winding
failure.
A wooden crate shell should be constructed to secure the motor during storage. This is similar to an
export box but the sides & top must be secured to the wooden base with lag bolts (not nailed as export
boxes are) to allow opening and reclosing many times without damage to the shell.
Minimum resistance of motor winding insulation is 5 Meg ohms or the calculated minimum, which ever is
greater. Minimum resistance is calculated as follows: Rm = kV + 1
where: (Rm is minimum resistance to ground in MegOhms and
kV is rated nameplate voltage defined as KiloVolts.)
Example: For a 480VAC rated motor Rm =1.48 megohms (use 5 M).
For a 4160VAC rated motor Rm = 5.16 megohms.
Preparation for Storage
1. Some motors have a shipping brace attached to the shaft to prevent damage during transportation.
The shipping brace, if provided, must be removed and stored for future use. The brace must be
reinstalled to hold the shaft firmly in place against the bearing before the motor is moved.
2. Store in a clean, dry, protected warehouse where control is maintained as follows:
a. Shock or vibration must not exceed 2 mils maximum at 60 hertz, to prevent the bearings from
brinelling. If shock or vibration exceeds this limit vibration isolation pads must be used.
b. Storage temperatures of 10C (50F) to 49C (120F) must be maintained.
c. Relative humidity must not exceed 60%.
d. Motor space heaters (when present) are to be connected and energized whenever there is a
possibility that the storage ambient conditions will reach the dew point. Space heaters are optional.
Note: Remove motor from containers when heaters are energized, reprotect if necessary.
3. Measure and record the resistance of the winding insulation (dielectric withstand) every 30 days of
storage.
a. If motor insulation resistance decreases below the minimum resistance, contact your Baldor
District office.
b. Place new desiccant inside the vapor bag and reseal by taping it closed.
c. If a zipperclosing type bag is used instead of the heatsealed type bag, zip the bag closed
instead of taping it. Be sure to place new desiccant inside bag after each monthly inspection.
d. Place the shell over the motor and secure with lag bolts.
4. Where motors are mounted to machinery, the mounting must be such that the drains and breathers
are fully operable and are at the lowest point of the motor. Vertical motors must be stored in the
vertical position. Storage environment must be maintained as stated in step 2.

MN400

General Information 1-3

21233A IQUITOS - PL #20748

5. Motors with antifriction bearings are to be greased at the time of going into extended storage with
periodic service as follows:
a. Motors marked Do Not Lubricate on the nameplate do not need to be greased before or during
storage.
b. Ball and roller bearing (antifriction) motor shafts are to be rotated manually every 3 months and
greased every 6 months in accordance with the Maintenance section of this manual.
c. Sleeve bearing (oil lube) motors are drained of oil prior to shipment.
The oil reservoirs must be refilled to the indicated level with the specified lubricant, (see
Maintenance). The shaft should be rotated monthly by hand at least 10 to 15 revolutions to
distribute oil to bearing surfaces.
d. Provisions for oil mist lubrication These motors are packed with grease. Storage procedures
are the same as paragraph 5b.
e. Oil Mist Lubricated These bearings are protected for temporary storage by a corrosion
inhibitor. If stored for greater than 3 months or outdoor storage is anticipated, connected to the oil
mist system while in storage. If this is not possible, add the amount of grease indicated under
Standard Condition in Section 3, then rotate the shaft 15 times by hand.
6. All breather drains are to be fully operable while in storage (drain plugs removed). The motors must
be stored so that the drain is at the lowest point. All breathers and automatic T drains must be
operable to allow breathing and draining at points other than through the bearings around the shaft.
Vertical motors should be stored in a safe stable vertical position.
7. Coat all external machined surfaces with a rust preventing material.
An acceptable product for this purpose is Exxon Rust Ban # 392.
NonRegreaseable Motors
Nonregreasable motors with Do Not Lubricate on the nameplate should have the motor shaft rotated
15 times to redistribute the grease within the bearing every 3 months or more often.
All Other Motor Types
Before storage, the following procedure must be performed.
1. Remove the grease drain plug, if supplied, (opposite the grease fitting) on the bottom of each bracket
prior to lubricating the motor.
2. The motor with regreasable bearing must be greased as instructed in Section 3 of this manual.
3. Replace the grease drain plug after greasing.
4. The motor shaft must be rotated a minimum of 15 times after greasing.
5. Motor Shafts are to be rotated at least 15 revolutions manually every 3 months and additional grease
added every nine months (see Section 3) to each bearing.
6. Bearings are to be greased at the time of removal from storage.
Removal From Storage
1. Remove all packing material.
2. Measure and record the electrical resistance of the winding insulation resistance meter at the time of
removal from storage. The insulation resistance must not be less than 50% from the initial reading
recorded when the motor was placed into storage. A decrease in resistance indicates moisture in the
windings and necessitates electrical or mechanical drying before the motor can be placed into
service. If resistance is low, contact your Baldor District office.
3. Regrease the bearings as instructed in Section 3 of this manual.
4. Reinstall the original shipping brace if motor is to be moved. This will hold the shaft firmly against the
bearing and prevent damage during movement.

1-4 General Information

MN400

21233A IQUITOS - PL #20748

Section 2
Installation & Operation
Overview

Location

Caution:
Mounting

Alignment

Caution:

MN400

Installation should conform to the National Electrical Code as well as local codes and practices. When
other devices are coupled to the motor shaft, be sure to install protective devices to prevent future
accidents. Some protective devices include, coupling, belt guard, chain guard, shaft covers etc. These
protect against accidental contact with moving parts. Machinery that is accessible to personnel should
provide further protection in the form of guard rails, screening, warning signs etc.
It is important that motors be installed in locations that are compatible with motor enclosure and ambient
conditions. Improper selection of the motor enclosure and ambient conditions can lead to reduced
operating life of the motor.
Proper ventilation for the motor must be provided. Obstructed airflow can lead to reduction of motor life.
1. Open DripProof/WPI motors are intended for use indoors where atmosphere is relatively clean, dry,
well ventilated and noncorrosive.
2. Totally Enclosed and WPII motors may be installed where dirt, moisture or dust are present and in
outdoor locations.
Severe Duty, IEEE 841 and Washdown Duty enclosed motors are designed for installations with high
corrosion or excessive moisture conditions. These motors should not be placed into an environment
where there is the presence of flammable or combustible vapors, dust or any combustible material, unless
specifically designed for this type of service.
Hazardous Locations are those where there is a risk of ignition or explosion due to the presence of
combustible gases, vapors, dust, fibers, or flyings. Facilities requiring special equipment for hazardous
locations are typically classified in accordance with local requirements. In the US market, guidance is
provided by the National Electric Code.
Do not lift the motor and its driven load by the motor lifting hardware. The motor lifting hardware
is adequate for lifting only the motor. Disconnect the load (gears, pumps, compressors, or other
driven equipment) from the motor shaft before lifting the motor.
The motor must be securely installed to a rigid foundation or mounting surface to minimize vibration and
maintain alignment between the motor and shaft load. Failure to provide a proper mounting surface may
cause vibration, misalignment and bearing damage.
Foundation caps and sole plates are designed to act as spacers for the equipment they support. If these
devices are used, be sure that they are evenly supported by the foundation or mounting surface.
After installation is complete and accurate alignment of the motor and load is accomplished, the base
should be grouted to the foundation to maintain this alignment.
The standard motor base is designed for horizontal or vertical mounting. Adjustable or sliding rails are
designed for horizontal mounting only. Consult your Baldor distributor or authorized Baldor Service Center
for further information.
Accurate alignment of the motor with the driven equipment is extremely important. The pulley, sprocket,
or gear used in the drive should be located on the shaft as close to the shaft shoulder as possible.
It is recommended to heat the pulley, sprocket, or gear before installing on the motor shaft.
Forcibly driving a unit on the motor shaft will damage the bearings.
1. Direct Coupling
For direct drive, use flexible couplings if possible. Consult the drive or equipment manufacturer for
more information. Mechanical vibration and roughness during operation may indicate poor alignment.
Use dial indicators to check alignment. The space between coupling hubs should be maintained as
recommended by the coupling manufacturer.
2. End-Play Adjustment
The axial position of the motor frame with respect to its load is also extremely important. The motor
bearings are not designed for excessive external axial thrust loads. Improper adjustment will cause
failure.
3. Pulley Ratio
The pulley ratio should not exceed 8:1.
Do not over tension belts. Excess tension may damage the motor or driven equipment.
4. Belt Drive
Align sheaves carefully to minimize belt wear and axial bearing loads (see End-Play Adjustment). Belt
tension should be sufficient to prevent belt slippage at rated speed and load. However, belt slippage
may occur during starting.
5. Sleeve bearing motors are only suitable for coupled loads.

Installation & Operation 2-1

21233A IQUITOS - PL #20748

Section 1
General Information
Doweling & Bolting After proper alignment is verified, dowel pins should be inserted through the motor feet into the
foundation. This will maintain the correct motor position should motor removal be required.
(Baldor motors are designed for doweling.)
1. Drill dowel holes in diagonally opposite motor feet in the locations provided.
2. Drill corresponding holes in the foundation.
3. Ream all holes.
4. Install proper fitting dowels.
5. Mounting bolts must be carefully tightened to prevent changes in alignment. Use a flat washer and
lock washer under each nut or bolt head to hold the motor feet secure. Flanged nuts or bolts may be
used as an alternative to washers.
WARNING:
Guards must be installed for rotating parts such as couplings, pulleys, external fans, and unused
shaft extensions, should be permanently guarded to prevent accidental contact by personnel.
Accidental contact with body parts or clothing can cause serious or fatal injury.
Guarding
Guards must be installed for rotating parts such as couplings, pulleys, external fans, and unused shaft
extensions. This is particularly important where the parts have surface irregularities such as keys, key
ways or set screws. Some satisfactory methods of guarding are:
1. Covering the machine and associated rotating parts with structural or decorative parts of the driven
equipment.
2. Providing covers for the rotating parts. Covers should be sufficiently rigid to maintain adequate
guarding during normal service.
Power Connection Motor and control wiring, overload protection, disconnects, accessories and grounding should
conform to the National Electrical Code and local codes and practices. Flying leads must be insulated with
two full wraps of electrical grade insulating tape or heat shrink tubing.
Conduit Box For ease of making connections, an oversize conduit box is provided.
The box can be rotated 360 in 90 increments.
Auxiliary conduit boxes are provided on some motors for accessories such as space heaters, RTDs etc.
AC Power

Connect the motor leads as shown on the connection diagram located on the name plate or inside the
cover on the conduit box. Be sure the following guidelines are met:
1. AC power is within 10% of rated voltage with rated frequency. (See motor name plate for ratings).
OR
2. AC power is within 5% of rated frequency with rated voltage.
OR
3. A combined variation in voltage and frequency of 10% (sum of absolute values) of rated values,
provided the frequency variation does not exceed 5% of rated frequency.
Performance within these voltage and frequency variations are shown in Figure 2-2.
Figure 2-1 Accessory Connections
One heater is installed in each end of motor.
Leads for each heater are labeled H1 & H2.
(Like numbers should be tied together).
Three thermistors are installed in windings and tied in series.
Leads are labeled T1 & T2.
Winding RTDs are installed in windings (2) per phase.
Each set of leads is labeled W1, W2, W3, W4, W5, & W6.
* One bearing RTD is installed in Drive endplate (PUEP), leads
are labeled RTDDE.
* One bearing RTD is installed in Opposite Drive endplate (FREP), leads
are labeled RTDODE.
* Note RTD may have 2Red/1White leads; or 2White/1Red Lead.

2-2 Installation & Operation

MN400

21233A IQUITOS - PL #20748

Section 1
General Information
+20

Changes in Motor Performance (%)

+15

Figure 2-2 Typical Motor Performance VS Voltage Variations


Maximum
Torque

Full -Load
Current

+10
+5

Full -Load
Current

Power
Factor

0
5

Efficiency

Efficiency

10
15
20

Power
Factor

Maximum
Torque
15

10

+5

+10

+15

Voltage Variations (%)


Rotation

MN400

All three phase motors are reversible. To reverse the direction of rotation, disconnect and lock out power
and interchange any two of the three line leads for three phase motors. For single phase motors, check
the connection diagram to determine if the motor is reversible and follow the connection instructions for
lead numbers to be interchanged. Not all single phase motors are reversible.
Adjustable Frequency Power Inverters used to supply adjustable frequency power to induction motors
produce wave forms with lower order harmonics with voltage spikes superimposed. Turntoturn,
phasetophase, and ground insulation of stator windings are subject to the resulting dielectric stresses.
Suitable precautions should be taken in the design of these drive systems to minimize the magnitude of
these voltage spikes. Consult the drive instructions for maximum acceptable motor lead lengths, and
proper grounding.

Installation & Operation 2-3

21233A IQUITOS - PL #20748

Section 1
General Information
First Time Start Up Be sure that all power to motor and accessories is off. Be sure the motor shaft is disconnected from
the load and will not cause mechanical rotation of the motor shaft.
1. Make sure that the mechanical installation is secure. All bolts and nuts are tightened etc.
2. If motor has been in storage or idle for some time, check winding insulation integrity.
3. Inspect all electrical connections for proper termination, clearance, mechanical strength and electrical
continuity.
4. Be sure all shipping materials and braces (if used) are removed from motor shaft.
5. Manually rotate the motor shaft to ensure that it rotates freely.
6. Replace all panels and covers that were removed during installation.
7. Momentarily apply power and check the direction of rotation of the motor shaft.
8. If motor rotation is wrong, be sure power is off and change the motor lead connections.
Verify rotation direction before you continue.
9. Start the motor and ensure operation is smooth without excessive vibration or noise.
If so, run the motor for 1 hour with no load connected.
10. After 1 hour of operation, disconnect power and connect the load to the motor shaft. Verify all
coupling guards and protective devices are installed. Ensure motor is properly ventilated.
Coupled Start Up This procedure assumes a coupled start up. Also, that the first time start up procedure was
successful.
1. Check the coupling and ensure that all guards and protective devices are installed.
2. Check that the coupling is properly aligned and not binding.
3. The first coupled start up should be with no load. Apply power and verify that the load is not
transmitting excessive vibration back to the motor though the coupling or the foundation. Vibration
should be at an acceptable level.
4. Run for approximately 1 hour with the driven equipment in an unloaded condition.
The equipment can now be loaded and operated within specified limits. Do not exceed the name plate
ratings for amperes for steady continuous loads.
Jogging and Repeated Starts Repeated starts and/or jogs of induction motors generally reduce the life of the motor
winding insulation. A much greater amount of heat is produced by each acceleration or jog than by the
same motor under full load. If it is necessary to repeatedly start or jog the motor, it is advisable to check
the application with your local Baldor distributor or Baldor Service Center.
Heating - Duty rating and maximum ambient temperature are stated on the motor name plate.
Do not exceed these values. If there is any question regarding safe operation, contact your local Baldor
District Office or Baldor Service Center.

2-4 Installation & Operation

MN400

21233A IQUITOS - PL #20748

Section 3
Maintenance & Troubleshooting
WARNING:

UL Listed motors must only be serviced by UL Approved Authorized Baldor Service Centers if
these motors are to be returned to a hazardous and/or explosive atmosphere.
General Inspection Inspect the motor at regular intervals, approximately every 500 hours of operation or every 3
months, whichever occurs first. Keep the motor clean and the ventilation openings clear. The following
steps should be performed at each inspection:
WARNING:
Do not touch electrical connections before you first ensure that power has been disconnected.
Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt the
installation, operation and maintenance of this equipment.
1. Check that the motor is clean. Check that the interior and exterior of the motor is free of dirt, oil,
grease, water, etc. Oily vapor, paper pulp, textile lint, etc. can accumulate and block motor
ventilation. If the motor is not properly ventilated, overheating can occur and cause early motor
failure.
2. Use a Megger periodically to ensure that the integrity of the winding insulation has been
maintained. Record the Megger readings. Immediately investigate any significant drop in insulation
resistance.
3. Check all electrical connectors to be sure that they are tight.
Relubrication & Bearings
Bearing grease will lose its lubricating ability over time, not suddenly. The lubricating
ability of a grease (over time) depends primarily on the type of grease, the size of the bearing, the speed
at which the bearing operates and the severity of the operating conditions. Good results can be obtained
if the following recommendations are used in your maintenance program.
Type of Grease A high grade ball or roller bearing grease should be used. Recommended grease for standard
service conditions is Polyrex EM (Exxon Mobil). Do not mix greases unless compatibility has been
checked and verified.
Equivalent and compatible greases include:
Texaco Polystar, Rykon Premium #2, Pennzoil Pen 2 Lube and Chevron SRI.
Relubrication Intervals Recommended relubrication intervals are shown in Table 3-1. It is important to realize that
the recommended intervals of Table 3-1 are based on average use.
Refer to additional information contained in Tables 3-2, 3-3 and 3-4.
Table 3-1 Relubrication Intervals *
NEMA / (IEC) Frame Size
Up to 210 incl. (132)
Over 210 to 280 incl. (180)
Over 280 to 360 incl. (225)
Over 360 to 5800 incl. (300)

10000
**

6000
2700 Hrs.
**
**
**

Rated Speed - RPM


3600
1800
5500 Hrs.
12000 Hrs.
3600 Hrs.
9500 Hrs.
* 2200 Hrs. 7400 Hrs.
*2200 Hrs.
3500 Hrs.

1200
18000 Hrs.
15000 Hrs.
12000 Hrs.
7400 Hrs.

900
22000 Hrs.
18000 Hrs.
15000 Hrs.
10500 Hrs.

Relubrication intervals are for ball bearings.


For vertically mounted motors and roller bearings, divide the relubrication interval by 2.

**

For motors operating at speeds greater than 3600 RPM, contact Baldor for relubrication recommendations.

MN400

Maintenance & Troubleshooting 3-1

21233A IQUITOS - PL #20748

Table 3-2 Service Conditions


Severity of Service
Standard
Severe
Extreme

Hours per day


of Operation
8
16 Plus
16 Plus

Low Temperature

Ambient Temperature
Maximum
40 C
50 C
>50 C* or
Class H Insulation
<29 C **

Atmospheric
Contamination
Clean, Little Corrosion
Moderate dirt, Corrosion
Severe dirt, Abrasive dust, Corrosion, Heavy
Shock or Vibration

Special high temperature grease is recommended (Dow Corning DC44). Note that Dow Corning DC44 grease does
not mix with other grease types. Thoroughly clean bearing & cavity before adding grease.

**

Special low temperature grease is recommended (Aeroshell 7).


Table 3-3 Relubrication Interval Multiplier
Severity of Service
Standard
Severe
Extreme
Low Temperature

Multiplier
1.0
0.5
0.1
1.0

Some motor designs use different bearings on each motor end. This is normally indicated on the motor nameplate.
In this case, the larger bearing is installed on the motor Drive endplate. For best relubrication results, only use the
appropriate amount of grease for each bearing size (not the same for both).
Table 3-4 Bearings Sizes and Types

Frame Size
NEMA (IEC)
56 to 140 (90)
140 (90)
180 (100112)
210 (132)
250 (160)
280 (180)
320 (200)
360 (225)
400 (250)
440 (280)
5000 to 5800 (315450)
5000 to 5800 (315450)
360 to 449 (225280)
AC Induction Servo
76 Frame 180 (112)
77 Frame 210 (132)
80 Frame 250(160)
*

Bearing Description
(These are the Large bearings (Shaft End) in each frame size)
Volume of grease
Weight of Grease to
to be added
Bearing
add *
3
in
teaspoon
oz (Grams)
6203
0.08 (2.4)
0.15
0.5
6205
0.15 (3.9)
0.2
0.8
6206
0.19 (5.0)
0.3
1.0
6307
0.30 (8.4)
0.6
2.0
6309
0.47 (12.5)
0.7
2.5
6311
0.61 (17)
1.2
3.9
6312
0.76 (20.1)
1.2
4.0
6313
0.81 (23)
1.5
5.2
6316
1.25 (33)
2.0
6.6
6319
2.12 (60)
4.1
13.4
6328
4.70 (130)
9.2
30.0
NU328
4.70 (130)
9.2
30.0
NU319
2.12 (60)
4.1
13.4
6207
6210
6213

0.22 (6.1)
0.32 (9.0)
0.49 (14.0)

0.44
0.64
0.99

1.4
2.1
3.3

Weight in grams = .005 DB


of grease to
be added
Note: Not all bearing sizes are listed. For intermediate bearing sizes, use the grease volume for the next
larger size bearing.

3-2 Maintenance & Troubleshooting

MN400

21233A IQUITOS - PL #20748

Caution: To avoid damage to motor bearings, grease must be kept free of dirt. For an extremely dirty
environment, contact your Baldor distributor or an authorized Baldor Service Center for
additional information.
Relubrication Procedure Be sure that the grease you are adding to the motor is compatible with the grease already
in the motor. Consult your Baldor distributor or an authorized service center if a grease other than the
recommended type is to be used.
Caution: Do not overlubricate motor as this may cause premature bearing failure.
With Grease Outlet Plug
1. With the motor stopped, clean all grease fittings with a clean cloth.
2. Remove grease outlet plug.
Caution: Overlubricating can cause excessive bearing temperatures, premature lubrication breakdown
and bearing failure.
3. Add the recommended amount of grease.
4. Operate the motor for 15 minutes with grease plug removed.
This allows excess grease to purge.
5. Re-install grease outlet plug.
Without Grease Provisions
Note: Only a Baldor authorized and UL or CSA certified service center can disassemble a UL/CSA
listed explosion proof motor to maintain its UL/CSA listing.
1. Disassemble the motor.
2. Add recommended amount of grease to bearing and bearing cavity. (Bearing should be about 1/3
full of grease and outboard bearing cavity should be about 1/2 full of grease.)
3. Assemble the motor.
Sample Relubrication Determination
Assume - NEMA 286T (IEC 180), 1750 RPM motor driving an exhaust fan in an ambient temperature of
43 C and the atmosphere is moderately corrosive.
1. Table 3-1 list 9500 hours for standard conditions.
2. Table 3-2 classifies severity of service as Severe.
3. Table 3-4 shows that 1.2 in3 or 3.9 teaspoon of grease is to be added.
Note: Smaller bearings in size category may require reduced amounts of grease.

MN400

Maintenance & Troubleshooting 3-3

21233A IQUITOS - PL #20748

Section 1
General Information
Table 3-5 Troubleshooting Chart
Symptom
Motor will not start
Excessive humming
Motor Over Heating

Possible Causes
Usually caused by line trouble, such
as, single phasing at the starter.
High Voltage.
Eccentric air gap.
Overload. Compare actual amps
(measured) with nameplate rating.
Single Phasing.
Improper ventilation.
Unbalanced voltage.
Rotor rubbing on stator.
Over voltage or under voltage.
Open stator winding.
Grounded winding.
Improper connections.

Bearing Over Heating

Misalignment.
Excessive belt tension.
Excessive end thrust.
Excessive grease in bearing.
Insufficient grease in bearing.
Dirt in bearing.

Vibration

Misalignment.
Rubbing between rotating parts and
stationary parts.
Rotor out of balance.
Resonance.

Noise
Growling or whining

Foreign material in air gap or


ventilation openings.
Bad bearing.

