Addendum to the Assembly and Operating Instructions

Transcription

1 Drive Technology \ Drive Automation \ System Integration \ Services * _017* Addendum to the Assembly and Operating Instructions Industrial Gear Units Motor Pump with Pressure Lubrication /ONP1 Edition 0/ /EN

2 SEW-EURODRIVE Driving the world

3 Table of contents Table of contents 1 Important information Motor pump with pressure lubrication Structure/function Wiring diagram (schematic illustration) Installation/assembly Notes on checking the oil level Startup Inspection/maintenance Malfunctions Permitted lubricants Supplier documentation Transfer Gear Pumps - Operating and Maintenance Instructions Transfer Gear Pumps - Technical data Pressure Switch - Operating Instructions Bourdon tube pressure gauge - data sheet Bimetal thermometer - data sheet Flow switch - Operating instructions Flow switch - data sheet Pressure sensors - data sheet Single Filter - Operating instructions Duplex filter Pi Operating instructions Maintenance Indicators - Operating Instructions... 12

4 1 Important information 1 Important information INFORMATION This addendum describes amendments to the Pressure Lubrication System operating instructions. Observe the additional information specified in this document. This document does not replace the detailed operating instructions. 4

5 Motor pump with pressure lubrication Structure/function 2 2 Motor pump with pressure lubrication 2.1 Structure/function Structure With pressure lubrication, a motor pump supplies all bearing points and gearing above the oil sump with oil via a tube system inside the gear unit. The motor pump is used, for example, if the shaft end pump speed is 400 min -1, or for inverter operation if using a shaft end pump is only possible to a certain extent. The motor pump is mounted externally to the gear unit and is independent from the speed of the gear unit. For gear unit sizes X140 - X20, the pump is equipped with an integrated pressure control valve. INFORMATION In addition, observe the operating instructions of the motor pump manufacturer. The following figures show the gear unit in mounting positions M1 and M5 with the standard mounting surfaces for the motor pump. INFORMATION Mounting surfaces deviating from the standard require the construction of a new piping set. This may affect the minimum oil viscosity. A comprehensive individual check is required. Contact SEW EURODRIVE. 5

6 2 Motor pump with pressure lubrication Structure/function Mounting position M1 / mounting surface F6 [1] [1] [2] [] [4] [2] [] [4] [7] [6] [5a] [1] Motor [5a] Duplex filter [2] Pump [5b] Single filter [] Suction pipe [6] Pressure switch [4] Measuring group [7] Pressure pipe [7][6][5b] Mounting position M5 / mounting surface F1 [1] [2] [] [6][5a] [4] [7] [1] Motor [5a] Duplex filter [2] Pump [5b] Single filter [1] [2] [] [6] [5b] [4] [7] [] Suction pipe [6] Pressure switch [4] Measuring group [7] Pressure pipe

7 Motor pump with pressure lubrication Structure/function 2 Hydraulics diagram single filter The following figure shows an example of the standard gear unit structure of the oil supply systems. [] [4] [1] M [2] [5] [6] [1] Motor [4] Pressure switch [2] Pump [5] Check valve [] Single filter [6] Gear unit The following figure shows possible options that can be installed. [1] [2] [] [4] [1] Pressure sensor [] Manometer [2] Thermometer [4] Flow switch 7

8 2 Motor pump with pressure lubrication Structure/function Hydraulics diagram duplex filter The following figure shows an example of the standard gear unit structure of the oil supply systems. [] [4] [1] M [2] [5] [6] [1] Motor [4] Pressure switch [2] Pump [5] Check valve [] Duplex filter [6] Gear unit The following figure shows possible options that can be installed. [1] [2] [] [4] [1] Pressure sensor [] Manometer [2] Thermometer [4] Flow switch 8