3-4 Maintenance & Troubleshooting

Possible Solutions
Check source of power. Check overloads, fuses,
controls, etc.
Check input line connections.
Have motor serviced at local Baldor service center.
Locate and remove source of excessive friction in
motor or load.
Reduce load or replace with motor of greater capacity.
Check current at all phases (should be approximately
equal) to isolate and correct the problem.
Check external cooling fan to be sure air is moving
properly across cooling fins.
Excessive dirt build-up on motor. Clean motor.
Check voltage at all phases (should be approximately
equal) to isolate and correct the problem.
Check air gap clearance and bearings.
Tighten Thru Bolts.
Check input voltage at each phase to motor.
Check stator resistance at all three phases for
balance.
Perform dielectric test and repair as required.
Inspect all electrical connections for proper
termination, clearance, mechanical strength and
electrical continuity. Refer to motor lead connection
diagram.
Check and align motor and driven equipment.
Reduce belt tension to proper point for load.
Reduce the end thrust from driven machine.
Remove grease until cavity is approximately 3/4 filled.
Add grease until cavity is approximately 3/4 filled.
Clean bearing cavity and bearing. Repack with correct
grease until cavity is approximately 3/4 filled.
Check and align motor and driven equipment.
Isolate and eliminate cause of rubbing.
Have rotor balance checked are repaired at your
Baldor Service Center.
Tune system or contact your Baldor Service Center
for assistance.
Remove rotor and foreign material. Reinstall rotor.
Check insulation integrity. Clean ventilation openings.
Replace bearing. Clean all grease from cavity and
new bearing. Repack with correct grease until cavity
is approximately 3/4 filled.

MN400

21233A IQUITOS - PL #20748

Suggested bearing and winding RTD setting guidelines


Most large frame AC Baldor motors with a 1.15 service factor are designed to operate below a Class B
(80C) temperature rise at rated load and are built with a Class H winding insulation system. Based on
this low temperature rise, RTD (Resistance Temperature Detectors) settings for Class B rise should be
used as a starting point. Some motors with 1.0 service factor have Class F temperature rise.
The following tables show the suggested alarm and trip settings for RTDs. Proper bearing and winding
RTD alarm and trip settings should be selected based on these tables unless otherwise specified for
specific applications.
If the driven load is found to operate well below the initial temperature settings under normal conditions,
the alarm and trip settings may be reduced so that an abnormal machine load will be identified.
The temperature limits are based on the installation of the winding RTDs imbedded in the winding as
specified by NEMA. Bearing RTDs should be installed so they are in contact with the outer race on ball
or roller bearings or in direct contact with the sleeve bearing shell.
Winding RTDs Temperature Limit In 5C (405C Maximum Ambient)
Class B Temp Rise 3 80C
(Typical Design)
Alarm
Trip
130
140
140
150

Motor Load
3 Rated Load
Rated Load
to 1.15 S.F.

Class F Temp Rise 3 105C


Alarm
155
160

Class H Temp Rise 3 125C

Trip
165
165

Alarm
175
180

Trip
185
185

Note: S Winding RTDs are factory production installed, not from ModExpress.

S When Class H temperatures are used, consider bearing temperatures and relubrication requirements.
Bearing RTDs Temperature Limit In 5C (405C Maximum Ambient)

AntiFriction
Sleeve
Alarm
Trip
Alarm
Trip
95
100
85
95
110
115
105
110
Note: * Bearing temperature limits are for standard design motors operating at Class B temperature rise.
** High temperature lubricants include some special synthetic oils and greases.
Greases that may be substituted that are compatible with Polyrex EM (but considered as standard lubricants)
include the following:
Texaco Polystar
Rykon Premium #2
Chevron SRI #2
Mobilith SHC100
Pennzoil Pennzlube EM2
Chevron Black Pearl
Darmex 707
Darmex 711
PetroCanada Peerless LLG

Bearing Type
Oil or Grease
Standard*
High Temperature**

See the motor nameplate for replacement grease or oil recommendation.


Contact Baldor application engineering for special lubricants or further clarifications.

MN400

Maintenance & Troubleshooting 3-5

21233A IQUITOS - PL #20748

3-6 Maintenance & Troubleshooting

MN400

21233A IQUITOS - PL #20748

Baldor District Offices


UNITED STATES
ARIZONA
PHOENIX
4211 S 43RD PLACE
PHOENIX, AZ 85040
PHONE: 602-470-0407
FAX: 602-470-0464
ARKANSAS
CLARKSVILLE
1001 COLLEGE AVE.
CLARKSVILLE, AR 72830
PHONE: 479-754-9108
FAX: 479-754-9205
CALIFORNIA
LOS ANGELES
6480 FLOTI LLA
COMMERCE, CA 90040
PHONE: 323-724-6771
FAX: 323-721-5859
HAYWARD
21056 FORBES STREET
HAYWARD, CA 94545
PHONE: 510-785-9900
FAX: 510-785-9910
COLORADO
DENVER
3855 FOREST STREET
DENVER. CO 80207
PHONE: 303-623-0127
FAX: 303-595-3772
9980 PARK MEADOWS DRIVE
SUITE 214
LONE TREE, CO 80124-6739
PHONE 303-339-9629
FAX: 303-339-9633
CONNECTICUT
WALLINGFORD
65 SOUTH TURNPIKE ROAD
WALLINGFORD, CT 06492
PHONE 203-269-1354
FAX: 203-269-5485
FLORIDA
TAMPA/PUERTO RICO/
VIRGIN ISLANDS
3906 EAST 11TH AVENUE
TAMPA, FL 33605
PHONE: 813-248-5078
FAX: 813-247-2984
GEORGIA
ATLANTA
62 TECHNOLOGY DR.
ALPHARETTA, GA 30005
PHONE: 770-772-7000
FAX: 770-772-7200
5490 MCGINNIS FERRY PLACE
SUITE 133
ALPHARETTA, GA 30005
PHONE 770-752-4254
FAX: 770-752-4257
ILLINOIS
CHICAGO
4 SAMMONS COURT
BOll NGBROOK, IL 60440
PHONE 630-296-1400
FAX: 630-226-9420
INDIANA
COLUMBUS
3300 TENTH ST
COLUMBUS, IN 47201
PHONE 812-378-2556
FAX: 812-378-2555
INDIANAPOLIS
5525 W. MINNESOTA STREET
INDIANAPOLIS, IN 46241
PHONE: 317-246-5100
FAX 317-246-5110
IOWA
DES MOINES
1800 DIXON STREET, SUITE C
DES MOINES, IA 50316
PHONE: 515-263-6929
FAX 515-263-6515
KANSAS
5030 BOB BILLINGS PKWY STE B
LAWRENCE, KS 66049
PHONE: 785-749-4339
FAX: 785-749-4217

MARYLAND
BALTIMORE
6660 SANTA BARBARA RD.
SUITE 22-24
ELKRIDGE, MD 21075
PHONE 410-579-2135
FAX 410-579-2677
MASSACHUSETTS
BOSTON
6 PU LLMAN STREET
WORCESTER, MA 01606
PHONE: 508-854-0708
FAX 508-854-0291
MICHIGAN
DETROIT
33782 STERLING PONDS BLVD.
STERLING HEIGHTS, MI48312
PHONE: 586-978-9800
FAX 586-978-9969
GRAND RAPIDS
668 THREE MILE ROAD NW
GRAND RAPIDS, MI 49504
PHONE: 616-785-1784
FAX 616-785-1788
MINNESOTA
MINNEAPOLIS
21080 134TH AVE. NORTH
ROGERS, MN 55374
PHONE 763-428-3633
FAX 763-428-4551
MISSOURI
ST LOUIS
422 INDUSTRIAL DRIVE
MARYLAND HEIGHTS, MO 63043
PHONE 314-298-1800
FAX 314-298-7660
KANSAS CITY
1501 BEDFORD AVENUE
NORTH KANSAS CITY, MO 64116
PHONE: 816-587-0272
FAX 816-587-3735
NEW YORK
AUBURN
ONE ELLIS DRIVE
AUBURN, NY 13021
PHONE: 315-255-3403
FAX 315-253-9923
NORTH CAROLINA
GREENSBORO
1220 ROTHERWOOD ROAD
GREENSBORO, NC 27406
PHONE: 336-272-6104
FAX 336-273-6628
OHIO
CINCINNATI
2929 CRESCENTVILLE ROAD
WEST CHESTER. OH 45069
PHONE 513-771-2600
FAX 513-772-2219
CLEVELAND
8929 FREEWAY DRIVE
MACEDONIA, OH 44056
PHONE: 330-468-4777
FAX 330-468-4778
29525 CHAGRIN BLVD SUITE 208
CLEVELAND,OH 44122
PHONE: 216-360-8296
FAX 216-360-4172
OKLAHOMA
TULSA
2 EAST DAWES
BIXBY. OK 74008
PHONE: 918-366-9320
FAX 918-366-9338
OREGON
PORTLAND
20393 SW AVERY COURT
TUALATIN, OR 97062
PHONE: 503-691-9010
FAX 503-691-9012
PENNSYLVANIA
KING OF PRUSSIA
1060 FIRST AVE STE 400
KING OF PRUSSIA, PA 19406
PHONE 610-768-8018
FAX 215-672-5759

PHILADELPHIA
OAKVILLE, ONTARIO
1035 THOMAS BUSCH
2750 COVENTRY ROAD
MEMORIAL HIGHWAY
OAKVILLE, ONTARIO L6H 6R1
PHONE: 905-829-3301
PENNSAUKEN, NJ 08110
PHONE: 856-661-1442
FAX: 905-829-3302
FAX: 856-663-6363
DORVAL, QUEBEC
PITTSBURGH
95 RUE LINDSAY
159 PROMINENCE DRIVE
DORVAL QUEBEC H9P 2S6
PHONE: 514-422-8818
NEW KENSINGTON, PA 15068
PHONE: 724-889-0092
FAX: 514-422-8982
FAX: 724-889-0094
MONTREAL, QUEBEC
TENNESSEE
1844 WI LLiAM STREET
MONTREAL, QUEBEC H3J 1R5
MEMPHIS
PHONE 514-933-2711
4000 WI NCHESTER ROAD
FAX: 514-933-8639
MEMPHIS, TN 38118
PHONE 901-365-2020
VANCOUVER,
FAX: 901-365-3914
BRITISH COLUMBIA
1538 KEBET WAY
TEXAS
PORT COQUITLAM,
ADDISON
BRITISH COLUMBIA V3C 5M5
3939 BELT LINE ROAD #250
PHONE 604-421-2822
ADDISON, TX 75001
FAX: 604-421-3113
PHONE 972-499-7746, 499-7747
WINNIPEG, MANITOBA
FAX: 972-242-1505
54 PRINCESS STREET
DALLAS
WINNIPEG, MANITOBA R3B 1K2
3040 QUEBEC
PHONE: 204-942-5205
DALLAS, TX 75247
FAX: 204-956-4251
PHONE: 214-634-7271
AUSTRALIA
FAX: 214-634-8874
UNIT 3,6 STANTON ROAD
HOUSTON
SEVEN HILLS, NSW 2147, AUSTRALIA
4647 PINE TIMBERS
PHONE: (61) (2) 9674 5455
SUITE # 135
FAX: (61) (2) 9674 2495
HOUSTON, TX 77041
PHONE: 713-895-7062
UNIT 8, 5 KELLETTS ROAD
FAX: 713-690-4540
ROWVILLE, VICTORIA, 3178
AUSTRALIA
UTAH
PHONE: (61) (3) 9753 4355
SALT LAKE CITY
FAX: (61) (3) 97534366
2230 SOUTH MAl N STREET
ELSALVADOR
SALT LAKE CITY, UT 84115
PHONE: 801-832-0127
RESIDENCIAL PINARES DE SUIZA
FAX: 801-832-8911
POL. 15 #44,
NVA SAN SALVADOR EL SALVADOR
VIRGINIA
PHONE +5032288-1519
RICHMOND
FAX: +503 2288-1518
6767 FOREST HILL AVE STE 305
CHILE
RICHMOND, VA 23225
PHONE: 804-545-6848
LUIS THAYER OJEDA 166
FAX: 804-545-6840
OF 402 - PROVIDENCIA
SANTIAGO, CHILE
WASHINGTON
PHONE 56-2-290-0762
KIRKLAND, WA
FAX: 56-2-290-0762
550 KIRKLAND WAY STE 205
CHINA
KIRKLAND, WA 98033
PHONE: 425-952-5000
5299 BEl SONG ROAD
FAX: 775-255-8019
SONGJIANG
201611 SHANGHAI, CHINA
WISCONSIN
PHONE: +86 21 57605335
MILWAUKEE
FAX: +86 21 57605336
2725 SOUTH 163RD STREET
UNIT 905, 9TH FLOOR,
NEW BERLIN, WI 53151
TOWER B WANDA PLAZA
PHONE 262-784-5940
NO. 93 JIANGUO ROAD,
FAX 262-784-1215
CHAOYANG DISTRICT
WAUKESHA
BEIJING, 100022, CHINA
N14 W23777 STONE RIDGE DRIVE
PHONE +86 (010) 58205516
SUITE 170
FAX +86 (010) 58204231
WAUKESHA, WI 53188
GERMANY
PHONE: 262-347-2000
FAX: 262-437-0258
DIESELSTRASSE 22
D-85551 KIRCHHEIM
INTERNATIONAL SALES
MUNICH, GERMANY
FORT SMITH, AR
PHONE: +49 89 90 5080
P.O. BOX 2400
FAX: +49 89 90 50 8492
FORT SMITH, AR 72902
HERMANN-HEINRICH-GOSSENPHONE: 479-646-4711
STRASSE 3
FAX: 479-648-5895
D-50858 KOLN, GERMANY
CANADA
PHONE 49223437941 0
EDMONTON, ALBERTA
FAX: 49 223437941 64
4053-92 STREET
INDIA
EDMONTON, ALBERTA T6E 6R8
PHONE: 780-434-4900
14. COMMERCE AVENUE
FAX: 780-438-2600
MAHAGANESH COLONY
PAUD ROAD
11428-168 STREET
PUNE - 411038
EDMONTON, ALBERTA T5M 3T9
MAHARASHTRA, INDIA
PHONE: 780-822-7865
PHONE: 912025452717,25452718
FAX: 780-822-7878
FAX: 91 2025452719
MISSISSAUGA, ONTARIO
244 BRITANNIA ROAD EAST
MISSISSAUGA, ONTARIO L4Z 1S6
PHONE 905-890-5110
FAX: 905-890-5540

ITALY
BALDORASR AG
SUCCURSALE DI MENDRISIO
VIA BORROMINI, 20A
CH-6850 MENDRISIO
SWITZERLAND
PHONE 0041916409950
FAX: 0041916302633
JAPAN
DIA BLDG 802,
2-21-1 TSURUYA-CHO,
KANAGAWA-KU
YOKOHAMA, 221-0835, JAPAN
PHONE: 81-45-412-4506
FAX: 81-45-412-4507
KOREA
RM 1715, SUSEO TOWER, 725,
SUSEO-DONG, GANGNAM-GU,
SEOUL 135-757 KOREA
TEL: (82) 2 2226 9369
FAX: (82) 2 2226 9368
MEXICO
LEON. GUANAJUATO
KM. 2.0 BLVD. AEROPUERTO .
LEON 37545, GUANAJUATO, MEXICO
PHONE: 52 477 761 2030
FAX: 52477 761 2010
MIDDLE EAST & NORTH AFRICA
VSE INTERNATIONAL CORP.
P. O. BOX 5618
BUFFALO GROVE, IL 60089-5618
PHONE: 847 590 5547
FAX 8475905587
SINGAPORE
18, KAKI BUKIT ROAD 3
#03-09 ENTREPRENEUR
BUSINESS CENTRE
SINGAPORE 415978
PHONE (65) 67442572
FAX: (65) 67471708
PANAMA
AVE. RICARDO J. ALFARO
EDIFICIO SUN TOWERS MALL
PISO 2, LOCAL 55 .
.
CIUDAD DE PANAMA, PANAMA
PHONE: +507 236-5155
FAX: +507 261-5355
SWITZERLAND
POSTFACH 73
SCHUTZENSTRASSE 59
CH-8245 FEUERTHALEN
SWITZERLAND
PHONE: +41 526474700
FAX: +41 52 659 2394
TAIWAN
1F, NO 126 WENS HAN 3RD STREET,
NANTUN DISTRICT,
TAICHUNG CITY 408
TAIWAN R.O.C
PHONE: (886) 4 238 04235
FAX: (886) 4 238 04463
UNITED KINGDOM
6 BRISTOL DISTRIBUTION PARK
HAWKLEY DRIVE
BRISTOL BS32 OBF U.K.
PHONE: +44 1454850000
FAX: +44 1454859001
VENEZUELA
AV. ROMA OTA EL MILAGRO. URB.
CALIFORNIA NORTE
CARACAS, 1070
VENEZUELA
PHONE: 58-414-114-8623
FAX: 58-412-322-5790

21233A IQUITOS - PL #20748

BALDOR ELECTRIC COMPANY


World Headquarters
P.O. Box 2400 Fort Smith, AR 729012400
(479) 6464711 Fax (479) 6485792
www.baldor.com

2009 Baldor Electric Company


MN400

All rights reserved. Printed in USA


2/09

21233A IQUITOS - PL #20748

Product Information Packet

IDVSWDM3538
.5HP,1750RPM,3PH,60HZ,56C,3516M,TENV,F1

Copyright All product information within this document is subject to Baldor Electric Company copyright protection, unless otherwise noted.

21233A IQUITOS - PL #20748


Product Information Packet: IDVSWDM3538 - .5HP,1750RPM,3PH,60HZ,56C,3516M,TENV,F1

Product Detail
Revision:

Status:

PRD/A

Change #:

Proprietary:

No

Type:

AC

Prod Type:

3516M

Elec. Spec:

35WGT203

CD Diagram:

CD0005

Enclosure

TENV

Mfg Plant:

Mech Spec:

35S639

Layout:

35LYS639

Frame:

56C

Mounting:

F1

Poles:

04

Created Date:

Base:

Rotation:

Insulation:

Eff. Date:

Leads:

9#18

Literature:

Elec. Diagram:

03-04-2009

Replaced By:

Nameplate NP1608L
CAT NO

IDVSWDM3538

SPEC.

35S639T203G1

FRAME

56C

VOLTS

230/460

MAG CUR

HP

.5 TE

.5/.25

FLA

1.6/.8

RPM

1750

RPM MAX

6000

HZ

60

CLASS

SER.F.

1.00

DES

NEMA-NOM-EFF

82.5

WK2

0.0949

RATING

40C AMB-CONT

DE BRG

6205

ODE BRG

6203

SL HZ

SER.NO
INV WDG ISR WIRE

Page 2 of 8

21233A IQUITOS - PL #20748


Product Information Packet: IDVSWDM3538 - .5HP,1750RPM,3PH,60HZ,56C,3516M,TENV,F1

Parts List
Product ID
SA084979
RA078129
NS2512A01
35CB5001A03
11XW1032G06
35EP3100M72MU
HW4500A33
HW5100A03SP
35EP3300A75MU
HW4500A33
HW4606A02
12XN1032S20
HA1049A01
HA1049A01
HW2502D13
HA7000A04
MJ5001A02
10XF0440S02
LB1164
MJ1000A02
HA3100S12
LB1125C01
LC0145B01
NP1608L

Description
SA 35S639T203G1
RA 35S639T203G1
INSULATOR, CONDUIT BOX X X
CONDUIT BOX KIT, FOR SUPER II WASHDOWN
10-32 X .38, TAPTITE II, HEX WSHR SLTD U
SPL FR EP-ENCL-203 BRG-DIE CAST ALUM(BAL
1/8 NPT STAINLESS,HOLO-KROME #13002,PRES
WAVY WASHER (W1543-017)
PU E.P., CAST-FACE MTD-56C-205 BRG(BALL
1/8 NPT STAINLESS,HOLO-KROME #13002,PRES
JM CLIPPER/SEAL (LWE-0938-1624-AL23)
10-32 X 1-1/4 HEX M.S. , STAINLESS STEEL
DUBO LOK WASHER SIZE 10 (NYLON LOCK SEAL
DUBO LOK WASHER SIZE 10 (NYLON LOCK SEAL
SS KEY, 3/16 SQ X 1.375
KEY RETAINER 0.625 DIA SHAFTS
732 CL SEALANT 3 OZ DIXIE BEARING 289100
04-40 X 1/8 TYPE F HEX HD STAINLESS STIC
LABEL,WARNING AND DRAIN F/HOSE DOWN
MOBIL POLYREX EM/35LB
THRUBOLT 7.625 LENGTH 1.250 TH LENGTH SS
STD (STOCK) CARTON LABEL BALDOR WITH FLA
CONNECTION LABEL
WD, INV DUTY, SS, UL CSA, LASER

Quantity
1.000
1.000
1.000
1.000
1.000
1.000
3.000
1.000
1.000
3.000
1.000
2.000
2.000
4.000
1.000
1.000
0.001
2.000
1.000
0.050
4.000
1.000
1.000
1.000

Page 3 of 8

21233A IQUITOS - PL #20748


EAT no'R.RELIANCE~

Product Information Packet: IDVSWDM3538 - .5HP,1750RPM,3PH,60HZ,56C,3516M,TENV,F1

Parts List (continued)


Product ID
35PA1066
PK3082

Description
PACKING GROUP COMBINED PRINT
STYROFOAM CRADLE

Quantity
1.000
1.000

Page 4 of 8

21233A IQUITOS - PL #20748


Product Information Packet: IDVSWDM3538 - .5HP,1750RPM,3PH,60HZ,56C,3516M,TENV,F1

Performance Data at 460V, 60Hz, 0.5HP (Typical performance - Not guaranteed values)
General Characteristics
Full Load Torque:

1.5 LB-FT

Start Configuration:

DOL

No-Load Current:

0.5 Amps

Break-Down Torque:

6.7 LB-FT

Line-line Res. @ 25C.:

34.1 Ohms A Ph / 0.0 Ohms B Ph

Pull-Up Torque:

5.1 LB-FT

Temp. Rise @ Rated Load:

37C

Locked-Rotor Torque:

5.6 LB-FT

Temp. Rise @ S.F. Load:

0C

Starting Current:

6.5 Amps

Load Characteristics
% of Rated Load: 25

50

75

100

125

150

S.F.

Power Factor:

32.0

52.0

65.0

74.0

79.0

83.0

0.0

Efficiency:

69.0

80.0

83.0

83.5

83.0

82.0

0.0

Speed:

1790.0

1775.0

1765.0

1750.0

1740.0

1720.0

0.0

Line Amperes:

0.52

0.57

0.75

0.8

0.87

1.0

0.0

Page 5 of 8

21233A IQUITOS - PL #20748


Product Information Packet: IDVSWDM3538 - .5HP,1750RPM,3PH,60HZ,56C,3516M,TENV,F1
Performance Graph at 460V, 60Hz, 0.5HP (Typical performance - Not guaranteed values)
.... ,,. lI"I1JI. . . . _
llIf

----------------

..

IIIf

I11III

..

..
..... ..
..
... ..
....
...
....
,.

II

u
u

II

"

If

"

---

Bf'_ _ _ _ _ _ _ _ _ _ _ __

III

III

II
II

III

II

UI'r-____-2.m~==~~-~-~~~-~-~~~-~-~~~-~-~~~-~____~w~~~__~~~~~~~~-,

..

__ _

UI

III

III

u
iii

If

u
___
ft._""'

fl'IJIIf

..

...

II

III

..iii

...

..

lII'IL~~-~~n~~~~~~II~~~~~~II~~~~~-L-~~~~~~-~~~~
. ~"-'
.

"...,,,

,.,,.,,..~

Page 6 of 8

21233A IQUITOS - PL #20748


Product Information Packet: IDVSWDM3538 - .5HP,1750RPM,3PH,60HZ,56C,3516M,TENV,F1

35LYS639
510-520 - 1106
521-528 = 12.06
529-535 = 12.94
536-546 = 14.31

1-----6.62 - - - - I

----...

1-.12
1.88

- - ----~o~

(J)

.19 KEY
,1.38 LONG

" I"

(J)

~2.59-

I
--==rf

.6250
.6245

4.15

45

'
THERMAL
(WHEN
REO'D)

(J)

r,

III

~
(J)

1
45'1

5.73

-2.06-

6.5 o

4.500
4.497

/L

~4

HOLES
3 W/PLUGS
EA. END

LEAD HOLE
.50 N.P. T.

4 HOLES
'>or .p--:.3:::8-16 TAP ON
5.88 DIA. B,C.
I

4.62-----J

l~

INSTALL DUBO-LOK
),
WASHER UNDER RET.
IV ~),- RING SCREW HEAD

P'~~

t::'

~
--Il-

PULLEY END DETAIL

'"'"

~e~U~S~TO~M~E~R~I~S~R~E~S~P~ON~S~'B=L~E~F~O~R~O~E~IT~RM~'~NI~N~G_T~H~A~T~M~O~T~O~R~P~E~R~FO~R~M~A~N~eE~IS~S~UI~TA~B~L=Er'~N_m~E~A~p~p~L~le~A~~~ON~.~______~~____________________~ ~

r.R~EV~'JO~E~S=C'~U=PO=A=T=E=L=A=YO=U~T~P~E~R~8~O~M~'~FR~E~P~~~~~~~~~~~~~~Ja~~~~T~T)()~~~~~.~J)~~~~J)~~~~~.~~~!:.~L~"~~~~~C:~I:~j!~D~
~
B
VERSION: 02
TOR: 000000460581
~
.......
~EV. LTR:

69SAlg

FILE, \AAA\00093\292

REVlSED, 13,12,34 03/27/2008

VlERT 56e TENV 35M W02 (PAINT FREE) INV DUTY W/RAISED LTR NP
SH 1 of 1

Page 7 of 8

21233A IQUITOS - PL #20748


Product Information Packet: IDVSWDM3538 - .5HP,1750RPM,3PH,60HZ,56C,3516M,TENV,F1

CD0005

1-BLU

LOW VOLTAGE
(2Y)

4-YEL
7-PNK

,,r------------------,,r",,,
I I
"T"
,i

HIGH VOLTAGE

(1 Y)

@4

J-BRN

OPTIONAL
THERMOSTATS

L. . . . . . . . . . . . . . . . . .

rrr

(...... ....,
........./ ...... ~------

9-GRY

J-BRN

8-RED

~2-WHT

LINE

LINE

NOTES:
1. INTERCHANGE ANY TWO LINE LEADS TO REVERSE
ROTATION.
2. OPTIONAL THERMOSTATS ARE PROVIDED WHEN
SPECIFIED.
3. ACTUAL NUMBER OF INTERNAL PARALLEL CIRCUITS
MAY BE A MULTIPLE OF THOSE SHOWN ABOVE.
4. LEAD COLORS ARE OPTIONAL.
NUMBERED AS SHOWN.

LEADS MUST ALWAYS BE


,--

o
o

~R~EV~.~DE~S7C:~RE~~=SE~T~O~S~H=OW~OP~T~IO~NA~L~C=OL~O=RS~------------------,------B--A-L-D--O-R---E--L-E-C--T-R--I-C--C--o-.------~~
REV. LTR: E I BY: JLP
<:;00008

REVISED: 01/19/99 10:15


FILE: AAA00005140

I TOR: 0171435

I MOL: -

3PH, DV, 9 LEADS

Page 8 of 8

AN EMPLOYEE-OWNED COMPANY

SPEED REDUCER

5-49

This page intentionally left blank.

5-50

21233A IQUITOS - PL #20748

21233A IQUITOS - PL #20748

TABLE OF CONTENTS
Page

SM-CYCLO SPEED REDUCERS


. . ...
. ............
. . . . . . . ...
. . . ..
. . . ......
. . . . . . . . ..
. .
.
. . . . . ....
. . .. . ... . ................
. .. . . .... .... A-2
A2
Mounting ..
General Construction . .. . ..... . . . ...............
. . . . . . . . . . .........
. . . . . . . . . . . . ...................
. . . . . . .
. . .... A-3
. . . . . . . . . . . ..................
...
. . . . . . . . . . . .. . ......... . ... . . . . ..
. . A-5
Lubrication .......................
Bearings, Oil Seals,
Seals , Gaskets .........
..... . .........
. . . . . . . ...
. .
. . ..
. . . . ..
. . ... .... . . A-11
Bearings,
. . .... . . . . . . . . . . . . . . . ,. . . ..
Disassembly, Assembly ..................
..... . . . . . . .... ..................
. .. . . . .
. . . . . . . . ......
. . ... . .......
. .. . . . . . .....
. . . . . ...
. . ....
. .. A-14
Inspection , Ordering Replacement Units or Parts, Storage . . . . . . .
. . . . . . . ..
. . . . ...
. . . A-16
Daily Inspection,
. ... . . . ..
Troubleshooting and Repair ...... . ..
. . . . .......
. .. ...
. ...
.. .. ............
.. .. ....... A-17
. . .......
. . . . . . . . ....
. . . . . . ...... .. . ..
SM-CYCLO GEARMOTORS
SMCYCLO

....
............
. . .. ...
. , . . . . . ...
. . . .. . . ......
.......
. .......
.. ....
.. . . B-2
. . . ..
. ....... . .......
. .....
....... ... ....
.. . ...
. . .. ...
Mounting ..
....... . ......
. . . . .. . . ... . .... B-3
General Construction ............. ............ . ..............
. ..................
...
. .......
. ... . . . . . .........
.... .. .. . .......
. ... . ..
. ...
.... ..
. . . .. ..
. ...................
.. .. . . . .. . ......... B-5
Lubrication ...........
Seals, Gaskets .. ...
. . ..
. .....
. . . . . . . . ....
. . . . . . . . . . .... ......
. . . . . . ...
.........
. ... .....
. . . .. B-11
. ... . ... . . . .
Bearings, Oil Seals.
. . . .......
.. . .... ....
. ....
. . ... .. . ........
Electric Motor . . ....
. . . . . ............ .. ..........
. .......
.. ............
..... . B-14
. . . . .........
. ..... . . . ....
. . . . . .......
.. .. . . . ... . . .......
. . . ..........
. . . . ........
.... B-15
General Construction of Motor ........
.
.. . . . ..
..........
... . . . ..
..
. . .. ...
. .. B-16
. ......... .. ..
. ..... . ......
Motor Inspection and Start-up .....
. . . . ......
. . . .
. . . . . ......
. . . .. .....
. . . .....
. .. ..
. ....
.. ....
. .... . B-17
B-1 7
Motor Bearings and Oil Seals .... . ..
.. . . .
. ...
.. ....
.. .. . . . ..... . . . . . . . .. ... . . . . . . . ....
. . . .......
. .. . .. . ....
. . . . ....
. . . . B-20
Gearmotor Disassembly, Assembly . . .........
Troubleshooting and Repair ...........................
.....
. . . . . . . . . . . . . . . . . . . ..
. . . .. ..
. . . ......
. . B-22
. .... ...
......
.. . . . ...
Maintenance, Inspection, Ordering Replacement Units or Parts, Storage ......
. . .. .. . ..
. . . .....
. .. .....
.. . ... . ...
. . ... B-24
SM-CYCLO BRAKEMOTORS
SMCYCLO

. .. . . . . ....
General Construction ..
. . . . . ...
. . . . . . . .
. .
. . ....
. . . ., . ..
. . . . ...
. . . . . .. .. . .. . . _ ..... . . . C-3
FB Models Standard Specifications ......
. . ....... ... ... . ..
. .
. . .
. . .... .. ...
....
. ......
.. . . .. ...
..
. . . ..
. . .....
...... C-4
Construction , Operation & Maintenance .....
. . . . . . . ........
. . . . . . . . . .....
. . . . . . . ... . . ......
. . . . . . . .... . .. C-5
FB Models Construction,
FB Models Wiring Diagrams ....................
. . ....
. . .. ...
. . . . .... .
. ......
. .. . C-1
C-100
.... . . . . ... .. ..... . . . .......
. . . .... .
. .. _ .. .. .. ..
FB Models Troubleshooting .. . . _. .. . . ....
....._
. . . . ...
. . . ... . . .. . . . .. . . . . .....
. ... . ...
... . ......
... . .. . C-12
Model CMB-20 ....
. . .. . ... ... . . .. .................................
..... .. . . .... ....................
Model
... . ... . ..........
..... . C-13

WARNINGS
,..
". Consult factory ifIf SM-Cyclo
SM -Cyclo speed reducers are driven by D.C. motors
motors,, variable
frequency A.C. drives, or speeds other than standard catalog input speeas.
speee s.
,..
re to ins
tall and operate SM-Cyclo
).0- Be su
sure
install
SM -Cyc lo speed reducers
reducers,, gearmotors and
brake
motors in compliance
brakemotors
comptiance with
wit h applicable local and national
nat ional safety codes.
codes .
Appropriate guards for rotating shafts should be used and are available from the
factory.
,..
).0- When using
uSing SM-Cyclo speed reducers
reducers,, gearmotors
geamnotors or brakemotors in a system for
human transport, install a secondary safety device in order to minimize the risk of
accidents that may result in personal injury, death or equipment damage.

21233A IQUITOS - PL #20748

SM-CYCLO
SPEED REDUCERS

21233A IQUITOS - PL #20748

SECTION A CONTENTS
Mounting ..........
_. A-2
. ....
General Construction
...............
... A-3, 4
...........................
. .. . .... .. A-5-10
Lubrication .................
Grease Units.
Units .........................
. ..... A-7, 8
.. A-7
Designated Greases ..................
Grease Replenishment & Change ........ A-7
.. A-7, 8
Quantities of Grease ................
. .... A-8 - 10
Oil Units ..
..........................
...... A-8
Oil Fill Procedure,
Procedure, Oil Gauge
Standard Oils .........
..................
. ............
. .. A-8
... A-9
Oil Quantities
......... .. . .. ....

. . .. .. .. ....
Allowable Oil Viscosity
... A-9
Oil Change ___ ....... .
......
. .. A-9
........ A-9
Forced Lubrication
..........
Oil Level Dimensions
......
___ A-1
0
A-10
Bearings, Oil Seals & Gaskets ...........
.... A-11-13
Dissassembly, Assembly ...............
..
. A-14, 15
Daily Inspection ...........
. .... A-16
Ordering Correct Replacement Units & Parts ... A-16
Storage & Operation After Storage .......... A-16
Trouble Shooting. . . . . . . . . . . . . . .
. .. A-17
. .. A-18
Notes .................................
. ..

Mounting
1. Mounting on Exact Planes
The Horizontal Type oil-lubricated units must be
mounted on horizontal surfaces. Where they are
surfaces, some modifications may
mounted on inclined surfaces,
necessary. Specify mounting plane inclination at time
be necessary.
of ordering.
2. Accurate Alignment
Where the reducer is connected to the motor and the
driven machine through couplings, align the shafts
accurately. Where the reducer is connected through V
pulleys or sprockets, insure that the belts or chains are
neither too tight nor too slack.
slack.
3. Overhung Load Positions
Overhung loads should be located as close to the
SM-CYCLQ3 6000 Series
bearing as possible. (See the SM-CYCLOO
Catalog page E-8.)
4. Foundations
Foundations must be rugged enough to withstand shock
and stress applied from the load side through the
reducer.
reducer.

A-2

Correct

Incorrect

Reducer Wall

Reducer Wall

Square And Parallel

5. Secure Housing
Where the reduction units are operated under conditions
of vibration andlor
and/or frequent starts and stops, it is
recommended to secure them on their mounting
surfaces by inserting dowel pins into the knock-holes
provided on the foot of the casing
casing.. This will insure that
bending or shearing forces are reduced on the mounting
bolts. Pins must be securely inserted, particularly when
the units are to be operated under conditions of severe
recurrent peak loads.

6. Mounting Accessibility
The reduction units must be mounted in locations with
easy accessibility for lubrication maintenance purposes.

7_ Ventilation
7.
When the SM-CYCLO Speed Reducer is mounted in a
separate enclosure, be sure that adequate ventilation is
provided.

Correct Method

Incorrect Method

21233A IQUITOS - PL #20748

GENERAL CONSTRUCTION
Fig. A-1
A-1 Speed Reducer - Horizontal Foot Mount, Single Reduction

Table A-1. Speed Reducer


Main Parts
Part No.

13
12
25
18
104H

106

10
19
301
11
3-13
308
303
3-11
311

305

304

202

203

204
2-04

201

Fig.
Fi
g. A-2 Speed Reducer - Vertical Base Mount, Single Reduct
Reduction
ion

r----------------- 58

28
41 ---------\
39

46
42---.....:c+
42------'=e.t (43)
t(43)

38-----I::::::r=....L~~
38
----t:::~..L~g
35------------------/
35 ------- - - - - - - - - - - - /

59
40

Note: For details of oil seals, bearings or gaskets, refer to A-11 - 13.
tAeter to Table A-16 on Pg
Pg.. A-9 for units which require a positive displacement pump.
Pt. No. 58 - frame sizes 6195-6275 only
only;; Pt. No. 59 - frame sizes 6205-6275 only.
HSee
"See Fig. A-3, Page A-4
A-4;; f See Fig. A-4, Page A-4.

101
102
103
104H
104H
106
2-01
201
2-02
203
204
205
301
302
303
3-04
3-05
305
"306
3-07
307
3-08
308
3-09
309
3-10
310
3-11
311
3-13
ft 5-01
501
ft 5-02
502
f5-03
t5'03
f5-04
t5'04
6
7
8
9
10
11
12
13
14
ft15
15
18
19
25
26
28
29
35
38
39
40
41
41
42
43
46
1'55
f 55
1'57
t57
-58
-59

Part Name
Slow Speed Shaft w/pins
Bearing A
Bearing B
Oil Seal Collar-Horizontal
Slow Speed Shaft Rollers
Ring Gear Housing
Ring Gear Pins
Ring Gear Rollers

Cycle Disc
Spacer Ring

High Speed Shatt


Bearing C
Bearing 0

Eccentric Bearing Assembly


Eccentric Key
Balance Weight

Spacer
Spacer
Spacer
Retaining Ring
Retaining Ring
Collar
Intermediate Shaft w/Pins
Bearing F
Bearing G
Eccentric Bearing Assembly
Gasket Set
Casing Nuts & Bolts
High Speed End Shield
Cooling Fan & Set Screw
Fan Cover
Fan Key
Bolts For SS Oil Seal Housing
Bolts,, Spacers For Fan Cover
Bolts

Plug
Grease Nipple
Stow Speed Output Oil Seal
Slow

High Speed Input Oil Seal


Horizontal Oil Seal Housing
Horizontal Case

Oil Fill Plug


Oil Gauge-Horizontal Unit
Vertical Oil Seal Housing
Vertical Case (Integ
(Integral
ral V Type)
Oil Gauge-Vertical Unit

Cam
Piping Set & Oil Signal
Plunger Pump
Positive Displacement Pump

Drain Plug
Intermediate Cover
Eye Bolt

Oil Slinger
Spacer

A-3

21233A IQUITOS - PL #20748

GENERAL CONSTRUCTION
Fig. A-3 Speed Reducer/Single Disc
Type (Frame Size 6060-6095)

Fig . A-4 Speed Reducer/Double Reduction

15

Speed Reducer - Single Disc


SM-CYCLo" single reduction, Models No.
SM-CYCLO'
No. 6060-6095,
employ the use of a single planetary gear (Cycloid
Disc) and a balance weight.

Multiple Reduction Reducers


Multiple reduction SM-CYCLO' Reducers are a combi
nation of standard reduction mechanism assemblies
connected using an intermediate shaft (Part No.
No. 501)
501 )
and intermediate cover (Part No. 55) between th
them
em..

Table A-2. Frame Sizes and Ratio Combination of Double Reduction Models
Frame Size Combination

Frame
Size
6060DA
6065DA
6070DA
6075DA
6090DA
6095DA
6100DA
6105DA
6120DA
6120D8
6120DB
6125DA
6125DB
6125D8
6130DA
6130DB
6130D8
6130DC
6135DA
6135DB
6135D8
6135DC
6140DA
6140DB
6140D8
6140DC
6145DA
6145DB
6145D8
6145DC
6160DA
6160DB
6160D8
6160DC
6165DA
6165D8
6165DB

A-4
A4

Second

First

Stage
6060
6065
6070
6075
6090
6095
6100
6
105
6105
6120
6120
6125
6125
6130
6130
6130
6135
6135
6135
6140
6140
6140
6145
6145
6145
6160
6160
6160
6165
6165

Stage
6060
6065
6065
6065
6075
6075
6075
6075
6075
6095
6075
6095
6075
6095
6105
6075
6095
6105
6075
6095
6105
6075
6095
6105
6095
6105
6125
6095
6105

Reduction Ratio Combination


First
Second
Total
Stage
Stage
Ratio
Ratio
Ratio
104
13
8
11
11
121
143
13
11
165
15
11
195
15
13
231
21
21
11
273
21
13
11
319
29
377
29
13
473
43
11
43
13
559
649
59
11
731
43
17
841
841
29
29
1003
17
59
43
1247
29
87
17
1479
1849
43
43
2065
59
35
2537
59
43
3045
87
35
3481
3481
59
59
4437
51
87
87
5133111
59
5133'"
6177
71
87
7569
87
87
[11 For frame
fram e sizes 6205DA, D8
DB or DC - 6265DA, D8
DB or
Note:
Note. [t]
DC, second stage ratio is 59 and first stage ratio is 87.

~~t~;

21233A IQUITOS - PL #20748

LUBRICATION
Standard Type Mounted Reducer (Slow Speed Shaft Horizontal)l,,2
Horizontal)[1,2]]
Table A-3, Horizontal Mounted Single Reduction Reducers
Ratio
~n

Frame Size
S ize

60606065
60706075
60806085
60906095
61006105610H
61106115
61206125612H
6130 6135
61306135
61406145614H
61606165616H
61706175
61806185
61906195
6205
6215
6225
6235
6245
6255
6265
6275

5
1 5

11

8
1 8

23

15

17

21

25

29

35

43

51
51

59

71

87

119

59
87~

Grease
Maintenance
Maintenance- Free Grease Lubrication
Lubrication (MF)

Lubricated
Lubricated
(G)

,--,------

Oil Bath Lubrication (PS)


(PB)

,
-,------

,
-,------

Table A-4.
A-4. Horizontal Mounted Double Reduction Reducers

~n
Ratio

Frame Size

60600A 60650A
60700A 60750A
60900A 60950A
61000A 61050A
61200A 612006
61250A 612506
61300A 61350A
613008613506
61300C 61350C
61400A 614006
61400C
61450A 614506
61.50C
61600A 61650A
616006616506
61700A 61750A
617008617506
61800A 61850A
61600C 61650C
61700C 61750C
618006618506
61900A 61950A
619006619506
62050A 620506
62150A 621506
62250A 622506
62350A 623506
62450A 624506
62550A 625506
62650A
62750A

104 1121 1143 165 1195 1231 1273 1319 13n I473 1559 1649 1731 1841 1'00311015 1'247 1479 1849 12065 12537 13045 13481 14437 I51 33IS1n 17569

LJ
'--

MaintenanceMaintenance-Free
Free Grease Lubrication (MF)

5133L

Grease Lubrication (G)

165

0D

Oil Bath Lubrication (PS)


(PB)

3n

Notes: [1]
(1] Tables A-3
A3 and A-4 show the standard lubrication method when the Cyclo drive is driven at the standard
standa rd Input
input speed.
speed.
[2] Ratios shown in white in Tables A-3 and A4 are unavailable for
for the given unit sizes.
sizes.

A-5
A5

21233A IQUITOS - PL #20748

LUBRICATION
Vertical)[1,2,3]3!
Standard Vertical Mounted Reducer (Slow Speed Shaft Vertical)11,2,
Table A-S.
A-5. Vertical Mounted Single Reduction Reducer

~n
Ratio

Frame Size

60606065
60706075
60806085
6080 6085
60906095
61006105
611061 15
61206125
61306135
61406145
61606165
61706175
61806185
6190 6195
6205
6215
6225
6235
6245
6255
6265
6275

5
5

66

8
1 8

11

13

15

21

17

25

29

35

43

51

59

71

87

119

59
87~
87~

(M F)
Maintenance-Free Grease Lubrication (MF)
Grease
Lubricated
(G)

- --,

Oil Bath Lubrication (PB)


(PBl

,
- --

..

..
-

r--

- -r

r--

TP

- -r

TP

,
- --

TP

TP

TP. Positive
PoSItive Displacement Pump Lubrication
Lubncatlon (see Table A-16.)
TP.
A- 16.)

Table A-S.
A-5. Vertical Mounted Double Reduction Reducer

Frame Size

Ratio 104 121 143 '65 1'95 123' 1273 13'9 1377 1473 1559 1649 173' 184' 1'003 1'01511247 1479 1849 12065]2537 3114513481' 443715133j6m I7569

60600A 60650A
60700A 60750A
60900A 60950A
61000A 61050A
61200A 612006
61250A 612508
61300A 61350A
613008613506
61300C 61350C
61400A 614006
61400C
61450A 614506
61450C
6160oA61650A
616006616506
61700A 61750A
617006617506
61800A 61850A
61600C 61650C
61700C 61750C
618006618506
61900A 61950A
619006619506
62050A 620506
62150A 621506
62250A 622506
62350A 623506
62450A 624506
62550A 625506
62650 A
62750A

LJ

LJ

5 13 3 L

MaintenanceFree Grease Lubrication (MF)


Maintenance-Free

Grease Lubrication (G)

473
641
1015

165

..

1649

~
2537

(P)

'j
TP : Positive
Dis lacement Pum Lubrication see Table A-16

Notes: [1] Please consult the factory for applications where the slow speed shaft is up.
[2] Tables A-5 and A-6 show the standard lubrication method when the Cyclo
Cycla drive is driven at the standard input
in put speed.
[3] Ratios shown in white in Tables
Tabl es A-5 and A-6
A6 are unavailable for the given unit sizes.

A-6
A6

21233A IQUITOS - PL #20748

Table A-7. Standard Greases[1]

Lubricants

SMCyclo

Grease Lubricated Models

Ambient Temperature[2
Temperature[2jj

Those models listed in Tables A-3 - A-6 as grease


lubricated are filled with grease before shipment to the
customer and are ready for use.

OF
of

Shell Oil

14

-10

to

Shell Alvania"
Alvania"
Grease 2

50
SO

(NLGI Grade #2)

to

II

122

Speed Reducer

Table A-B. Grease Replenishment and Change Interval


Model
Single and Double Reduction
Maintenance Free Type

Condition

Interval[3j
Interval[3]

Replenishment

NOT REQUIRED

Overhaul[4]

Every 20,000 Hours or


Every 4 - 5 Years

Replenishment
Double Reduction
Change

Less Than 10 Hours Per Day


Operation

Every 3 - 6 Months

10 - 24 Hours Per Day Operation

Every 500
SOO - 1000

Speed Reducer Mechanism, High


Speed Shaft Bearings (Speed
Reducer Type)

Every 2 - 3 Years

Slow Speed Shaft Bearings

Every 3 - 5 Years

Replenishment and Change Guidelines


Replenish grease to the reduction mechanism 1/3 to 1/2 of
A-1 0 for the first reduction
the quantity listed in Table A-9 or A-10
A-B.
stage at the interval recommended in Table A-8.

Apply grease liberally to the central part (i.e., around the


eccentric bearings) of the mechanism
mechanism.. Apply grease to both
the slow speed and high speed shaft bearings as you would
to ordinary bearings at the time of re-assembly.

overhauling . refill with


When the unit is disassembled for overhauling,
the grease quantities indicated in Table A-9 or A-10. Or
alternatively. 80% of the space around the reduction
alternatively,
mechanism and slow speed shaft bearings of single
units. and 50% around the reduction mechanism
reduction units,
of both the first and second stage of double reduction units.

If excessive grease is added, agitation heating of the grease


will raise the operating temperature of the unit. Avoid
excessive greasing, but do not supply an insufficient amount
of grease. When the grease is insufficient, it will raise the
unit's operating temperature due to breakdown of the
lubrication films on the eccentric bearing. In this case, if the
operating temperature rises, supply grease immediately.

Slightly larger quantities may be supplied to lower reduction


units, and somewhat smaller quantities for high
ratio units.
reduction ratio units.
Table A-g.
A-g. Single Reduction Grease Quantities - oz. (g.)
Frame Size

6060
606S
6065

6070
6075

6080
6085

6090
6095
3.2 (90)

Speed Reduction Mechanism

0.9 (2S)
(25)

2.3 (65)
(6S)

Slow Speed Shaft Bearing

1.2 (35)
(3S)

2.S (70)
2.5

6100
6105
610H

6110
6115

6120
6125
612H

4.9 (140)

7.1 (200)

11.6 (330)

3.2 (90)

4.2 (120)

I
I

3.S (100)
3.5

Notes: [1] Avoid the use of grease other than shown in Table A-7.
[2] Consult the factory when the drives are used under widely fluctuating temperatures, ambient temperatures other than those listed in
Table A-7, or any other special conditions.
[3]Single
[3] Single reduction frame sizes 6060 - 612H and double reduction frame sizes 60600A - 61250B are maintenance free units. Grease
replenishment is not necessary. Where longer life of the drive is expected or if re-Iubricating is preferred before the recommended
interval, refer to Tables A-7, A-a, A-9 and A-10.
A-l0.
[4] Overhauling consists of disassembling the unit, replacing the seals and gaskets, cleaning the internal parts and then repacking the unit
with designated grease.

A-7

21233A IQUITOS - PL #20748

LUBRICATION
Table A-l0. Double Reduction Grease Quantities - oz. (g.)
60900A 61000A
60600~ 160700A
1 60700~ 160900A
61000~ 1 61200~ 1612008 61300~ 1613008
1~'3008 61300C 1 61400~ 1 61400~ 161400C
60650A 60750A 60950A 61050A 61250A 612508 61350A 613508 61350C 61450A 614508 61450C

Frame Size
Speed Reduction
Mechanism
Mechanism (1st Stage)

0.9
(25)

Speed Reduction
Mechanism (2nd Stage)

0.9
(25)

Slow Speed Shaft


Shafl
Bearing (2nd Stage)

1.2
(35)

3.2
1 (90)

4.9
4.9
(140)
3.5
(100)

3.2
1 (90)
11.6
(330)

0.9
(25)

3.2
(90)

Speed Reduction
Mechanism (1st Stage)

3.2
(90)

I
1

4.9
4.9 1 11.6
(140)
(1 40)
(330)

3.2
3.2
(90)

4.9
(140)

3.2
(90)

1 11.6
(330)

4.9 1 15.9
(140)
(450)

11.6
11 .6
(330)

35.3
(1000)

38.8
(11
00)
(1100)

52.9
(1500)

Shaft
Slow Speed Shafl
(2 nd Stage)
Bearing (2nd

10.6
(300)

17.6
(500)

21.2
(600)

24.7
(700)

62150A 1621508
15.9
(450)

1 26.5
(750)

62250A 1 622508
15.9
(450)

62350A 1 623508

1 35.3
(1000)

26.5
(750)

38.8
(1100)

62450A 1 624508
26.5
(750)

38.8
(1100)

11 .6
15.9 1 11.6
(450)
(330)

26.5
(750)

Frame Size

4.9
(140)

1 62050A 1620508
161900~
619508

Speed Reduction
Mechanism (2nd
(2 nd Stage)

Speed Reduction
Mechanism (1st
(151 Stage)

10.6
(300)

61600~ 1616008
1 61600~ 161600C
61600C 61700A
61700~ 161700~
~1700~ 161700C 61800~ 1618008 61900~
61650A 616508 61650C 61750A 617508 61750C 61850A 618508 61950A

Frame Size

15.9
(450)

4.2
(120)

0.9
(25)

4.9
1
(140)

1 15.9
(450)

62550A 1625508 1 62650A


52.9
(1500)

35.3 1
(1000)

Speed Reduction
Mechanism (2nd Stage)

70.5
(2000)

88.2
(2500)

141 .1
(4000)

158.7
(4500)

211.6
(6000)

Slow Speed Shaft


Bea ring (2nd Stage)

28.2
(800)

31.7
(900)

35.3
(1000)

38.8
(11 00)

42.3
(1200)

282.2

I (8000)
45.9
I (1300)

Oil Lubricated Models


Oil Fill Procedure
Oil lubricated models are not filled with oil prior to shipping.
shipping.
start up, remove the oil fill plug (See Pg.
Pg . A-3,
Before start-up,
Fig.
Fig. A-2, Part #28) and fill the reducer with recommended
oil. Refer to Tables A-11 - A-14 for standard oil
oil,, allowable
viscosity, quantity, and change interval. The oil level must
be to the upper red line on the oil level gauge while the unit
is not operating, and above the lower red line during
operation. If too much oil is supplied, the unit's operating
temperature will rise due to the churning heat of the oil , or
oil will leak across the high speed shaft oil seal.
Before filling a vertical base type unit with oil, remove the
#14).. After filling,
vent plug (Pg. A-3 , Fig . A-2 , Part #14)
filling , apply
teflon sealing tape to threads of the vent plug before
installing .
installing.
When draining oil,
oil, remove drain plug (Fig. A-5, Part #46) or
lower side plug of the oil level gauge.

Oil Level Gauge


The gauge must be replaced when it becomes difficult to
hose.
check the oil level due to discoloration of the vinyl hose.
Use the standard vinyl oil gauge for a reducer
redu cer operating in
ambient temperature -4'F
-4' F to 100' F (-20'C
(-20' C to 40' C). Where
the reducer is used at ambient temperatures greater than
100' F (40' C) or less than -4' F (-20' C), a glass gauge set
or a dipstick is recommended.
The oil level gauge can be attached on either side of the
units. Attach on the side that is most
casing on horizontal units.
convenient for checking the oil level. (The oil level gauge is
usually attached on the right side when viewed from the
slow speed shaft end
end.)
.)

Table A-ll.
A-It. Standard Oils
Ambient
Temperature[l.t1
Temperature{'~l

'F

GulfOU
Gulf
011

Exxon Oil
all

Mobil Oil
011

Shell 011

BPOII
8POII

Spartan~
SpartanEP 68

Mobilgear" 626
(ISO VG 68)

Omara~ Oil
Omala
68

e
Energol~
Energol
GR-XP 68

Omala- Oil
100,150
100.150

Energol
Energot*'
GR-XP 100
GR-XP 150

Omala- Oil
220,320,
460

Energol
EnergolGR-XP 220
GR-XP 320
GR-XP460

14t041
14 to 41

-10to 5

EP Lubricant
HD68
H068

o to 35

EP Lubricant
HO
HD 100
HD 150
HO

Spartan-

32 to 95

EP 100
tOO
EP 150

Mobilgear" 627, 629


(ISO VG 100, 150)

SpartanEP 220
EP 320
EP460

Mobilgear-Mobilgeare

30 to
50

EP Lubricant
Lu bricant
H0
HD 220
HD
HO 320
HD
HO 460

86 to
122

Fig.A-S

'C

630,632
630.632
633,634
(ISO VG 220-460)

..

-0:
~:
0

Q
0

"~

Notes. [1] Use the lower vIscosIty


VISCOSity 011
011 specIfIed
speCified for each ambIent
ambient temperature range for use In winter
wInter or relatively
relatIvely low ambient temperatures.
[2] Please consult the factory for consistent use in
in ambient temperatures other than 32F
32F" 104F (DOC
(OC " 40C).

A-8

""

21233A IQUITOS - PL #20748

Table A-12. Oil Fill Quantities!l]


Quantities!1]
Single Reduction
Mounting Configuration
Horizontal
Vertical

Frame
frame Size

Double Reduction
Mounting Configuration
Horizontal
Vertical

Frame
frame Size

U.S.
u .S. gal.

liter

U.S.gal.
u.S. gal.

liter

6130.6135

0. 18

0.7

0.29

1.1

6160DC, 6165DC

U.S. gal.

6140, 6145,614H
6145. 614H

0.18

6170DC, 6175DC

0.37

0.29
0.26

1.1

6160,6165. 616H
6160,6165,616H

0.7
104
1.4

0.40
0.63

1.0

6180DB,6185DB

0.92

liter
1,5
1.5

U.S. gal.

liter
1.0

6170, 6175
6170,6175

0.50

1.9

0.50

1.9

6190DA,6195DA

1.5

5.8

6180,6185
6180.6185

0.66

2.5

0.53

2.0

6190DB,6195DB
6190DB,
6195DB

1.6

6.0

0.26
0.50
0.53
0 .53
0.7
0.711
0.71

6190,6195

1.1

4.0

0.71

2.7

6205DA.
6205DA, 6205DB

1.6

6.0

2.9

11

6205

1.5

5.5

1.5

5.7

6215DA,6215DB

2.6

10

3.7

14

6215

2.2

8.5

2.0

7.5

6225DA, 6225DB

2.9

11

4.8

18

6225

2.6

10

2.6

10

6235DA, 6235DB
6235DA.

4.5

17

6.1

23

6235

4.0

15

3.2

12

6245DA, 6245DB

4.8

18

7.7

29

6245

4.2

16

4.0

15

6255DA, 6255DB

6.1

23

11.1

42

6255

5.5
5
.5

21

11.1

42

6265DA

8.5

32

13.5

51

6265

7
.7
7.7

29

13.5

51

6275DA

15.9

60

(15.9)

(60)

6275

14.8

56

(15,9)
(15.9)

(60)

204
2.4
3.5

1.9
2.0

2.7
2.7

( ) with trochoid pump

Table A-14. Oil Change Interval

Table A-13. Allowable Oil Viscosity


80 SUS
sus

Minimum Allowable Viscosity To

Maximum Allowable Viscosity


To Allow Easy Starting

Oil Bath

20,000 SUS
At Operation Start

Forced Oil
Lubrication

10,000 SUS
At Operation Start

Initial Oil Change

After 500 Hours of


Primary Operation

Under Every Condition

Every 6 Months

Less Than 10 Hours/Day


Operation

Every 2,500 Hours

10 - 24 Hours/Day
Operation

Subsequent Oit
Oil
Change

High Ambient Temperature,


Temperature ,
Every 1 - 3 Months High Humidity or
Atmosphere of Active Gas

Forced Lubrication For Vertical Units

Plunger Pump Lubrication

Table A-15. Plunger Pump Type


Small Size Pump

Large Size Pump


Frame Size
Ratio

Ratio

Frame Size
6160,
6175,
616O, 6165, 6170, 6t75,
6180, 6185,6190,6195
6185, 6190, 6195

6205,6215,6225,6235,
6205,
6215,6225, 6235,
See
A5 6245, 6255, 6265, 6275
Table A-5

6160DC, 6165DC, 6170DC,


6160DC,
6175DC, 6180D8,
6180DB, 6185DB,
6185D8,
See
6195DA, 6190D8,
A6
6190DA, 6195DA.
6190DB, Table A-6
6195D8
6195DB

Operation Condition

Oil Change Interval

During Operation

Maintain Lubricating Oil


011 Film

See
Table A-5
A5

6205DA, 6205DB,
6205D8, 6215DA,
6215DB, 6225DA, 6225DB,
6215D8,
See
6235DA, 6235DB,
6235D8, 6245DA, Table A-6
A6
6245DB, 6255DA, 6255D8,
6245D8,
6255DB,
6265DA

The plunger pump (Fig. A-2, Part #42) is automatically


operated by a cam (Fig.
(Fig, A-2, Part #40) fitted on the slow
#1-0
1)., The number of pumping
speed shaft (Fig. A-2, Part #1
-01)
cam teeth required is in direct relation to the reduction ratio
and frame size. Please consult the factory for input speeds
standard.
other than standard,

Table A-16. Positive Displacement (Trochoid) Pump Type


Trochoid Pump[2,3}

Cyclo Drive
Type

Vertical
Shaft

...,

50 Hz Zone
Max. Pressure

60 Hz Zone
Max.
Max. Pressure

Frame
Size

Reduction
Ratio

Pump Type

Pump Motor

gaUmin
gaVmin

Ilmin
I/min

psi

IImin
Ilmln

psi

6275

29 , 43 ,
59
, 87
59,87

TOP216HAVB3
TOP216HA-VB3

1 HP (0.75 kW) 4P

6.3

24.0

113.8

7.6

28.8

71.1

5.0

6275DA

All

TOP204HA-VB3
TOP204HAVB3

(004
112 HP (0
.4 kW) 4P

1.6

6.0

227.6

16

1.9

7.2

163.6

11.5

Positive Displacement
Dtsplacement (Trochoid) Pump Lubrlcatton
Lubrication
Forced oil lubrication is accomplished by using a positive
displacement pump and motor that requires an additional
electric power source. It is recommended that the main

Flow

Flow

kgflcm' gallmln
gal/min

kgf/cm 2

motor be interlocked with the pump motor to avoid operation


without lubrication. The pump must be started 30 seconds
or longer before the main motor is operated,
operated.

Notes: [1] Please consult the factory for oil quantities when the reducer/gearmotor is mounted in any other position or angle.
[2] Consult the factory when using an inverter.
2 ), is a standard aUachment
[3] A relief valve,
valve , pressure set at 42.7 psi (3 kgf/cm
kgf/cm2).
attachment on the trochoid pump
pump..

A-9

21233A IQUITOS - PL #20748

OIL LEVEL DIMENSIONS


Foot Mount Horizontal Type
Fig.A-6

.,
r-e
Frame Size:
Only 6130 - 6145

Base Mount Vertical Type


Frame Size: 6130 - 614H
Fig. A-7

~m

----'

' ,>

Table A-H . Oil Level Dimensions (Inches)

Frame Size

61306135

1.38

2.17

5.91

4.65

6140
, 6145, (614H)
6140,6145,

1.38

2.17

5.91 (6.30)

4.65

61606165, (616H)

1.57

2.76

6.30 (7.87)

33.70
.70

61600C-61650C
61600C61650C

1.18

1.77

6.30

3.70

A
A

8
B

61706175

1.97

3.35

7.87

4.96

1.85

2.72

7.52

61700C61750C

1.18

1.77

7.87

4.96

61806185

2.17

3.94

6.66
8.66

5.91

61800B-61850B
616008616508

1.38

2.17

6.66
8.66

5.91
6.61

61906195
6190-6195

2.26

3.25

9.84

61900A-61950A
61900A61950A

1.18
1.16

1.77

9.84

66.61
.61

61900B-61950B
619008619508

1.38

2.18

9.84

66.61
.61

6205

2.12

3.19

9.84

6.06

62050A

1.26

1.93

99.84
.84

6.06

62050B
620508

1.26

2.13

9.84

6.06

6215

2.05

3.03

10.84

6.85

62150A

1.18

1.97

10.43

6.85

62150B
621508

1.57

2.76

10.43

6.85

6225

2.25

3.43

11.03

6.85

62250A

1.26

2.05

11.03
11
.03

6.85
6.85

Base Mount Vertical Type


Table A-18. Oil Level Dimensions (Inches)
Frame Size: 6130 - 614H

5.79

Base Mount Vertical Type


Frame Size: 6160 - 6275
Fig.A-8
Fig. A-8

r------,

1
)B
~____________
~
_____________~e
JI~I

rH---...I~AA

I
!I

Base Mount Vertical Type


Table A-19. Oil Level Dimensions (Inches)
Frame Size:
Size' 6160 - 6275

62250B
622508

1.85

3.43

11.03
11 .03

6235

2.48

3.47

11 .81
.81

7.64
7.84

Frame Size

B
8

te

62350A

1.57

2.75

11.81
11 .81

7.64

61606165,616H
61606165,
616H

1.02

1.42

4.68

2.72

62350B
623508

1.97

3.35

11.81
11 .81

77.64
.64

6170
6175
61706175

1.69

2.48

6.02

3.78

6245

2.76

3.78

13.19

8.46
8 .46

6180-6185
61806185

1.93

2.72

6.81

4.25

62450A

1.65

2.72

13.19

8.46

61906195

2.09

3.27

7.87

5.47

62450B
624508

2.00

3.35

13.19

8.46

6205

1.46

2.05

7.09

3.54

6255

3.19

4.17

14.76

9.02

6215

1.46

2.05

7.09

3.54

6225

1.46

2.05

7.87

3.54

6235

1.46

2.05

7.72

3.54

6245

1.46

2.05

7.96

3.54

A-10

62550A

1.97

3.35

14.76

9.02

62550B
625508

2.05

3.23

14.76

99.02
.02

6265

3.23

4.21

15.75

10.16

62650A

2.28

3.27

15.75

10.16

6275

3.35

4.53

21.26
21 .26

11.22
11 .22

'6255

4.33

4.92

19.76

6.57

62750A

2.26

3.25

21.26
21 .26

11 .22
11.22

'6265

4.65

5.24

21.69
21
.69

7.17

6275

1.97

2.76

13.39

5.51

-Note:
Note: V6255 & V6265 all
011 Gauge IS on the Ring Gear HOUSing
V-Casing..
instead of V-Casing

21233A IQUITOS - PL #20748

BEARINGS, OIL SEALS, GASKETS


Fig. A-9

Slow Speed Shaft

High Speed Shaft

Table A-20. Slow Speed Shaft Bearing


Frame Size
du(tlon
106

Sin

Double Reduction
6060DA.6065DA
lA

Bearing

Slow 51> ted Shaft


art #1-02
Bearing

'art #10:

lOB
109
61

10H

61

12H

61

14H

6090DA. 6095DA
61 oODA. 6' 05DA

6130DA.
6140DA.
616UUA,
6170DA.

DA.6125DA.
DA.6130 DB.
DA.6 1 DB.

.6'
.6'
.6'
.6'

"I'

.6135[
.6145[
.6165D(
,6175l

22;
;1'1

3TM

I
22' I

,61B
.619

DA,
DA.

I
~2
m~2

~2

N'
N'
N'
NL
2,

;2
14(;2
16C2

<R

Table A-21 . High Speed Shaft Bearing


High Speed lhaft
:haft

Frame Size
Single Reduction

Double Reduction

6060.6065
6U6U,
6065

6060DA. 6065lJA. 600DA. 6075lJA

6070,6075
6070.6075

6090DA,
6090DA.

~:~r~~~;

6301

6301Z

607YXX

6302Z
6302,
Referta
Aeferta
Table A22

I 611YSS.
y~~, 611GSS
611~~~

Referta
Aeferta
Table A22

6090,6095

612UU",
6120D8,

~;~~~~,
~;~~~~, ~;~~~~,
~;~~~~ 6145DB,
~~~~~~, ~~~~~~,
~~~~~~, ~~~~~~
6145lJB,

6302RSH2

6302Z

6130DC,

~;~~~~, ~;~~~~'.
~~~~~~'. ~;~~~~:
~~~~~~: ~~~~~~'
~;~~~~.
~~~~g~, 6165D8,

6302RSH2

6302Z

6302RSH2
6302 H ~ H 2

6302,
6302<:

6120, 6125,612H

6160DC, 6165~~956~r~~~05~r5D(;,
6165~f9566~0~fo5~X5DC, 6190DA,
6190DA,

6304

6305Z

6130,6135

6180DB, 6 1 85~:;;~1~~:256~15DB
6180lJB,
85~:;566~~~:2566~5LJB,, 6205DB,
6205LJB,

6305

6306

14H
4H
;16H
16H

61~
61

611 ,
61E

625
626
627

6;
621~

5R
SA
7R
1R

'35DA,,6245DA
6245DA
,6255lJB
DB
,6245DB
DB
DA,6275DA
,6275DA

Qty.
IOty

6301SH

6100,6105,610H
100, 105,
6110,6115
61 ,6115

~~~e;;~~~
~~~e;;:
60 ,XX

~~;~~~,
~;~~~~', ~;~~~,
~;~~~ 6125DA,
~~~~~~, ~~~~~~,
~~~~~~, ~~~~~~

6080,6085
6080.6085

~:~r~~~o~
630

630

,V,
lEV:
,V16
16
,V
,V'
,V,
OV'
N, 3tE OV
,V'
,V'
N,
OV
,J4
~J4

N,
N,
NJ
N,
N,
N,
N.
N,

6306
6308
640
09
21
21

11V'
IV'
12V'
14V
15V
18V
lBV
222:
22BL'

;X
Y~X
;X
;18YS;
;19YS;
5X
320(lX:

;xx
<x

iX;
7GXX

2
2
2
2
2
2
2
2
2
2

Note. [1]
Note:
[1} For grease lubncated
lubricated models, a sealed bearing should be used, whIch
which changes the followmg
follOWing letters In the part number to those shown In
bold: NR (SId.)
(Sid.) - ZNR;
ZNR ; NXR - ZNXR ; None - add Z.

A-1
A-111

21233A IQUITOS - PL #20748

BEARINGS, OIL SEALS, GASKETS

Slow Speed Shaft

Intermediate
Inte
rmediate Shaft
(For Double Reduction Units)

A-22. Eccentric Bearing


Table A-22.

High Speed Shaft


Shalt

frame Size
High Speed Shaft,
Shalt,
Motor Shaft
Part #3-04

~
Shaft
Shalt
Part #504

6090, 6095

6100, 6105

6120, 6125

6130,6135
6130,
6135

6140, 6145

6160, 6165

60900A
60950A

61000A
61050A

61200A, 61250A
61200A,61250A
61200B,61250B

61300A, 61350A
61300B, 61350B
61300C, 61350C

61400A, 61450A
61400B, 61450B
61400C, 61450C

61600A,61650A
61600A, 61650A
61600B, 61650B
61600C,
61600C , 61650C

Reduction
Ratio

60906YRX

610060BYRX
6100608YRX

612060BYRX
6120608YRX

6140611YSX
6140611
YSX

6140611YSX

616060BYRX2
6160608YRX2

8
B

6090B15YSX
6090815YSX

6100608YRX
610060BYRX

6120608YRX
612060BYRX

61406 11YSX
6140611YSX

6140611YSX

6160608YRX2
616060BYRX2

11

6090B1 5YSX
6090815YSX

6101,.,5YRX
6101 1-1 5YRX

6121115YSX

614061
1YSX
61406 11YSX

6140611YSX

6161,.,5YSX
61611-15YSX

13

6090815YSX
6090B15YSX

61011-15YRX
6101"'5YRX

6121317YSX

6141317YSX

61413
17YSX
6141317YSX

6161,.,5YSX
61611-15YSX

15

6090B15YSX
6090815YSX

6101115YRX
6101"'5YRX

612
1115YSX
6121115YSX

614131 7YSX
6141317YSX

614131
6141317YSX
7YSX

6161,.,5YSX
6161 115YSX

17

60917YSX

61017YSX

6121317YSX

61413
614
13 17YSX

61413 17YSX
6141317YSX

6161725YSX

21
21

60921YSX

61021YRX

61221YRX

6142125YSX

6142125YSX
6142
125YSX

6161725YSX

25

6092529YSX

6102529YRX

6122529YSX

6142125YSX

6142 125YSX

6161725YSX

29

6092529YSX

6102529YRX

6122529YSX

6142935YSX

6142935YSX

6162935YSX

35

60935YSX

61035YRX

61235YRX

6142935YSX

6142935YSX

6162935YSX

43

60943YSX

61043YSX

61243YSX

6144359YSX

6144359YSX

6164351YSX
6164351YSX

51

60951YRX

61051YRX

6125159YSX

6144359YSX

6144359YSX

59

60959YSX

61059YRX

6125159YSX

6144359YSX

6144359YSX

61659YSX

71

60971YRX

61071YRX

61271B7YSX
6127187YSX

61471B7YSX
6147187YSX

61471B7YSX
6147187YSX

61671YRX2

B7
87

60987YSX
609B7YSX

610B7YRX
61087YRX

61271B7YSX
6127187YSX

6147
1B7YSX
6147187YSX

61471B7YSX
6147187YSX

616B7YSX
61687YSX

119

6091 19YSX

61011 9YSX
610119YSX

IL

g No. Stamped]
Bearin
Bearing
on
Surface
on Surface

l
Eccentric Bearing Single Type
Frame Sizes

A-12

Eccentric Bearing Double Type


Frame Sizes

Eccentric And Bearings For Eccentric


Frame Sizes

21233A IQUITOS - PL #20748

Table A-23. Intermediate Shaft Bearing


Intermediate Shaft

Frame SIze
Size

Bearing F

Intermediate Shaft
Eccentric

Part '#5-02
5-02

Bearing G
Part #5-03

60650A
60600A,
6060DA, 6065DA

6301

6909

607YXX

6070DA,
60750A
60700A, 6075DA

6301

6909

607YXX

60900A, 6095DA
6090DA,
60950A

6302RSH2

61000A, 61 050A
6100DA,6105DA

FrsmeSlze
Frame
Size

Bearing F

Eccentric
Bearing
8earlng

Part #5-02

Bearing G
Part #5-03

61800A,
6180DA, 61850A
6185DA

6407

6208

618YSX

6180D8, 618508
618008,
6185D8

6407

6213

618YSX

6007

6190DA,
61900A, 61950A
6195DA

6408

6210

619YSX

6302RSH2

6007

619008,619508
6190D8,6195D8

6408

6213

619YSX

61250A
61200A,
6120DA,6125DA

6304

6007

6205DA
62050A

NJ310EV7

6210

620GXX

612008,612508
6120D8, 6125D8

6304

6205

620508
6205D8

NJ310EV7

6310

620GXX

61300A,61350A
6130DA,6135DA

6305

6007

62150A, 621508
6215DA,
6215D8

NJ311EV16

6311

621GXX

6225DA,
62250A, 622508
6225D8

NJ312EVll

6313

622GXX

6235DA, 623508
62350A,
6235D8

NJ313EVll

6314

623GXX

6245DA
62450A

NJ314EV7

6315

624GXX

Bearing

Qty.
Oty.

Part #5-04

Refer to

Qty.

Part #5-04

6130D8, 613508
613008,
6135D8

6305

6206

6130DC,
6135DC
61300C , 61350C

6305

6206

6140DA,6145DA
61400A,61450A

6305

6007

6140D8,6145D8
614008
,614508

6305

6206

624508
6245D8

NJ314EV7

6316

624GXX

6140DC,
61400C, 6145DC
61450C

6305

6206

6255DA, 625508
62550A,
6255D8

NJ316EVI
NJ316EVl

6318

625GXX

6307R

6207

6265DA
62650A

NJ317EVl
NJ317EVI

6320

626GXX

6275DA
62750A

NJ417

22220 RH

627GXX

6307R

6208

6406

6207

617YSX

6406

6208

617YSX

6160DA,6165 DA
61600A,61650A
616008,616508
6160D8,6165D8

6160DC,
6165DC
61600C , 61650C
6170DA,6175DA
61700A,61750A
617008,617508
6170D8,6175D8

6170DC,
61700C, 6175DC
61750C

Table A-22

Table A-24. Oil Seals


Slow Speed Shaft
Shalt Part #18

Frame Size

High Spead
Speed Shaft
Shalt Part #19

Dimension (mm)

Typel1]

Dimension (mm)

Quantity

(1.0. x 0.0. x W)

Horizontal
Shaft
Shalt

Vertical
Shaft
Shalt

Typel1]]
Typel1

(1.0. x 0.0.
0 .0 . x W)

Quantity

6060,6065

D
0

30x47x8
30 x 47 x 8

17x30x6

6070,6075

0
D

30x47x8

17x30x6

6080,6085

0
D

45x62x9

17x30x6
17x30 x6

6090,6095

D
0

50x72x12

20x35x7

6100,6105

0
D

50x72x12

20x35x7

6110,6115

D
0

55x80x12

20x35x7

6120,6125

D
0

65x90x13

D
0

32x52x8

6130,6135

D
0

68x88x12

D
0

38x58xll
38x58x11

6140,6145
6140,6
145

D
0

65x88x12

D
0

38x58x 11
38x58xll

6160,6 165

D
0

85xll0x
85x110x 13

D
0

55x78x12
55 x 78 x 12

6170,6175

D
0

95x130x15
95x130x 15

0
D

60x82x 12

6180,6185

D
0

110x145x15

D
0

65x88x12

6190,6195

D
0

120x155x16

70x88xl0

6205

D
0

120x155x16

70x88xl0

6215

D
0

130x160x14
130x 160 x14

75x 100x 13
75xloox13

6225

D
0

145x175x14

75xl00x13

6235

0
D

160x190x16

85x ll
11 0x13

6245

0
D

170x200x
170 x 200 x 16

95x 120x13
95x120x13

6255

D
0

190 x 225 x 16

S
S

110x140
x14
110x140x14

6265

0
D

200 x 240 x 20

110x140x14

6275

D
0

230 x 270 x 20

120x150x14
x150x14
120

Note: [lJ
(I) D
Nole:
0 Indicates
Indlcales lip (dust proal
prool and seal lip) type.

A-13

21233A IQUITOS - PL #20748

DISASSEMBLY/ASSEMBLY
Disassembly
SM-CYCLO~ Reducers are designed to provide
SM-CYCLOS
maximum ease when disassembing and reassembling;
they require no special maintenance skills.

1. Remove the complete SM-CYCLOS


SM-CYCL~ Reducer with
adaptor (motorized type) from the driven machine.
2. Remove the plug at the bottom of the oil gauge to
drain all oil from the unit.
3. Remove the cooling fan cover and fan from those
Speed Reducers (not motorized) equipped with a
cooling fan, and stand the unit on a solid base with its
high speed shaft side down.
down . Remove the through bolts
housing,, and
for the high speed end shield , ring gear housing
side,, thus separating the unit into
lift the slow speed side
two parts so that the inner mechanism can be removed
(Figs.
(Figs. A-12 - A17).
AI7).
Note: If the reducer is motorized (C-adaptor and
coupling) remove the motor and coupling before
following the procedure outlined above. As a final step ,
remove the adaptor and cooling fan .
easily, gently drive a
4. If the unit will not separate easily,
wedge at the line X shown in Fig. A-1
on page A-3 (if
A-Ion
this produces a burr, be sure to remove it before
reassembly).
5. To lift the slow speed side, attach an eyebolt to the
tapped hole on the end of the slow speed shaft and
use a hoist or chain block (Fig. A-12).
6. Take out the slow speed shaft rollers,
rollers, item 1-06,
page A-3 (Fig . A-13). Check the slow speed shaft pins
(1-01) to see whether any rollers have adhered to
them
them..
7. Using both hands, lift out the top cycloid disc (2-04)
on the slow speed side (Fig . A-14).

8. Remove the spacer ring (2-05).


(2-05) .
B.
9. The eccentric (3-04) can be removed from the
input shaft (3-01) after taking out the retaining ring
(3-10) and the inner bearing raceway (Figs . A-15,
A-16).
Note: In certain sizes,
sizes, the eccentric bearings are
roller bearings without a retainer. Remove bearings of
the top disc before proceeding with the next step.
10. Take out the second disc located on the motor
side. (Also remove second disc bearings and
eccentric with inner bearing raceway if required.)
11. Remove the ring gear housing (2-01).
12. Follow these steps to remove the slow speed
shaft (1-01) with its bearings from the casing (26): (a)
Remove the horizontal oil seal housing (25).
(25) . (b) With
a wooden or hard rubber mallet, rap the inner end of
the slow speed shaft to expose the retaining ringo
ring"
from the outer raceway of the bearing. (c) Remove
the retaining ring. (d) Rap the outer end of the slow
speed shaft with a wooden or hard rubber mallet, and
casing.
remove it from the casing.
13. The high speed shaft (3-01) with bearings is
removed from the high speed shaft end shield (8) by
tapping the shaft end after first taking off the retaining
ring (3-11).
14. The cycloid disc is made from heat-treated
bearing steel and the spacer ring is cast iron. Take
care not to strike them together while handling.
handling .
The above instructions cover complete disassembly.
In ordinary cases, however, only the removal of the
eccentric , and removal of the
cycloid discs and the eccentric,
slow speed shaft from the slow speed end cap is
necessary.
necessary.
ONate:
"Note: Retaining ring is part of bearing A
(Part No. 1-02).

Assembly
SM-CYCLOReducers are reassembled by reversing
SM-CYCLOS
the disassembly procedure. Care must be taken to
exclude dust or foreign matter from the moving parts,
parts,
and to see that gaskets are properly placed to make the
assembly oil-tight.
Following are some helpful points to remember when
assembling SM-CYCLO
SM-CYCLOS Reducers.
1. Set the ring gear housing and insert the ring gear
rollers;; then test-rotate the pins and rollers by
pins and rollers
hand . (Apply grease liberally to the ring gear pins and
rollers before they are inserted in grease lubricated
SM-CYCLOReducers.)
SM-CYCLoe
2. Cycloid discs are a matched pair. Each carries the
same number stamped on one side of the disc.
3. Set the cycloid disc with the stamped number face up
as shown in Fig. A-17.

A-14

4. Insert the spacer (3-07) and then insert the


eccentric with bearings by rapping with a wooden or
hard rubber mallet (Fig. A-16).
5. Insert the other spacer and the inner bearing
raceway. Secure them with the retaining ring
(Fig
(Fig.. A-15).
6. Set the spacer ring in place.
7. Insert top disc in such a way that the mark is
lBO' opposed to the mark on the bottom disc
180'
(Fig.A-13).

B.
8. Insert slow speed shaft rollers (Fig . A-13).
9. Put the slow speed shaft pins into the rollers (Fig.
A-12). The above instructions are for eccentric
bearings with retainer. Following are the instructions
suggested for roller bearings without retainer.
a. First insert the eccentric with inner raceways of
bearings by rapping with a wooden or hard rubber
mallet.

21233A IQUITOS - PL #20748

Fig.A-12
Fig. A-12

Fig. A-15

Note: Insert second disc with


number facing slow speed side,
side,

exactly 1800 opposed to number


on first disc.
Note: Set disc with number facing

..J
slow speed side. _ _ _ _ _.J

b. Apply grease to the raceway of the eccentric on the


disc. Fix the rollers and set disc in place.
place.
c. Insert the spacer ring and set second disc in such a
0
way that mark is 180
180 opposed to mark on the bottom
disc.
Eccentric Bearing Replacement Precautions
The eccentric bearings are specially designed for installation on SM-CYCLDSMCYCLO" Reducers.
Reducers. They are special
roller bearings without outer raceways (refer to the list
of bearings on pages A12
A-12 - A-13).
A-13) .
It is necessary to insert replacement bearings with
numbered surfaces of the inner raceways facing
outward. Note that incorrect insertion of the bearings
(i .e., insertion of bearings with numbered surfaces
inside) causes trouble.
Disassembly and Assembly of Sizes SOSO-S095
SM-CYCLO Reducers
Small sizes 6060-6095
60606095 have a single disc system, so
they differ in construction from larger sizes in the
following ways:
1. A balance weight is provided in lieu of the twodisc
two-disc
system. Refer to figure A-18.
2. The balance weight must be positioned exactty
exactly 180
1800
as opposed to that of the eccentric.
3. There are no end plates on either side of the
eccentric. In all other respects, 6060-6095 have
exactly the same construction as the larger sizes.
Follow the instructions given under "Disassembly and
Assembly".
Disassembly Of Output Side (SOSO-S12H)
1. With casing supported , tap output shaft until it is
disengaged from casing.
casing .
2. Remove bearing "A" by using pulling tool.
3. Replace all bearings, gaskets and seals when
when'
A-II - A-t3).
A-13).
reassembling. (Pages A-It

Assembly 01 Output Side (SOSO-SI2H)


(6060-612H)
1. Assemble the "8"
"6" bearing (Part No.
No. 103)
1-03) on the slow
speed shaft (Part No. 1-01).
101). Heating of "8"
"6" bearing is
recommended for easier assembly.
assembly,

Note: Do not exceed temperature of 200F.


2. Assemble the casing (Part No. 26) over the slow speed
1-01), being
shaft (Part No.
No. 1-01),
bein9 sure to maintain "X" (Fig. A-18).
3. Carefully tap bearing "A" (Part No. 1-02)
3.
102) onto the slow
speed shaft (Part No.
No. 1-01)
101) until the bearing is flush with the
shoulder of the casing.
4. Place the collar (Part No. 1-04H)
104H) onto the slow
speed shaft (Part No. 1-01). Heating the collar is
recommended for easier assembly.
assembly.

5. Insert the oil seal (Part No. 18), lip in, into the casing
(Part No. 26).

Note: Measure for dimension "xn


"X" preferably in 3 places to
insure proper spacing.

Fig.A-18
Fig. A-18

1-01

X" Dimension
DimenSion (Inches)

Frame Size
6060/65
6070fl5
6070175
6080/85
6090/95
6100/05
610H
61101151201
6110115/201
25, 612H
25,612H

DimensiDn
OimensiDn
0.046. 0.007
0.046

0.042 0.007
0.046,0.007
0.046
, 0.007
0.046 0.007
0.046.0.007
0.042 0.007

A-IS
A15

21233A IQUITOS - PL #20748

DAILY INSPECTION
1. Visually check the oil level gauge on the vertical
unit,
unit, forcedlubricated
forced-lubricated type. Check lubrication flow by
viewing piping set and oil signal (Part No. 41). Faulty
oil ,
operation is caused by a lack of lubrication oil,
damage to the plunger pump (Part No. 42) or the
positive displacement pump (Part No.
No. 43) or the
clogging of pipes, etc.
etc. In case of faulty operation , stop
and inspect the unit immediately.
immediately.
2. A temperature rise of approximately I 05' F (40.6' C)
above ambient on the surface of the ring gear housing
(Part No. 2-01) is allowable if the temperature

fluctuation is small. If temperature rises rapidly from a


stable condition
condition,, add the recommended oil or grease
(Tables A-7 and A-11). A rapid temperature rise may
be caused from a lack of lubrication.
persists , stop
If after lubricating unit, the problem persists,
operation and consult factory.
factory.
3. When an abnormal sound is heard from inside the
unit, stop operation and inspect the unit.
unit,
4. If the lubrication oil leaks,
leaks, replace the damaged or
worn part with a new one. (Refer to Part No. 1-04H,
Page A-3.)

Ordering Correct Replacement Units Or Parts


The SM-CYCLO"
8M-CYCLOS is fully standardized to offer maximum
part interchangeability among models of the same frame
size.. However, there are many frame sizes,
size
sizes, models and
8M-CYCLOS. Therefore
types in the production range of SM-CYCLO".
to get correct replacement units or parts, proper
information to identify the speed reducer in question is
essential. The name plate,
plate , which is secured to the body
of the drive,
drive, provides this identifying data.

Name Plate on SM-CYCLO

Please give the full description shown on the name plate


distributor. Be sure to include the SERIAL
to your distributor.
NUMBER and MODEL NUMBER. This information,
along with our production records, will enable us to
provide you with the correct replacement unit or parts.

INPUT

SM-CYCLO
CHESAPEAKE, VIRGINIA

.~.". '.
~~~~

MODEL
RATIO

SERVICE FACTOR

HP

OUTPUT TORQUE

RPM
IN-LB

SERIAL NO.

Storage And Operation After Storage


Storage 6 Months-1 Year

Operation After Storage 6 Months-1 Year

Oil-Lubricated

Oil-Lubricated

1. Completely fill unit(s) with a rust-preventive oil


(8hell VSI
(NP20 or equivalent) or a circulating oil (Shell
V81 No.
100 or equivalent)
equivalent)..

1. Completely drain the rust preventive , or circulating


oil from unit.

2. At approximately 3 month intervals, rotate the input


shaft a sufficient number of times to insure all internal
components remain coated.
coated . (The higher the ratio,
ratio, the
greater the amount of rotations needed for proper
lubrication.)
lubrication .)
Grease-Lubricated
Grease-lubricated models do not require any special
storage.. (Inspect unit before
attention during storage
operation.)
Note: For both the Oil-Lubricated and GreaseLubricated models, if units are to be stored for a
period exceeding I year, consult factory.

A-16

2. Flush unit with the recommended operating oil as


shown in Table A-11
A-II..
3. After flushing
flushing,, fill the unit to the proper oil level with
the recommended lubricating oil.
Grease-Lubricated
Add 'h of the recommended quantity of new grease as
shown in Table A-1
A-I O.
Note: Consult the factory before operating units stored
I year.
for periods greater than 1

21233A IQUITOS - PL #20748

TROUBLESHOOTING AND REPAIR

This troubleshooting guide is to help you identify and overcome common problems of reducers. If you have a problem
below, please consult factory.
not listed below,
PROBLEM WITH
THE REDUCER

reducer, replace with


Check rated capacity of reducer,
unit of sufficient capacity or reduce load.

Insufficient lubrication.
lubrication .

Check lubricant level and adjust up to


recommended levels.

Excessive lubrication
lubrication..

Check lubricant level and adjust down to


recommended level.

Wrong lubricant.

Flush out and refill with correct lubricant as


recommended .

Weak mounting
structure.

Inspect mounting of reducer.


reducer. Tighten loose bolts
and/or reinforce mounting and structure.

Loose hold down bolts.

bolts..
Tighten bolts

Overloading unit may


result in damage to disc.

Disassemble and replace disc. Recheck rated


capacity of reducer.

May be due to lack of


lubricant.

Replace bearing. Clean and flush reducer and fill


with recommended lubricant.

Overload.

reducer, replace with unit


Check rated capacity of reducer,
of sufficient capacity or reduce load.
load .

Insufficient
Lubricant

Level of lubricant in the


reducer not properly
maintained.
maintained.

Check lubricant level and adjust to


factory-recommended level.

Damaged Pins
& Rollers

Overloading of reducer.

Disassemble and replace ring gear pins and


rollers. Check load on reducer.

Input Shaft
Broken

Overloading of reducer
can cause damage.

Replace broken shaft. Check rated capacity of


reducer.

Key missing or sheared


off on input shaft.

Replace key.

Lack of lubricant.

Replace eccentric bearing. Flush and refill with


recommended lubricant.

Coupling loose or
disconnected.
disconnected.

Properly align reducer and coupling. Tighten


coupling.

Caused by dirt or grit


entering seal.

Replace seals. Breather filter may be clogged.


Replace or clean filter.

Overfilled reducer.

Check lubricant level and adjust to recommended


level.

Vent clogged.

Clean or replace element, being sure to prevent


any dirt from falling into the reducer.

Improper mounting
position , such as wall or
ceiling mount of
horizontal reducer.

Mount horizontally or rework reducer to wall or


ceiling mount.

Runs Hot
Improper
Lubrication

Loose
Foundation
Bolts
Worn Disc
Runs
Noisy
Failure of
Bearings

Eccentric
Bearing Broken

Worn
Seals

Oil
Leakage

SUGGESTED
REMEDY

Load exceeds the


capacity of the reducer.

Overloading

Output Shaft
Does Not Turn

POSSIBLE
CAUSES

A-1?
A-17

This page intentionally left blank.

5-70

AN EMPLOYEE-OWNED COMPANY

FREEWHEEL
CLUTCH

5-71

This page intentionally left blank.

5-72

21233A IQUITOS - PL #20748

Bulletin E 8.733
Installation, Lubrication, Maintenance Instructions
Ringspann Freewheel Clutches
FRS 300 thru 1000
FRZ 300 thru 1000
FRSG 300 thru 1000
21233A - FRSG-550

RINGSPANN
CORPORATION

Tel: 847-678-3581
Fax: 847-678-3583

5130 North Pearl Street


Schiller Park, IL 60176

Web: www.ringspanncorp.com
Email: info@ringspanncorp.com

21233A IQUITOS - PL #20748

Introduction

Installation

FRS, FRZ and FRSG models are general purpose ball


bearing freewheels suitable for overrunning,
backstopping and light duty indexing applications.

1. Mount the freewheel and key on the shaft.

Ringspann FR_ Series freewheels mount on a


through-shaft with the inner race driven by a key.

The O.D. of the outer ring is designed as a mounting


surface or pilot for attaching the driven member.

The O.D. of the outer ring is ground concentric with


the bore to provide proper alignment and installation.

Failure to follow these instructions


may result in product damage, equipment damage,
and serious or fatal injury to personnel.

Pre-installation Check
Before installing, check:
1. Shaft to Bore fit:
Freewheel Bore
0 to 2 inches dia.

Shaft Fit Guide


Line fit to .002 inches loose

2 to 4 inches dia.

Line fit to .0025 inches loose

4 to 7 inches dia.

Line fit to .003 inches loose

Note: Oil lubricated freewheels may only be used on


applications with mounting orientations within 5
degrees of horizontal. Grease lubricated freewheels
may be used on applications with non-horizontal
orientations.
Apply pressure only to face of freewheel inner ring.
2. Application of pressure to the outer ring could
damage the bearings. For ease of mounting, it is
permissible for oil lubricated freewheels to be
immersed in hot, clean oil (not exceeding
200F/93C) for ten to fifteen minutes prior to
mounting.
3. Secure the axial position of the freewheel inner ring
onto the shaft. Approved methods of axial retention
include the use of shaft collars, keeper plates,
retention rings, or retention keys.
4. Mount attaching parts to the freewheel outer ring as
required by the application.
If a torque arm is to be mounted to the freewheel,
allow 1/4 to 1/2 inch clearance between stops and
torque arm.

Note: Machine builders may use non-standard shaft fits


to mount Ringspann freewheels. In this event, direct any
questions concerning shaft fit to the machine builder.

Tapped mounting holes are provided in each end of


the outer ring. Center the gear, pulley or sheave on
the outer ring. Avoid excessive over-hung loads.

2. Key and keyseat

Check with Ringspann Corporation if the freewheel


must support large side loads during overrunning
cycle of operation as damage may occur.

Hardness: Use a hardened key, from 30 to 40


Rockwell C scale. Use materials AISI 1141, 1045
or 4130
Overrunning & Backstopping
Fit: Break edges of the key before installing, to
prevent any bearing at these points. Install with a
push fit. Be sure the key seats squarely. Do not use
force fit.
Length: The key must be equal to the length of the
inner ring for proper engagement.
Indexing
Fit: Fit the key up to .001 inch interference on Width
dimension to prevent loosening in indexing service.
Do no exceed .001 inch tight.
3. Rotation
Determine proper direction of free rotation for
application and orientate the freewheel to match
based on the directional arrows marked freewheel.

5. All Ringspann freewheels are lubricated before


leaving the factory. However, check the following
Lubricant table for the proper lubricant and fill level
for each type application and ambient operating
temperature range. Change the lubricant or add oil
to proper level, if required.
6. Check for proper rotation by spinning the freewheel
by hand.

Lubrication
Proper lubrication and lubricant maintenance are the
most important single maintenance factors for long,
effective, trouble-free operation of freewheels. Read the
following instructions and follow them carefully for
maximum performance and utilization of Ringspann
freewheels.
Always recheck oil level in freewheel after
installation and before start up.

21233A IQUITOS - PL #20748

Oil Lubrication
Use oils selected from the following table according to
the application and ambient temperature existing at the
freewheel.
Note: FRS and FRZ-300 thru 1000 freewheels are
shipped from Ringspann half full of Dexron III Automatic
Transmission Fluid.
For applications where the ambient temperature
exceeds +150F (+65C) consult Ringspann.
Do not use lubricants of the EP type
(extreme pressure characteristics) or those
containing slippery additives such as sulfur
phosphate, graphite, or molybdenum disulphide.
Temp. Range Recommended Oil Lubricant
0F to 150F
MOBIL Multi-Purpose ATF (Dexron III)
TEXACO Havoline ATF (Dexron III)
CHEVRON ATF (Dexron III)
-20F to 60F

MOBIL DTE-15M
TEXACO Rando-HDZ 46
CHEVRON Hydraulic Oil AW MV 46

-50F to 32F

MOBIL Aero HF
TEXACO Aircraft Hydraulic Oil 5606G
CHEVRON Aviation Hydraulic Oil A

Important: Do not mix oils. When switching from one


brand or type to another, drain old oil and flush
freewheel with mineral spirits, such as MOBIL
SOLVASOL or equivalent. Do not use any solvent
containing Carbon Tetrachloride.
The use of lubricants in freewheel
assemblies, other than shown, can compromise proper
function that may cause personal injury or property
damage and will automatically void any warranty.
Ringspann is not responsible for any lubrication changes
made after the freewheel leaves our factory.

Oil Lubrication Maintenance


1. Inspect the oil level once a month or every 160
hours of operation, whichever occurs first. Indexing
applications that operate in excess of 150 strokes
per minute and severe duty applications may require
more frequent oil level inspection.
2. Add oil if necessary to maintain the proper level.
Overrunning, Backstopping ....... 1/2 full
Indexing ..................................... 7/8 full
3. To assure continued efficiency of operation, flush
freewheel every 6 months with mineral spirits.
Do not use any solvent containing Carbon
Tetrachloride as seal damage may occur.

Important: Under severe operating conditions, such


as heavy dust or twenty-four hours per day
operation, flushing may be required at shorter
intervals.
Flushing will remove waxes and gums formed by
vaporization of the oil and helps assure continued
efficiency of operation. See Flushing Procedure.
4. Flush with mineral spirits and relubricate before use
if freewheel has been out of service or in storage for
six months or more. Use recommended oils only.
In cases of dirty or abrasive environment or severe
operating conditions (24 hours per day), it is
recommended that oil be changed every month.
5. If the freewheel is out of service or in storage for two
years or more, new seals should be installed before
freewheel is put into service.

Oil Lubrication Filling Procedure

Overrunning and Backstopping Applications


1. Rotate freewheel outer ring as shown in Figure A.
2. Remove (A) and (B) plugs and add oil through (A)
until oil flows from (B). The freewheel is now 1/2 full.
3. Reinstall (A) and (B) plugs with sealing washers and
tighten to prevent leakage.
Indexing Applications (up to 150 strokes per minute)
Note: Contact Ringspann for indexing applications in
excess of 150 strokes per minute
1. Rotate freewheel outer ring as shown in Figure B.
2. Remove (A) and (C) plugs and add oil through (A)
until oil flows from (C). The freewheel is now 7/8 full.
3. Reinstall (A) and (C) plugs with sealing washers and
tighten to prevent leakage.

Flushing Procedure
1. Rotate freewheel outer ring to locate plug (B) in the
6 oclock position.
2. Remove plug (B) and drain oil from freewheel.
Remove plug (C) for better drainage.
3. Reinstall plug (B) and completely fill freewheel with
mineral spirits. Reinstall plug (C).

21233A IQUITOS - PL #20748


4. Rotate freewheel slowly for several minutes to break
up and dissolve any oily residue.

2. Lubrication should be done with the freewheel at


normal operating temperature.

5. Remove plug (B) from 6 oclock position and drain


mineral spirits. Remove plug (C) for better drainage.

Note: Freewheels are designed to purge excess grease


during operation. Purge will stop as soon as internal
temperatures and pressures stabilize.

6. Reinstall and tighten plug (B).


7. Relubricate the freewheel according to Oil
Lubrication Filling Procedure.

Use Recommended Greases Only

8. Reinstall and tighten open plugs to prevent leakage.

Disassembly and repair of Ringspann


freewheels in the field is not recommended and will void
any warranty.

Freewheel Rebuilding Service

Grease Lubrication
Use greases selected from the following table:
FISKE BROS.
Lubriplate Aero
Lubriplate Low-Temp
MOBIL

Ringspann freewheels are precision devices


manufactured under careful controls to meet exacting
standards. When reconditioning is required, freewheels
should be returned to Ringspann for service

Mobilith SHC-100
Mobilgrease XHP 221

Rotating Equipment

Note: FRSG-300 thru 1000 freewheels are shipped from


Ringspann packed with FISKE BROS. Lubricate Aero

Use no other greases unless a specific


recommendation has been made by Ringspann.

If ambient temperature of freewheel application is


below +20F/-7C or above +120F/ + 55C, consult
Ringspann for special lubricant recommendations.

Grease lubrication may be used if:


o

The freewheel is inaccessible for frequent


lubrication maintenance.

Conditions do not permit maintenance frequency


required for oil lubricated freewheels.

The freewheel orientation is vertical (or greater


than 5 degrees from horizontal).

The freewheel is operated in the presence of


severe abrasive dust.

Do not attempt to convert oil lubricated freewheels to


grease lubrication. Any such conversion may result
in malfunction and will void any warranty.

Grease Lubrication Maintenance


Add grease to freewheel once per month under normal
operating conditions. Under severe operating conditions,
such as heavy dust or twenty-four hours per day
operation, grease should be added every 2 weeks

Grease Lubrication Procedure


1. Wipe all grease fittings clean and then pump new
grease into all fittings until clean grease flows out
around the seals on both sides of the freewheel.

Rotating equipment is potentially


dangerous and should be properly guarded. The user
should comply with all applicable safety codes to guard
rotating equipment.

Warranty
Ringspann Corporation seller agrees to repair or
replace (at its sole option), defective materials or
workmanship for a period of one year from the date of
delivery. Seller must be notified of such a defect within a
reasonable time after discovery (not to exceed thirty (30)
days), and the defective product must be delivered,
prepaid to the sellers factory with evidence that, it has
been properly installed, maintained and operated in
accordance with the sellers instructions. Sellers limited
warranty excludes remedy for damage or defect caused
by abuse; failure to resist corrosion or erosion from any
corrosive agent or fluid, due to deposits of foreign
material from any fluid; modifications not executed by
Seller; improper installation or operation; defects or
failures arising out of, in any way related to, or as a
result either direct or indirect, of the Buyers failure to
properly advise Seller of all normal and special operating
conditions, known to or suspected by Buyer, when Seller
is manufacturing the Equipment for a specific operation;
or normal wear and tear under usage. This remedy is
exclusive and is given in lieu of any warranty of
merchantability, fitness, for a particular purpose or any
other warranty, whether express or implied. Seller shall
not be liable for consequential damages (including but
not limited to, loss of use, lost profits, business
interruption and the like), incidental damages, indirect
damages, whether the claim for such damage is based
upon warranty, contract, tort, strict liability or any other
theory of recovery.

RINGSPANN
CORPORATION

Tel: 847-678-3581
Fax: 847-678-3583

5130 North Pearl Street


Schiller Park, IL 60176

Web: www.ringspanncorp.com
Email: info@ringspanncorp.com

AN EMPLOYEE-OWNED COMPANY

BELT DRIVE

5-77

This page intentionally left blank.

5-78

21233A IQUITOS - PL #20748

!
w
e
N Poly Chain GT Carbon Belt
Nothing Tougher
Gates new Poly Chain GT Carbon
belt is part of a powerful synchronous
belt drive system that outperforms
roller chain in even the most demanding high-torque applications.
Gates Poly Chain GT Carbon belt
offers enhancements that exceed the
current market-leading Poly Chain
GT2 belt, including:
better performance
more flexibility for use with backside idlers
greater resistance to moisture

Why carbon?
In todays high-performance driven
world, parts that need to be incredibly
strong and lightweight arent made of
steel. Theyre made of premium grade
carbon fiber.

Gates is the first to apply these premium grade carbon fibers in a patented dynamic application, providing
the Poly Chain GT Carbon belt with
exceptionally high power transmission capacity, strength, flexibility and
durability.
Poly Chain GT Carbon drives pack
a lot of power into a small space,
matching the capacity of roller
chain drives width-for-width in
most pitch sizes.

The Ideal Roller Chain


Alternative
maintenance-free drive
outlasts roller chain 3-to-1
accommodates the use of
backside idlers
compact drive components
provide versatility to drive
designers

Gates new Poly Chain GT Carbon belt offers performance enhancements


that exceed the current market-leading Poly Chain GT2 belt.

21233A IQUITOS - PL #20748

Industrial Belt Design - Drive Detail Report


Design Flex Pro by the Gates Corporation
Designed For:

Provided By:

Steve Haymore
WesTech Engineering, Inc.
3625 S. West Temple
Salt Lake City, Utah 84115
United States
shaymore@westech-inc.com
(801) 265-1000 Phone
(801) 265-1080 Fax

Application: 21233A - IQUITOS CITY

INPUT

DriveR

Drive Information
Speed Ratio:
Input Load:
Service Factor:
Design Power:
Center Distance:

DriveN

RPM:
0.8
0.3 +5%/-4%
2.37 Down Motor: 3500.0 Gearbox: 4437.00
0.04 hp Gearbox: 0.04 hp
1.6
Bushings Checked: TL, No MPB
0.06 hp
Belts Checked: Poly Chain Carbon
14.4 to 17.6 in
Electric Motor, 3-Phase, VFD / Soft Start

SELECTED DRIVE
Belt Type: Poly Chain Carbon - 14M
Speed Ratio:
dN RPM:
Rated Load:
Belt Pull:
Center Distance:
Install/Take-Up Range:

Noise:

TENSION

2.31 Down
0.3
0.14 hp, ODR: 2.11
1183 lbf
16.05 in
14.72 in to 16.09 in

Part No:
Product No:
Top Width:
Weight:
Rim/Belt Speed:
RPM:
Bushing Part No:
Bore:
Pitch Diameter:

Belt

DriveR

DriveN

14MGT-1750-20
9274-4125
-0.61 lbf
1 ft/min
0.2
----

14MX-39S-20
7719-2039
1.44 in
9.8 lbf
1 ft/min
0.8
2517
0.5 in - 2.6875 in
6.84 in

14MX-90S-20
7719-2090
1.44 in
41 lbf
1 ft/min
0.3
3525
1.1875 in - 3.9375 in
15.79 in

47 dB @ 1 Hz

New Belt

Used Belt

Static Tension (Per rib/strand):


623 to 679 lbf
453 to 510 lbf
Static Belt Pull:
1195 to 1304 lbf
869 to 978 lbf
When planning to re-install used belts, measure
Rib/Strand Deflection Distance:
0.24 in
0.24 in
and record the tension before removing and
Rib/Strand Deflection Force:
42 to 46 lbf
32 to 35 lbf
re-install at the recorded tension.
Sonic Tension Meter:
2770 to 3022 N
2015 to 2267 N
Belt Frequency:
169 to 177 Hz
144 to 153 Hz
505C/507C Model STM Settings: Weight: 7.9 g/m,Width: 20 mm/#R, Span: 391 mm

NOTES
- Drive over-designed and efficiency may be reduced.
- The DriveN pulley/bush weight exceeds 50 lbf. Exercise care during installation.
- Design Flex Drive Solutions assume Gates products and are not applicable to non-Gates products.
- Gates products are not intended for use in any application where the failure of the product to perform could cause injury or death. This
includes use on aircraft propeller or rotor drive systems or other in-flight systems necessary for safe flight.

2/25/2011 2:04 PM

Page 1 of 1

1.68/1.50/1.54/ North America

21233A IQUITOS - PL #20748

Tr o u b l e s h o o t i n g
Symptom
Unusual noise

Tension loss

Diagnosis
Misaligned drive
Too low or high belt tension
Backside idler
Worn sprocket
Bent guide flange
Belt speed too high
Incorrect belt profile for the sprocket
(i.e., HTD etc.)
Subminimal diameter
Excess load

Correct alignment
Adjust tension to recommended value
Use inside idler
Replace sprocket
Replace sprocket/flange
Redesign drive
Use proper Gates Poly Chain GT CarbonTM belt/sprocket

Weak support structure


Excessive sprocket wear
Fixed (nonadjustable) centers
Excessive debris
Excessive load
Subminimal diameter
Belt, sprockets or shafts running too hot

Reinforce the structure


Use alternate sprocket material
Use inside idler for belt adjustment
Protect drive
Redesign drive for increased capacity
Redesign drive using larger diameters
Check for conductive heat transfer from
prime mover
Reduce ambient drive temperature to
180F maximum

Unusual belt degradation, such as softening


or melting
Belt tracking

Possible Remedy

Belt running partly off unflanged sprocket


Centers exceed 8 times small sprocket
Excessive belt edge wear

Redesign drive using larger diameters


Redesign drive for increased capacity

Correct alignment
Correct parallel alignment to set belt to track on
both sprockets
Correct alignment

Flange failure

Belt forcing flanges off

Correct alignment or properly secure flange


to sprocket

Excessive belt edge wear

Damage due to handling


Flange damage
Belt too wide
Belt tension too low
Rough flange surface finish
Improper tracking
Belt hitting drive guard or bracketry

Follow proper handling instructions


Repair flange or replace sprocket
Use proper width sprocket
Adjust tension to recommended value
Replace or repair flange (to eliminate abrasive surface)
Correct alignment
Remove obstruction or use inside idler

Premature tooth wear

Too low or high belt tension


Belt running partly off unflanged sprocket
Misaligned drive
Incorrect belt profile for the sprocket
(i.e., HTD, etc.)
Worn sprocket
Rough sprocket teeth
Damaged sprocket
Sprocket not to dimensional specification
Belt hitting drive bracketry or other structure
Excessive load
Insufficient hardness of sprocket material
Excessive debris
Cocked bushing/sprocket assembly

Adjust tension to recommended value


Correct alignment
Correct alignment
Use proper Gates Poly Chain GT CarbonTM belt/sprocket

www.gates.com/pt

Replace sprocket
Replace sprocket
Replace sprocket
Replace sprocket
Remove obstruction or use inside idler
Redesign drive for increased capacity
Use a more wear-resistant material
Protect belt
Install bushing per instructions

The Driving Force in Power Transmission.

113

21233A IQUITOS - PL #20748

Tr o u b l e s h o o t i n g
Symptom
Tooth shear

Diagnosis

Possible Remedy

Excessive shock loads


Less than 6 teeth-in-mesh
Extreme sprocket runout
Worn sprocket
Backside idler
Incorrect belt profile for the sprocket
(i.e., HTD, etc.)
Misaligned drive
Belt undertensioned

Redesign drive for increased capacity


Redesign drive
Replace sprocket
Replace sprocket
Use inside idler
Use proper Gates Poly Chain GT CarbonTM belt/sprocket

Excessive shock load


Subminimal diameter
Improper belt handling and storage prior to
installation
Debris or foreign object in drive
Extreme sprocket runout
Sprocket has too little wear resistance
(i.e., plastic, aluminum, softer metals)

Redesign drive for increased capacity


Redesign drive using larger diameters
Follow proper handling and storage procedures

Belt cracking

Backside idler
Extreme low temperature startup
Extended exposure to harsh chemicals
Cocked bushing/sprocket assembly
Misaligned drive
Too low or too high belt tension

Use inside idler


Preheat drive environment
Protect drive
Install bushing per instructions
Correct alignment
Adjust tension to recommended value

Excessive temperature
(belt, bearing, housing,
shafts, etc.)

Incorrect belt profile (i.e. HTD, etc.)


Incorrect belt profile for the sprocket (i.e. HTD, etc.)

Use proper Gates Poly Chain GT CarbonTM belt/sprocket


Use proper Gates Poly Chain GT CarbonTM belt/sprocket

Vibration

Too low or too high belt tension


Bushing or key loose

Adjust tension to recommended value


Check and reinstall per instructions

Tensile break

114

Gates Corporation

Correct alignment
Adjust tension to recommended value

Protect drive
Replace sprocket
Use alternate sprocket material

www.gates.com/pt

AN EMPLOYEE-OWNED COMPANY

UPPER BEARING

5-83

This page intentionally left blank.

5-84

SKF - Product data

Page 1 of 1
21233A IQUITOS - PL #20748

Spherical roller thrust bearings

Principal
dimensions

Basic load ratings


dynam ic
st at ic

in
3,1496

Tolerances , see also text


Recommended fits
Shaft and housing tolerances

C0

lbf
6,6929

2,126

151000

366000

Fatigue
load
limit
Pu

Minimum
load
factor

Speed ratings
Mass
Refer ence
Lim it ing
speed
speed

Designation

lbf

r/ m in

lb

43400

0,25

2200

12,3

29416 E *

3800

* - SKF Ex plor e r be a r in g

http://www.skf.com/skf/productcatalogue/jsp/viewers/productTableViewer.jsp?imperial=true&&CADexists=true&action=PPP&presentati... 12/19/2008

This page intentionally left blank.

5-86

AN EMPLOYEE-OWNED COMPANY

LOWER BEARING

5-87

This page intentionally left blank.

5-88

21233A IQUITOS - PL #20748

Spherical roller bearings, cylindrical and tapered bore


Principal
dimensions
d

Basic load ratings


dynamic
static

12,5984

2,3622

127000

in
9,4488

C0

Fatigue
load
limit
Pu
lbf

r/min

261000

22000

1700

lbf

Speed ratings
Reference Limiting
speed
speed

Mass

Designation

* - SKF Explorer bearing

2000

lb

29,8

23948 CC/W33

This page intentionally left blank.

5-90

AN EMPLOYEE-OWNED COMPANY

ENCLOSURES

6-1

This page intentionally left blank.

6-2

MAIN BEARING & DRIVE


DETAIL

7,300 LBS. DRY) EST.


12,000 LBS. (FULL OF WATER) EST.

1
D102

NOTES

PRIMARY ARM #1

1.

A STAR (*) DENOTES VARIANCE FROM CONTRACT DOCUMENTS AND


SHOULD BE PARTICULARLY NOTED.

2.

CONTRACTOR TO VERIFY OR SUPPLY ON APPROVAL ALL DIMENSIONS SHOWN IN


CLOUD.

3.

THE FOLLOI'l1NG DEFINES THE RESPONSIBILITY OF I'I1ESTECH ENGINEERING INC.


I'I1TH REGARDS TO THE INFORMATION AND DIMENSIONS SHOWN ON THE DRAWING.

-H~

E'

E'"
",,,,
....

(A)

THIS DRAI'I1NG IS NOT TO BE USED FOR CONSTRUCTION OR INSTALLATION


PURPOSES UNTIL IT BEARS THE APPROVAL OF THE OWNER, ENGINEER, OR
THEIR DULY AUTHORIZED REPRESENTATIVE.

(B)

DIMENSIONS, LOADS, AND OTHER INFORMATION ARE PROVIDED TO


ACCOMMODATE THE EQUIPMENT TO THE STRUCTURE AS SHOWN.

(C)

I'I1ESTECH IS NOT RESPONSIBUE FOR CONCRETE DESIGN. THE CUSTOMER IS


TO PROVIDE REINFORCING STEEL AND DETERMINE SIZES TO SUIT LOCAL
REQUIREMENTS.

(D)

WESTECH IS NOT RESPONSIBUE FOR DAMAGE, INJURY OR LOSS RESULTING


FROM INCORPORATION OR USE OF THIS EQUIPMENT.

(E)

CHARGES FOR MODIFlCA TlON, ADDITIONS OR CORRECTIONS TO THE


EQUIPMENT I'I1LL NOT BE ACCEPTED BY I'I1ESTECH, UNLESS PRIOR APPROVAL
IS OBTAINED IN WRITING FROM AN AUTHORIZED I'I1ESTECH REPRESENTATIVE.

",.1

LOCA~ON FOR SPREADERS


FOR ROTA ~ONAL BRAKING.
THRUST MUST BE NEUTRALIZED
FOR PROPER DRIVE

ffi

OPERA~ON.

SECONOARY
ARM #1

ffi

I'I1ESTECH DOES NOT FURNISH CONCRETE, GROUT, CONCRETE REIENFORCING, PIPING,


VALVES, PIPE SUPPORTS OR FlTTlNGS, WALL BRACKETS, ELECTRICAL WIRING,
CONDUIT, EUECTRICAL EQUIPMENT, ERECTION, FlELD PAINTING OR PAINT,
FIELD I'I1ELDING OR WELD ROD, WATER FOR TESTING, GREASE, OR LUBRICATING
OIL, EXCEPT AS SPECIFlCALLY NOTED.

5.

ALL FASTENERS 1'I1L1L BE 304 STAINLESS STEEL

ffi

6.

ALL TIE RODS, TURNBUCKUES AND CLEVISES WILL BE 304 STAINLESS STEEL.

7.

TOP COVER AND DRIVE MOUNTING BRACKETS WILL BE 304 STAINUESS STEEL.

STABILIZING BEARING
SEE DETAIL ~

PLATFORM J

TYP. SPREADER
ARRANGEMENT DETAIL ~

4.

CENTER MAST
(304 S.S.)

FLUSH GATE
SEE DETAIL ~

(304 5.5.)

8.

ANCHOR BOLTS I'I1LL BE 304 STAINUESS STEEL.

9.
10.

WESTECH I'I1LL FURNISH: SEVEN (7) 28 m (91'-10") DIA. UNITS AS SHOWN


AND NOTED.
WORK I'I1TH DRAI'I1NG D102.

11.

DESIGN FLOW RATES: 40 Lis (634 GPM) TO 215 Lis (3,408 GPM)

12.

SPARE PARTS INCLUDED:


SPREADER AND ORIFlCE ASSEMBLY EQUAL TO 15% REQUIRED.
LUBRICATION FOR START-UP OF EACH UNIT.

CENTER BARREL
(304 5.5.)
ANNULAR ADJUSTABLE
WEIR (304 5.5.)

Ef'"
EO
1f).1

INFLUENT PORTS

~I')

"'~
0

MECHANICAL SEAL DETAIL

50mm (1/2" NPT) WATER~GHT CONDUIT BY OTHERS.

PRIMARY ARM #2

"'t.>

.!:,~

PLAN VIEW

E'"
E<C

&

1f)::J

gt.>

8) EPOXY ANCHOR BOLTS,


175mm (6h EMBEDMENT
3/4" DIA. x 11 1/4" LG.
(304 ST. SR.)

~E RODS
(304 ST. SR.)

DN 500mm (20")
INFLUENT PIPE

460mm
(18") WALL CLEARANCE
VENT PIPES
89.10 m ELEV.
TOP OF WALL

87.76 m ELEVATION TOP OF


MEDIA AND CONCRETE*

PREPARED FOR:

IQUITOS CITY WWTP


IQUITOS, PERU

CUSTOMER:

AQUA ENGINEERING & SERVICES S.A.


PANAMA CITY, PANAMA

AGENT:

SPENA SAC
LIMA, PERU

CUSTOMER P.O. NO.: 19

CENTER PIER

BioDoc

ROTARY DISTRIBUTOR

GENERAL ARRANGEMENT

MODEL

LRS
DAlE
This drawing Is property 01 YlESlECH ENGINEERING. INC. and Is transmitted In confidence. Neither receIpt nor
possessIon confers or transfers any rights to roprtlduce, use, or disclose. Tn whole or Tn port. data contained
hereIn for any purpose, without the written permission of M:SlECH ENGINEERING, INC., Salt Lake City. Utah

ELEVATION VIEW

rR~E~V~IS~ED~P=ER~S~UB~M~I~TT~A~L~A~P~PR~O~V~A~L~C~O~MM~E~N~T=S'~____________-t~~~~~O~7/~1~'-r.~~A~ ~15S;"'I5C:1HI
REV1SION

DATE

LTR

DRAWING NUMBER

PROJECT NUMBER

D101

21233A

REV.

SEAL BACKUP RING (304 ST. STL.)


WEIGHT GUIDE (304 ST. STL.)

1/2 HP MOTOR
1800 RPM
INVERTOR DUTY
WASHDOWN DUTY

CLOSED CELL NEOPRENE GASKET


CENTER BARREL
(304 ST. STL.)

FLEX CONDUIT
(BY WESTECH)

CENTER MAST
(304 ST. STL.)
- BEARING BACKUP RING
(ALUMINUM)
BEARING HOUSING
(ALUMINUM)

CYCLOIDAL SPEED
REDUCER

STABLIZING SPHERICAL

ROLLER BEARING
REDUCER MOUNTING BRAKET
WITH BELT TAKE-UP
(304 ST. STL.)

STATIONARY CENTER MAST


(304 ST. STL.)
SUPPORT CAGE
(304 ST. STL.)

MECHANICAL SEAL DETAIL

BELT GUARD
(304 ST. STL.)
SPLIT COVER RING (BOTTOM)
(CAST ALUMINUM)
FREE WHEELING CLUTCH

TOP COVER
(304 ST. STL.)

STABILIZING BEARING DETAIL

REMOVABLE
OIL FILL PIPING

OIL FILL

OIL LEVEL PLUG


SPHERICAL THRUST BEARING
IN OIL BATH

OIL DRAIN
QUICK ACTING FLUSH GATE
(304 ST. STL.)

304 ST. STL. CONDUIT


(BY WESTECH)

SPREADER BOLT
(304 ST. STL.)

NEOPRENE GASKET

DISTRIBUTOR ARM
(304 ST. STL.)

MAIN BEARING & DRIVE DETAIL

FLUSH GATE DETAIL

SPREADER
(POLYCARBONATE)

GENERAL ARRANGEMENT DETAILS

SPREADER ARRANGEMENT

&,

.--------==-------r,;:;-rc;;;;;O:IiiiOAiTETEk(;;-.
WEsTECH
REVlSION

D102

21233A

&

GENERAL NOTES:
WORK WITH DRAWINGS D112, D113, D114 AND D115,
BUBBLED ITEMS REFER ~PAR~LlST DOCUMENT # 20748,
USE ANTI-SEIZE (ITEM 334 or 618 ON ALL STAINLESS STEEL FASTENERS,
APPLY PIPE JOINT COM
ND 0 TEFLON TAPE TO THREADS OF ALL PIPING JOINTS,

1.
2.
3.
4.

SHOP ASSEMBLY NOTES:


1.
2.
3,
4,
5.
6.
7.
8.
g,

SECONDARY
ARM #1

",'"

'"
SEE MAIN BEARING &
DRIVE DETAIL #1
ON DRAWING D113

@)

1"'\

I
I

------(I

@)

BOND FELT SEAL (ITEM 235 TO BEARING BACKUP RING (ITEM


AND
BEARING HOUSING (ITEM 03 WITH 2-PART EPOXY ADHESIVE"
ORIENT LOWER BEARING HOUSING (ITEM
WITH LUBRICATION HOLES HALFWAY
BETWEEN SUPPORT CAGE BRACES,
GREASE ALL SURFACES THAT CONTACT V-RING SEAL LIPS,
LOWER BEARING MUST BE PACKED WITH MOBIL TH SHC PM GREASE.
UPPER BEARING ROLLERS MUST BE LIGHTLY COATED WITH MOBIL TH SHC PM GREASE,
USE SILICON SEALANT ON ALL SEAMS OF SPLIT BEARING COVER (ITEMS i205J &
APPLY A CLOSED-LOOP BEAD OF SILICON SEALANT AROUND EACH BOLT
ONYoP
OF CENTER MAST (lnEM
JUST PRIOR TO BEARING SEAT (ITEM
INSTALLATION.
ENDS OF SEAL WEIGHTS (ITEM ~ MUST NOT TOUCH WHEN INSTALLED, GRIND ENDS
AS NECESSARY TO PROVlDE CLE7?RANCE BETWEEN ADJACENT WEIGHTS,
ADJUST SEAL PLATE FASTENERS (ITEM
UNTIL TOP OF SEALAATE (ITEM
IS FLUSH WITH SEAL MOUNTING FLANGE ON CENTER MAST (ITEM ~ AND FLAT TO

Hbi

,..,----- .... ~

//

!200),

SEE STABILIZING BEARING


DETAIL #2 ON DWG. D112

+/-0,005", SEAL PLATE GASKE H D BE COMPRESSED TO 1/8" - 1/!HICK.


ADD OR REMOVE SHIMS)J:fEMS 131 133 BETWEEN SUPPORT CAGE (InEM ~ AND
CENTER BARREL (lTEM~) AS
CC SARY,
1O. APPLY THREAD LOCKING COMPOUND (LO~ #262 OR EQUAL) TO THREADS OF
UPPER BEARING SEAT FASnENERS (InEM ~
11, DO NOT OVER-TIGHTEN SEAL MOUNTING BOLTS (InEM 1319),
SEAL RINGS MUST LAY FLAT AFTER BOLTS ARE TIGHTOO,
12. BOND FLUSH GATE GASKETS (ITEM
TO FLUSH GATES (lnEM
WITH 3M #1300 ADHESIVE.

PRIMARY
ARM #2

PRIMARY
ARM #1

SEE LOWER SEAL


DETAIL #3
ON DRAWING D112

SEE FLUSH GATE DETAIL #4


ON DWG, D112

'--T~~====t========~
I

6;3" EMBEDMENT

FIELD ASSEMBLY NOTES:

~I

1,

~'
~
.~

~
~

I
U

OPERATION AND MAINnENANCE MANUAL MUST BE READ BEFORE ERECTING


THIS EQUIPMENT,
2, REMOVE SHIPPING STRAPS (ITEM
AFTER SETTING CENTER ASSEMBLY
& PRIOR TO ROTATING ARMS,
3, ACCESS TO OIL LEVEL PLUG AND DRAIN PLUG IS THROUGH OPENING(S) IN
SUPPORT CAGE, ROTATE ARMS UNTIL OPENING LINES UP WITH SIGHT GLASS
OR DRAIN,
4, UPPER DISTRIBUTOR BEARING MUST BE FILLED WITH PROPER TYPE AND QUANTITY
OF OIL PRIOR TO OPERATION, SEE O&M MANUAL FOR DETAILS ON PROPER OIL.

5,

6,

7,

~a

GENERAL ERECTION

~SRT~~GC~~~ 0~~M~U@G~fr&~. CLEVlS (ITEMS @) @ & @) AND

SET CENTER ASSEMBLY ONTO ANCHOR BOLTS WITH CONDUIT CONNECTION IN BASE
ORIENTED TOWARD ELECTRICAL WIRING SOURCE,
ARM ITEM NUMBERS ARE STAMPED ON THE TOP EDGES OF THE CONNECTION FLANGES,

SECONDARY
15
ARM #2
L-________________________________________________________________________________________________________

g3

607

DA~

&.
&,

&.

This drawing Is property of WESTECH ENGINEERING, INC. and Ii! transmitted In confidence. Neither receipt nor

possession confers or transfers any rlgMs to reproduce, use, or disclose, In whole or In port. data eontalned
herein for ony purpose, without the written

.---_________
~~~-~I&=:!.I WIESTIECH
________________

perml~~lon

of WESTCH ENGINEERING, INC., Salt Lake City, Utah

DRAWING NUMBER

PROJECT NUMBER

D111

21233A

REV.

D..
R_rn_sl_ON______________~__~~_D_A~
__~~~____________~________________~__________&~~o~

SEAL DETAIL
/ARM (TYP)
ARM (TYP)

312

STABILIZING BEARING DETAIL


433 TO

FLUSH GATE DETAIL

430

TYPICAL FOR ALL PORTS

SHOP ASSEMBLY NOTES:

<1>
2.
3.
4.
5.
6.

0)
8.
9.
10.

~
12.

@)

BOND FELT SEAL (ITEM 35 TO BEARING BACKUP RING (ITEM


AND
BEARING HOUSING (ITEM 03 WITH 2-PART EPOXY ADHESIVE ..
ORIENT LOWER BEARING HOUSING (ITEM
WITH LUBRICATION HOLES HALFWAY
BETWEEN SUPPORT CAGE BRACES.
GREASE ALL SURFACES THAT CONTACT V-RING SEAL LIPS.
LOWER BEARING MUST BE PACKED WITH MOBILTH SHC PM GREASE.
UPPER BEARING ROLLERS MUST BE LlGHTlLY COATED WITH MOBILTH SHC PM GREASE.
USE SILICON SEALANT ON ALL SEAMS OF SPLIT BEARING COVER (ITEMS Q & ~.
APPLY A CLOSED-LOOP ~D OF SILICON SEALANT AROUND EACH BOLT H'od ON'!6P
OF CENTER MAST (ITEM ~ JUST PRIOR TO BEARING SEAT (ITEM
INSTALLATION.
BOND FLUSH GATE GASKET (ITEM
TO FLUSH GATES (ITEM
WITH 3M #1300 ADHESIVE.
ENDS OF SEAL WEIGHTS (ITEM Ii43) MUST NOT TOUCH WHEN INSTALLED. GRIND ENDS
AS NECESSARY TO PROVIDE CLtARANCE BETWEEN ADJACENT WEIGHTS.
ADJUST SEAL PLATE FASTENERS (ITEM
UNTIL TOP OF SEAL NTE (ITEM
IS FLUSH WITH SEAL MOUNTING FLANGE ON CENTER MAST (ITEM ~ AND FLAT TO
+/-0.005". SEAL PLATE GASKE H LD BE COMPRESSED TO 1/8 - 1/!HICK.
ADD OR REMOVE SHIMS)qEMS 131 133 BETWEEN SUPPORT CAGE (ITEM ~ AND
CENTER BARREL (ITEM~) AS
CC SARY.
APPLY THREAD LOCKING COMPOUND (LOC~ #262 OR EQUAL) TO THREADS OF
UPPER BEARING SEAT FASTENERS (ITEM 23
DO NOT OVER-TIGHTEN SEAL MOUNTING B LTS (ITEM
SEAL RINGS MUST LAY FLAT AFTER BOLTS ARE TIGHTMD.

)
@

GENERAL NOTES:
1.
2.
3.
4.

WORK WITH DWG. 0111, om, D114 & D115.


BUBBLED ITEMS REFER TO PARTS LIST DOCUMENT # 20748.
USE ANTI-SEIZE (ITEM
or
ON ALL STAINLESS STEEL FASTENERS.
APPLY PIPE JOINT COMPOUND OR TEFLON TAPE TO THREADS OF ALL PIPING JOINTS.

@ @

SPREADER DETAIL

FIELD ASSEMBLY NOTES:


OPERATION AND MAINTENANCE MANUAL MUST BE READ BEFORE ERECTING
THIS EQUIPMENT.
2. REMOVE SHIPPING STRAPS (ITEM
AFTER SETTING CENTER ASSEMBLY
& PRIOR TO ROTATING ARMS.
3. ACCESS TO OIL LEVEL PLUG AND DRAIN PLUG IS THROUGH OPENING(S) IN SUPPORT
SUPPORT CAGE. ROTATE ARMS UNTIL OPENING LINES UP WITH SIGHT GLASS OR DRAIN.
4. UPPER DISTRIBUTOR BEARING MUST BE FILLED WITH PROPER TYPE AND QUANTITY
OF OIL PRIOR TO OPERATION. SEE O&M MANUAL FOR DETAILS ON PROPER OIL.

1.

GENERAL ERECTION DETAILS

INSTALL ONE JAM NUT AG~IST EACH CLEVIS (lTEMS@@&@AND


TURNBUCKLE (ITEMS r427I 28 & r42m)'
INSTALL ONE JAM NU'F6N
CH 'sIDE OF ALL COUPLING NUTS (ITEM
6. SET CENTER ASSEMBLY ONTO ANCHOR BOLTS WITH CONDUIT CONNECTION IN BASE
ORIENTED TOWARD ELECTRICAL WIRING SOURCE.

5.

DESCRIP~ON

@ @ @.
DA~
PROJ. BY PROJ.CHKD.
This drawing Is property of WESTECH ENGINEERING, INC. and Is transmitted In confldence. Neither receipt nor

6i9ll.

posB.ession confers or transfers any rights to reproduce, use, or dIsclose. In whole or to part. dota contained
herem for ony purpose, without the written permls!!lon of WESlECH ENGINEERING. INC.. Salt Lake City. Utah
DRA\\ING NUMBER

,---------::::=
_ _ _ _ _,--:::-~::_r_::___,_~I&
RE'IISION
DA
l TR
~

WeSTeCH

D112

PROJECT NUMBER

REV.

21233A &

525
HOLE MUST
BE DOWN

510

BELT DRIVE DETAIL


VIEW FROM BOTTOM

THE CLUTCH MUST BE INSTALLED ON


THE REDUCER OUTPUT SHAFT SUCH
THA T WHEN THE REDUCER SHAFT IS
STATIONARY, THE CLUTCH HOUSING WILL ROTATE
FREELY COUNTERCLOCKWISE, AS VIEWED
FROM THE BOTTOM. THE UNIT WILL ROTATE
CLOCKWISE AS VIEWED FROM THE TOP.

STRAIGHT EDGE
1/16 MAX.
NOTES:
APPLY ANTI-SEIZE TO ALL STAINLESS FASTENERS.
WCAULK SEAMS WITH SILICONE SEALANT
DURING ASSEMBLY.
3. BUBBLED ITEMS REFER TO PARTS LIST DOC. #20748.
0APPL Y ANTI-SEIZE TO OUTSIDE OF O.D. TUBING
OF BEARING SEAT DURING SHOP ASSEMBLY.
WWELD ONE NUT TO END OF ALL THREAD (ITEM (s32))
AT SHOP ASSEMBLY. GRIND WELD SMOOTH AND'TCUSH.
VGREASE ALL SURFACES THAT CONTACT SEAL LIPS DURING
SHOP ASSEMBLY.
7. APPLY PIPE JOINT COMPOUND OR TEFLON TAPE TO THE
THREADS OF ALL PIPING JOINTS.
8. ORIENT TOP COVER (ITEM 107) WITH OIL FILL 9.JlL:..2AME SIDE
OF CENTER ASSE~ AS THE LADDER (ITEM ~ AND
PLATFORM (ITEM 22.
APPLY A CLOSED- OOP BEAD OF SILICON SEALANT
AROUND EACH BOLT HOLE ON TO~ OF CENTER MAST
PRIOR TO BEARING SEAT (ITEM
INSTALLATION.
1O. APPLY THREAD LOCKING COMPOUND (LOCTITE #262 OR
EQUAL) TO THREADS OF UPPER BEARING SEAT
FASTENERS (ITEM#W)
11. OPERATION & MAINTrnANCE MANUAL MUST BE READ
BEFORE ERECTING THIS EQUIPMENT.
12. SET CENTER ASSEMBLY ONTO ANCHORS WITH CONDUIT
CONNECTION IN BASE ORIENTED TOWARD ELECTRICAL
WIRING SOURCE.
13. FOR PROPER OPERATION OF THE DRIVE, THE SPREADERS
MUST BE LOCATED SUCH THAT THE HYDRAULIC THRUST
IS NEUTRALIZED AND THE ARMS DON'T ROTATE ON
THEIR OWN.
14. ACCESS TO OIL LEVEL PLUG IS THROUGH OPENINGS IN
SUPPORT CAGE. ROTATE ARMS UNTIL OPENINGS LINE UP
WITH LEVEL PLUG.
15. UPPER DISTRIBUTOR BEARING MUST BE FILLED WITH
PROPER TYPE AND QUANTITY OF OIL PRIOR TO
OPERATION. SEE O&M MANUAL FOR DETAILS ON
PROPER OIL.
USE LOCTITE #262 ON THE THREADS OF ITEM
WORK WITH DRAWINGS D111, D112.

FLEETING ANGLE
STRAIGHT EDGE
1/16 MAX.
TYP. FROM BOTH
SPROCKETS

ANGULAR MISALIGNMENT

@J)

ALIGNMENT DIAGRAM

FORCE 42 TO 46 LB. TO DEFLECT BELT .24" (NEW BELT)


FORCE 32 TO 35 LB. TO DEFLECT BELT .24" (USED BELT)
MIDSPAN

66>

1'7.

MAIN BEARING & DRIVE DETAILS

&

DRIVE ERECTION DETAILS

D111

BELT TENSIONING DIAGRAM

MODEL

LRS
DA1E
This drawing Is property of YiESlECH ENGINEERING, INC. and hi transmitted In confidence. Neither receipt nor

possession confers or transfers any rights to reproduce, use, or disclose. In whole or In part. data contained
hereIn for any purpo!le, without the written permission of WESTECH ENGINEERING. INC. Salt Loke City. Utah

DRAIIlNG NUMBER

~C~H~AN~G~ED~I~TE~M~N~UM=B~ER~FR~O~M~54~5~T~O~5~44~.______________~~~~O~B/~31~/~11r.&~~ES,..Ec: ..
RE'ilSION

DA1E

LTR

0113

PROJECT NUMBER

REV.

21233A &

DETAIL

SEE FLUSH GAT~


DETAIL 4
ON DWG. 0112

(~-~'~~

_______________

~~

__________________________________

~~~

__+-________________

~-L

DETAIL 2

______________~~________.________________~~~--~

LEFT-HAND
THREAD

'... _..../
PRIMARY ARM
TIE ROD DETAIL

~l,

DETAIL
l

SEE SPREADER
DETAIL 5
ON DWG. D112

RIGHT-HAND
THREAD

J12 GREEN
..

l, : m!~~~:::~+

_______

8 orB or

608
612

orB or

DETAIL 2

~_

DETAIL 3

'BLACK/RED

"---

SPREADER
DETAIL 5
ON DWG. D112

419
SEE FLUSH
DETAIL 4
ON DWG. D112

SECONDARY ARM
TIE ROD DETAIL

DETAIL 4
SECONDARY
ARM

PRIMARY
ARM

NOTES:
1. USE ANTI-SEIZE (ITEM ~) ON ALL STAINLESS STEEL FASTENERS.
2. USE PIPE THREAD COMWuND ON ALL PIPING THREADS.
3. WORK THIS DRAWING WITH PARTS LIST DOC. #20748.
4. WORK THIS DRAWING WITH 0111,0112,0113 & 0115.
5. TIE RODS ARE MARKED WITH PAINT COLORS SHOWN WITH ITEM NUMBERS.

TIE ROD ERECTION DETAILS

DAlE
This drawing Is property of YtSlECH ENGINEERING. INC. and Is transmitted In confidence. Nelther receipt nor
posses:!Iion confer3 or tron8f~ any rlghb to reproduce, use, or disclose, In whole or In port, data contained
herein for any purpO:!lc. without the written permIssion of WESTECH ENGINEERING, INC., Salt Lake City. Utah

DETAIL 1

&.
r--------------,---.---.--t=I&
REVlSION

DAlE

L1R

DRA v"NG NUMBER

WEsTECH

D114

PROJECT NUMBER

REV.

21233A &,

INNER
END

_____J

l~____

@
1~"

la'

lr'

1~"

li"

1~"

1"

1"

1"

1"

1"

la'

PRIMARY ARM #1

1~"

1~"

la"

la"

H"

7\
L~____

INNER
END

J
~

1~"

1~"

1~"

1~"

1~"

i"

1~"

1"

1"

1"

1"

1.
2.
3.
4.

1"

PRIMARY ARM #2
5.
2"

2"

~-----------

-------------

L~

%>

WORK WITH DRAWINGS Dlll, Dl12, Dl13 & Dl14.


BUBBLED ITEMS REFER ~PARTS LIST DOCUMENT # 20748.
USE ANTI-SEIZE (ITEM 18 ON ALL STAINLESS STEEL FASTENERS.
APPLY PIPE JOINT COMP ND OR TEFLON TAPE TO THREADS OF
ALL PIPING JOINTS.
ARM ITEM NUMBERS ARE STAMPED ON THE TOP EDGE OF
CONNECTION FLANGES.
NOZZLE LOCATIONS MARKED AS 2" DO NOT HAVE AN ORIFICE
PLATE INSTALLED BECAUSE THE SPREADER OPENING IS ALREADY
2" DIAMETER.

INNER
END

___

@
1~"

2"

~I

1~"

SECONDARY ARM #1

2"

f -----------

~\

1~'

-------------

gJ

INNER
END

.~

~"-

ARM & ORIFICE ERECTION DETAIL

~'"
:1i

2"
1~"

OJ

~
~
~

1~'
DAlE
Thill drawing Is propl!lrty of VwESTECH ENGINEERING, INC. and 15 tronsmlttlld In confidence. Neither receipt nor
possesBJon confe/"3 or transfers ony rights to reproduce, use, or disclose, In whole or In port, dolo contained
herein for ony purpose, wlthoul the wrltten pennlS!llon of YiESTECH ENGINEERING, INC. Solt Lake City, Utah

SECONDARY ARM #2

'"0
OJ

~
u

$.

CJ

.&,.

, - - - - - - - - - - - - - - - - - - . - - - , - - - . - - - - - t =DAlE
-t&
WIESTIECH
LTR
REVISION

DRAv.1NG NUMBER

D115

PROJECT NUI,4BER

21233A

REV.

WIRE TYPE: (SIZE PER UL S08A)


POWER/CONTROL 2W SHIELDED CABLE 3W SHIELDED CABLE -

THHN/MTW
UL SmE 2092
UL STYLE 2093

WIRE COLORS:
BLACK
WHITE
RED
PURPLE
GREEN
BLUE
2W CABLE BLACK
2W CABLE WHITE
3W CABLE BLACK
3W CABLE RED
3W CABLE WHITE
3W CABLE BLACK
3W CABLE RED
3W CABLE WHITE

440VAC POWER
120VAC NEUTRAL
120VAC CONTROL
REMOTE (DRY)
GROUND
24VOC
PROFIBUS SIGNAL POSITIVE (IB)
PROFIBUS SIGNAL NEGATIVE (lA)
MODBUS SIGNAL POSITIVE (01)
MODBUS SIGNAL NEGATIVE (02)
MODBUS COM
SPEED POT +10VOC
SPEED POT WIPER
SPEED POT 10VDC COM

24.00"
(610 mm)

NAME PLA TES:


1 2 2 2 2 2 2 2 9 -

22.50"

13.00"
-(330 mm)

MAIN DISCONNECT
ROTARY DISTRIBUTOR
PANEL 01
ROTARY DISTRIBUTOR
PANEL 02
ROTARY DISTRIBUTOR
PANEL 03
ROTARY DISTRIBUTOR
PANEL 04
ROTARY DISTRIBUTOR
PANEL 05
ROTARY DISTRIBUTOR
PANEL 06
ROTARY DISTRIBUTOR
PANEL 07
ROTARY DISTRIBUTOR
MUST BE AT A
COMPLETE STOP BEFORE
TURNING OFF MAIN
DISCONNECT.

(572 mm)

5 6 7 -

8 -

(11 mm)

..,.-------11-61
p~
~~~=>----------------~~
1!!~!:!1'1

r-

rV

L--

0
L.()

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...--.,

...--.,

E
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0
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Om

IT]

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I")r---.

'--"

'--"

~~
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REMOTE/POT/TIMER
VFD RUN
POTENTIOMETER
VFD STOPPED
OFF/ON
VFD FAULT

gc
~

'-

.....
u

fJ

=>
c

MB
,, ,

-~

CRl-4

00 III r

:O:~WINDOW

,, ,

1.5" X3" DUCT

PR

lJ

FBI

I-

LEGEND PLATES:
3 4 -

0.44"

Gi
00

c::

!:l

1&

><

"I

80
VFO

1.5" x3' DUCT

~111111111111111111111~1111111_~1
'--_ _
0_---'

TBI

CD

TB2 TB3 GND

~L___________________~===I.=5"=X=3='=DU=CT=JV

DOOR LAYOUT
NEMA 4X ENCLOSURE
(STAINLESS STEEL)

LEFT SIDE VIEW

NOTES:
1234-

:g

to

I')

...

to

IX)

DASHED WIRING AND EQUIPMENT ARE NOT BY WESTECH ENGINEERING.


THIS ORAWING WORKS WITH PARTS LIST H 21873.
THIS DRAWING WORKS WITH DRAWINGS El0D - EI6D.
SELECTOR SWITCH FUNCTION DESCRIPTION:
(1) REMOTE (REM): SPEED IS REFERENCED BY THE CUSTOMER PROFIBUS INPUT.
(2) POTENTIOMETER (POT): SPEEO REFERENCED BY THE PANEL DOOR POTENTIOMETER.
(3) TIMER: SPEED IS REFERENCED BY PRESET FREQUENCIES AND ACTIVATED BY A
TIMED SIGNAL CONFIGURED VIA THE PROGRAMMABLE RELAY. SEE FREQUENCY PRESET
TABLE ON DRAWING EllD, VFO PARAMETERS SP2-SPB.
5- MODBUS DATA BUS REQUIRES LINE TERMINATIONS AT BOTH ENOS. ENSURE THE SERIAL
BUS BEGINS AND ENOS WITH LINE TERMINATIONS AS SHOWN PER DRAWING EI3D.

en

IX)

PREPARED FOR:

IQUITOS CITY WWTP


IQUnOS, PERU

a-

::l
~

to

::l
~

INTERIOR LAYOUT

::t

ROTARY DISTRIBUTOR CONTROL PANEL LAYOUT


SCR1PDON

ROTARY DISTRIBUTOR BIODOC \!!1


Uoot.

CUSTOMER:

AQUA ENGINEERING & SERVICES SA


PANAMA CITY, PANAMA

AGENT:

SPENA SAC
LIMA, PERU

CUSTOMER P.O. NO.:

26

o
to
o

IX)

:g

DAn:

I
STD. BY

STD.C><KO. STD.APPva

I RD-3-3
SlZt

NONE

06-11

SCAlE

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PES

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PRru. BY PRo.tCHKD. PRo.tAPl'VO

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Ol

---1---~

IS

LINE 121-4

RIC

i~RIB

VFD FAULT

~~I~

WD RUNNING

1MW

,1MW

POI

'J/
TO EI20

f-- I
I
f--:

Y
I

FROM lINE 1106

1160

1159

1158

1157

1156

1155

i~

CR3-1
II 5
9

10

22

GND

..

..

..

.:::t::

I-I

27

26

24

23

15

-=

___ J.-lSl

---

II
---H
II
II

---/\II

___ J.

---

II

II

II

II
___ H

---/\

"

II

Ii01

PR

jJ

28

28

28

28

28

28

128

440/120 VAC 250 VA CPT

IX21X21X211 1213141S16171819-l101111121131141

120 VAC (181)

20

20

&. CR2-1B
1154

X2

H4

rtlTlllIII

&. CR2-1A

&.

&.

H2

wX.w

H3

1153

20

20

...

XI

------~

XI

Hll

MOD8US TO
NEXT PANEL
(SEE DRAWING E13D)

MODBUS TO
PREVIOUS PANEL
(SEE DRAWING E13D)

END

TAPED

10K OHM
POT

VFD RUNNING
TO LINE 1143

TO LINE 1146

WD FAULT

WD STOP (ENABLE)

PRESET
FREQUENCIES
(SEVEN TOTAL
SEE NOTE 4)

SELECTOR SWITCH
(REMOTE)

WD RUN (FORWARD)

---11--

--;-115

20

20

2n

IE;,

..--_20_F~R

3.2 AMP

1.S AMP
FNQ-R

&. Fl.F2

----------- ...,.l.....

440 VA<
S KAIC
15 AMP WAIN BREAKER (M8)

SCCR

---- ..+: =~

1152

1151

1150

1149

1148

1147

1146

1145

1144

1143

1142

1141

1140

1139

1138

1137

1136

1135

1134

1133

1132

1131

1130

1129

1128

1127

1126

1125

1124

1123

1122

1121

1120

1119

1118

1117

1116

1115

1114

1113

1112

1111

1110

1109

1108

1107

1106

1105

1104

1103

1102

1101

CRI

111105

13

1111-1-

13

Tffm31

IT
1311-1-120211112021

N'

~2

...

c:

PLUG-IN

T T

.. ... ........ 1ADAPTER

...

"~R?~~"?~" i

G; ]
PT

SW2

&.

LIGHT

WD FAULT

LIGHT

WD STOP

VFD RUN
LIGHT

PROGRAMMABLE
RELAY CPR)

VFD FAULT
RELAY

VFO RUNNING
RELAY

VFD ENA8LE
RELAY

RELAY

WD RUN

PARAMETERS TO BE VERIFIEO
WITH MOTOR NAMEPLATE DATA
VFD1 SN: 881104117412
VFD2 SN: 881104117441
VFD3 SN: 8BI111201122
WD4 SN: 8Bl104117411
VFD5 SN: 881047103216
VFD6 SN: 881038109154
VFD7 SN: 881104117417

SWl

fFoil

01-07(SEE E161:>2

lI6

LI4
LIS
60 HZ
8 HZ
60 HZ
60 HZ
60 HZ
60 HZ
60 HZ
rMP

L13

SEP

lI2

All
IEr
ndb
ndb
L3

run

LIZ

ccs

SINK
SOURCE

VAC FT
100

DESCRIPTION
300 SEC.
300 SEC.
6 HZ
120 HZ
0.9
lfo-HZ
440 V
0.9
1765 RPM
120 HZ
2C
LEL
UnS
NCr
nSP
IFr
tCC
tCt
r2

ACC
dEC
LSP
HSP
ItH
bfr

Frl
Cd1
Fr2
Cll
Cd2
LAC
rFC
CHCF
PSS>PS2
PSS>PS4
PSS>PS8
PSS>SP2
PSS>SP3
FUn PSS>SP4
PSS>SPS
PSS>SP6
PSS>SP7
PSS>SP8
Stc>Stt
Stc>nSt
CON
Add

1-0

drC

SEt

TERMINATION (183)

B.\..'______-'
,

,~r,- - - - - - I

, ..

&. VFD SETTINGS

A~6SE:E1tO

ROTARY
DRIVE
NOT
1.1

PARAMETERS CHANGED
FROM DEFAULT
MODEl PARAM.

I&.

~2

(~ 13!:::!::::::====::!...~2

1OOf01TcTS]i50TCl1 l C I 51

I.

lit!:

PROGRAMMABLE RELAY
CPR)

NVT
/lNV-RJ45A

&.~

'CR4)

I"t7\. \

14

RJ45 ADAPTER
(RJ45)

~~~~=-~

RJ45
(MODBUS)

1111

L:
&.

16 116

ANALOG (T82)

/151---~--

R2A

I'R2c

I. RIC

~B

"I :,'~

20

24

20

~~~
~~~

U2

281'24V

LINE TERMINATION:
INSTALL ADAPTER
IN LAST PANEL
ONLY
(SEE NOTE 5)

PR

TO LINE 1135

UOTOR
THERUOSTAT

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ISOLATED FROM ALL OTHER CONDUITS AND WIRING.

REQUIREMENTS AND RECOMMENDATIONS.

1~

SPARE
TERMINALS

ffi-+------I

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.................

PROFIBUSIMODBUS
COMMUNICATION
PANEL :

....................

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100-240 VAC POWER

CUSTOMERS

CUSTOMERS
REMOTE INDICATIONS

1&

DRIVE

II

NO CUSTOMER
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NO CONNECTION
(NOT USED)

-------

SIGNAL TERMINATIONS

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____ _lI _ _

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(SEE DRAWING E130)

MODBUS FROM PREVIOUS


OR FIRST DEVICE
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SIGNAL TERMINATIONS

G) READ VFD MANUAL TO CONFIRM THAT INSTALLATION IS INSTALLED PER MANUFACTURES

F) DO NOT EXCEED RECOMMENDED DISTANCE FROM VFD TO MOTOR (100 FT). IF DISTANCE IS
EXCEEDED A LONG LEAD FILTER WILL 8E REQUIRED.

THE SETIING MAY HAVE TO BE HIGHER FOR LONG MOTOR LEADS DuE TO LINE LOSSES.

E) CHECK THE VFD OVERLOAD SETIING TO INSURE PROTECTION TO THE MOTOR.

GROUNDED.

0) ALL INSTRUMENTATION WIRING SHOULD BE RUN IN SEPARATE CONDUIT AWAY FROM POWER AND
CONTROL WIRING. WIRE SHOULD 8E SHIELDED CABLE WITH ONLY ONE ENO OF THE SHIELD

AN APPROVED SHIELDED CABLE.

INSTRUMENTATION WIRING. OR POWER AND CONTROL WIRE TOGETHER. WITH POWER WIRING IN

FIELD WIRING DIAGRAM

IT[J--rs--MOTOR THERMOSTAT

i 0

NO CUSTOMER
CONNECTION

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;

i 0

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OUT TO THE MOTOR GROUND LUG.

C) ALL CONTROL WIRING SHOULD BE RUN IN SEPARATE CONDUIT AWAY FROM POWER AND

CONTROL PANEL GROUND BAR. AND FROM THE VFD

B) BE SURE TO INSTALL A HARD WIRE GROUND CONDUCTOR FROM THE POWER SOURCE TO THE

{ I ;:~[~~~=J
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. T-+-----r------- ~~T~~g~OWER

"

...........
.......

ROTARY
DISTRIBUTOR
CONTROL PANEL(S)

REMOTE INDICATION
7.5 AMPS @ 120VAC MAX.
BRANCH CIRCUIT PROTECTION BY OTHERS

RIP

ROTARY DRIVE
SWITCH IN REMOTE

~-L..-~

13

R P T

VFD FAULT

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1222

1221

1220

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1218

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1216

1215

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NOTES:
1234-

10

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:2

:2

OASHED WIRING AND EQUIPMENT ARE NOT BY WESTECH ENGINEERING.


THIS DRAWING WORKS WITH PARTS LIST # 21873.
THIS DRAWING WORKS WITH DRAWINGS El0D - EI6D.
SELECTOR SWITCH FUNCTION DESCRIPTION:
(1) REMOTE (REM): SPEED IS REFERENCED BY THE CUSTOMER PROFIBUS INPUT.
(2) POTENTIOMETER (POT): SPEED REFERENCED BY THE PANEL DOOR POTENTIOMETER.
(3) TIMER: SPEED IS REFERENCED BY PRESET FREQUENCIES AND ACTIVATED BY A
TIMED SIGNAL CONFIGURED VIA THE PROGRAMMABLE RELAY. SEE FREQUENCY PRESET
TABLE ON DRAWING El1D. VFD PARAMETERS SP2-SP8.
5- MODBUS DATA BUS REQUIRES LINE TERMINATIONS AT BOTH ENDS. ENSURE THE SERIAL
BUS BEGINS AND ENDS WITH LINE TERMINATIONS AS SHOWN PER THIS DRAWING.

a
If)

:2
PREPARED FOR:

IQUITOS CITY WWTP


IQUITOS. PERU

CUSTOMER:

AQUA ENGINEERING & SERVICES SA


PANAMA CITY. PANAMA

AGENT:

SPENA SAC
LIMA, PERU

CUSTOMER P.O. NO.:

26

NETWORK DIAGRAM
DSCI\'IPnON

ROTARY DISTRIBUTOR BIODOC

..

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51 E

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PR -

12
13
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11

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@1

DESCRIPTION
PRESET SPEED-2
PRESET SPEED 3
PRESET SPEED 4
PRESET SPEED 5
PRESET-SPEED-6
PRESET-SPEED-7
PRESET SPEED 8

SETTINGS

RUN

XX: XX

DO

Ql
02
03

PS2
PS3
PS4
SPARE

PR OUTPUTS

P'o,rC]

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START TIME

0:00
0:00

5:00
6:00
0:00
0:00

0:00

START TIMES (@)


PRESS THE OK. BUTTON TO DISPLAY THE MENU SCREEN
PRESS THE DOWN ARROW TO MOVE CURSOR TO STOP"
PRESS THE QIi BUTTON TO SWITCH THE DISPLAY TO RUN~
PRESS THE UP AND DOWN BUTTONS TO DISPLAY "PARAMETERS' SUB MENU AND PRESS "OK."
TO SHOW 00.
PRESS THE Q!S BUTTON THE 0 WILL FLASH
PRESS THE UP ARROW TO SHOW THE TIMER TO BE CHANGED.
PRESS QK THE CURSOR WIll FlASH THE NUMBER TO BE CHANGED.
PRESS THE RIGHT ARROW 4 TIMES TO SEE THE START TIME.
PRESS QK TO START THE EDIT OF THE START TIME.
USE THE LEFT AND RIGHT ARROWS TO MOVE BETWEEN HOUR OR MINUTE OF THE ON TIME.
USE THE UP AND DOWN ARROWS TO CHANGE THE NUMBERS.
PRESS Q!S TO SAVE THE SETTINGS.
PRESS THE RIGHT ARROW 2 TIMES TO GO TO OFF TIME.
USE THE LEFT AND RIGHT ARROWS TO MOVE BETWEEN HOUR OR MINUTE OF THE OFF TIME.
USE THE UP AND DOWN ARROWS TO CHANGE THE NUMBERS.
PRESS QK TO SAVE THE SETTINGS.
PRESS ~ TO GO TO THE MAIN SCREEN.
PRESS THE UP ARROW TO GET TO "RUN".
PRESS QK TO PUT THE OMRON IN RUN.
PRESS ~ TO GO BACK TO THE I/O SCREEN.

SETPOINT CHANGE INSTRUCTIONS

0:01
0:01
0:01

STOP TIME
5:00
6:00
0:00
0:01

LOCALVFD
MODBUS
ADDRESS

LOCALVFDPARAMETER

VFD2
001C
001E
0020
0022
0024
0026
0028
002A
002C
002E
0030
0032
0034
021C
021E
0220
0222
0224
0226
0228
022A
022C
022E
0230
0232
0234

VFD3
0036
0038
003A
003C
003E
0040
0042
0044
0046
0048
004A
004C
004E
0236
0238
023A
023C
023E
0240
0242
0244
0246
0248
024A
024C
024E

VFD4
0050
0052
0054
0056
0058
005A
005C
005E
0060
0062
0064
0066
0068
0250
0252
0254
0256
0258
025A
025C
025E
0260
0262
0264
0266
0268

VFD5
006A
006C
006E
0070
0072
0074
0076
0078
007A
007C
007E
0080
0082
026A
026C
026E
0270
0272
0274
0276
0278
027A
027C
027E
0280
0282

VFD6 VFD~
0084 009E
0086 OOAD
0088 00A2
008A OOM
008C 00A6
008E 00A8
0090 OOM
0092 OOAC
0094 OOAE
0096 OOBO
0098 00B2
009A 00B4
009C 00B6
0284 029E
0286 02A0
0288 02A2
028A 02A4
028C 02A6
028E 02A8
0290 02AA
0292 02AC
0294 02AE
0296 02BO
0298 02B2
029A 02B4
029C 0286

GATEWAY MEMORY START ADDRESS (HEX)

COMMUNICATION GATEWAY
PROFIBUS/MODBUS MEMORY LOCATIONS

12.
13.
14.
15.
16.
17.
18.
19.

11.

10.

8.
9.

7.

6.

4.
5.

3.

2.

1.

PR -

~
ABOVE IS A USTING OF ALL THE FIELD SELECTABLE SETTINGS IN
THE CONTROLLER.

1.

@6

@5

@4

@3

@2

IN. TIMER.MODE
SPARE
SPARE
SPARE
SPARE
SPARE

PR INPUTS

ZEN V2

I I I I I

o0

@O

345

DEC
HEX
PARAM
DESCRIPTION *
TYPE
VFD1
10#3201 16#OC81
ETA
STATUS WORD
READ
0002
10#3202 16#OC82
rFr
OUTPUT FREQ.
READ
0004
10#3203 16#OC83
FrH
FREQ. BEFORE RAMP
0006
READ
10#3204 16#OC84
CURRENT IN MOTOR
READ
LCr
0008
MOTOR TORQUE
10#3205 16#OC85
Otr
READ
OOOA
10#3206 16#OC86
EXTENDED STATUS WORD READ
En
OOOC
10#3207 16#OC87
Uln
LINE VOLTAGE
READ
OOOE
10#3209 16#OC89
tHd
DRIVE 1HERMAL STATE
READ
0010
MAX1HERMALREACHED
READ
10#3210 16#OC8A
TDM
0012
SPARE
READ
0014
SPARE
READ
0016
SPARE
0018
READ
SPARE
001A
READ
10#8501 16#2135
CMD
CONTROL WORD
WRITE
0202
10#8502 16#2136
LFr
FREQ. REFERENCE (BUS) WRITE
0204
10#11410 16#2C92
2ND PRESET SPEED
WRITE
0206
SP2
10#11411 16#2C93
SP3
3RD PRESET SPEED
WRITE
0208
10#11412 16#2C94
SP4
41H PRESET SPEED
WRITE 020A
10#11413 16#2C95
SP5
5TH PRESET SPEED
WRITE 020C
10#11414 16#2C96
SP6
61H PRESET SPEED
WRITE 020E
10#11415 16#2C97
SP7
7TH PRESET SPEED
WRITE
0210
10#11416 16#2C98
SP8
81H PRESET SPEED
WRITE
0212
SPARE
0214
WRITE
SPARE
WRITE
0216
SPARE
WRITE
0218
SPARE
WRITE 021A
* REFER TO VFD PROGRAMMING MANUAL FOR PARAMETER DETAILS

&.

:z

I I I I I I I

I 0 1

OMRON

PR

PROGRAMMABLE RELAY
DEVICE SETTINGS

WIRE TYPE: (SIZE PER UL 50BA)


POWER/CONTROL 2W SHIELDED CABLE JW SHIELDED CABLE -

THHN/MTW
UL STYLE 2092
UL STYLE 2093

WIRE COLORS:
WHITE
RED
GREEN
BLUE
2W CABLE BLACK
2W CABLE WHITE
3W CABLE BLACK
3W CABLE RED
3w CABLE WHITE

120VAC NEUTRAL
120VAC CONTROL
GROUND
24VDC
PROFIBUS SIGNAL POSITIVE (IB)
PROFIBUS SIGNAL NEGATIVE CIA)
MODBUS SIGNAL POSITIVE (01)
MOD BUS SIGNAL NEGATIVE (02)
MODBUS COM

f-I-

NAME PLATES:
1 -

PROFIBUS/MODBUS COMMUNICATION PANEL

0.44"

(11 mm)

12.00"
(305 mm) .......
10.50"

"\267 mmj

---r---~~

I!!~~~I
r--..

r--..

E
E

E
E

L()
'L()

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'-../

0
0

'I.J

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CIl

tD tD

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I

1" X 3" DUCT

GND

..- 0

_1111111111111-

'-../

TBl

TB2 TB3

a
1")'--_ _ _----'('1.

DOOR LAYOUT
NEMA 4X ENCLOSURE
(STAINLESS STEEL)

LEFT SIDE VIEW

NOTES:
1- DASHED WIRING AND EQUIPMENT ARE NOT BY WESTECH ENGINEERING.
2- THIS DRAWING WORKS WITH PARTS LIST # 21920.
3- THIS DRAWING WORKS WITH DRAWINGS El0D - EI6D.
4- SELECTOR SWITCH FUNCTION DESCRIPTION:
(I) REMOTE (REM): SPEED IS REFERENCED BY THE CUSTOMER PROFIBUS INPUT.
(2) POTENTIOMETER (POT): SPEED REFERENCED BY THE PANEL DOOR POTENTIOMETER.
(3) TIMER: SPEED IS REFERENCED BY PRESET FREQUENCIES AND ACTIVATED BY A
TIMED SIGNAL CONFIGURED VIA THE PROGRAMMABLE RELAY. SEE FREQUENCY PRESET
TABLE ON DRAWING EllD, VFO PARAMETERS SP2-SPB.
5- MOOBUS DATA BUS REQUIRES LINE TERMINATIONS AT BOTH ENDS. ENSURE THE SERIAL
BUS BEGINS AND ENDS WITH LINE TERMINATIONS AS SHOWN PER DRAWING E130.

fil

10

PREPARED FOR:

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INTERIOR LAYOUT

IQUITOS CITY WWTP


IQUITOS, PERU

CUSTOMER:

AQUA ENGINEERING & SERVICES S.A.


PANAMA CITY, PANAMA

AGENT:

SPENA SAC
LIMA, PERU

CUSTOMER P.O. NO.:

26

COMMUNICATION PANEL LAYOUT


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U;
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DASHED WIRING AND EQUIPMENT ARE NOT BY WESTECH ENGINEERING.


THIS DRAWING WORKS WITH PARTS LIST # 21920.
THIS DRAWING WORKS WITH DRAWINGS El0D - EI6D.
SELECTOR SWITCH FUNCTION DESCRIPTION:
(1) REMOTE (REM): SPEED IS REFERENCED BY THE CUSTOMER PROFIBUS INPUT.
(2) POTENTIOMETER (POT): SPEED REFERENCED BY THE PANEL DOOR POTENTIOMETER.
(3) TIMER: SPEED IS REFERENCED BY PRESET FREQUENCIES AND ACTIVATED BY A
TIMED SIGNAL CONFIGURED VIA THE PROGRAMMABLE RELAY. SEE FREQUENCY PRESET
TABLE ON DRAWING EllD, VFD PARAMETERS SP2-SPB.
5- MODBUS DATA BUS REQUIRES LINE TERMINATIONS AT BOTH ENDS. ENSURE THE SERIAL
BUS BEGINS AND ENDS WITH LINE TERMINATIONS AS SHOWN PER DRAWING EI3D.

N
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PREPARED FOR:

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IQUITOS CITY WWTP


IQUITOS. PERU

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OESCRIPnON

ROTARY DISTRIBUTOR BIODOC W

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CUSTOMER:

AQUA ENGINEERING & SERVICES SA


PANAMA CITY, PANAMA

AGENT:

SPENA SAC
LIMA, PERU

CUSTOMER P.O. NO.:

26

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