9 Motor pump with pressure lubrication Structure/function General information The motor pump is delivered as a complete unit but without electrical connections. Default As standard, the motor pump comprises: Pump with directly connected asynchronous motor (pump always running) Pressure switch that monitors the pump pressure. Warning or switch-off signal when the oil pressure reaches < 0.5 bar Measuring group (pressure switch installed as standard) Single filter with electrical/optical maintenance indicator Optional accessories The motor pump can be equipped with the following components as an option: Temperature switch /NTB with trip point for monitoring the cooling group, i.e. warning or gear unit shutdown at an oil temperature > 90 C Duplex filter with electrical/optical maintenance indicator Installed in the measuring group: Manometer Thermometer Flow switch Pressure sensor 9

10 2 Motor pump with pressure lubrication Structure/function 2.1. Function Observe the following control information for the individual components. Pump The pump motor has to be switched on 10 s prior to gear unit startup and is always running during operation of the gear unit. For gear unit sizes X140 20, a pressure control valve integrated in the pump limits the plant pressure if the pump is operated. INFORMATION Do not change the default setting of the valve. Oil supply system The oil supply system always starts up together with the gear unit max. start viscosity 5000 cst. Temperature switch/ntb (optional) Temperature monitoring of the system is realized using a temperature switch/ntb connected to the user's controller. At T > 90 C STOP GEAR UNIT/WARNING Filter The filter is monitored visually by a pressure deviation indicator, and electrically by a pressure deviation monitoring device. When m p > 2.2 bar WARNING (clean filter) General information The pressure switch requires a 10 s startup delay. Check valve The check valve opens at a pressure of 1 bar. 10

11 Motor pump with pressure lubrication Structure/function Interlocking specifications Gear unit enable The gear unit is enabled if the following condition is met: Oil pressure p > 0.5 bar (startup delay of 10 s) Oil temperature T < 90 C (optional) STOP gear unit/warning Gear unit STOP/warning if one of the following conditions is met: Oil pressure p < 0.5 bar Oil temperature T > 90 C (optional) Sizes and selection The performance data of the standardized motor pump is summarized in the following table. Size Pump size Type Motor data IEC standard Number of poles Connected load pump motor in kw Global motor in Hz Pump capacity at /min ONP1 6 KF 6 RF DRE 80M / ONP1 8 KF 8 RF DRE 80M / ONP1 10 KF 10 RF DRN 80M / ONP1 12 KF 12 RF DRN 90S / ONP1 16 KF 16 RF DRN 90S / ONP1 20 KF 20 RF DRN 90L / ONP1 25 KF 25 RF DRN 100L /

12 2 Motor pump with pressure lubrication Wiring diagram (schematic illustration) 2.2 Wiring diagram (schematic illustration) The wiring diagrams show a possible setup of the control for the cooling system Control circuit with optional temperature switch/ntb L1 F1 F2 S0 Emergency off S1 K5 Option S2 K5 P p < 0.5 bar p > 0.5 bar ϑ T2 opens at ϑ OIL > 90 C K1T 10 s K4 K5 K1T K1 K2 K Temp. signal to main motor control: Warning/switch-off N Main contactor "On" for main motor control Time-delay relay Main circuit L1 L2 L F F4 K4 K5 Signal from: Contactor K1, K2 Option: Signal from contactor K via temperature switch type NTB (NC) Warning/Switch-off Main motor control M1 M M2 M PE Main motor Pump motor

13 Motor pump with pressure lubrication Installation/assembly 2 2. Installation/assembly 2..1 Mechanical connection Connect the motor pump to the lubrication circuit according to the identifying markings and observing local regulations. In this respect, observe the following basic conditions: Do not reduce the specified cable cross section. It is important that you choose the correct wall thickness and material when selecting pipes, hoses and screw fittings Electrical connection Observe country-specific regulations during the electrical connection. With the standard design, connect the following components: Motor Temperature switch (optional) Pressure switch Filter maintenance indicator Observe the following information. Make sure that the pump rotates in the correct direction. Observe the motor data sheet. The pump motor has to be switched on 10 s prior to gear unit startup and is always running during operation of the gear unit. The pressure switch issues a warning signal when the pressure falls below 0.5 bar. The maintenance indicator of the filter indicates when the filter element needs to be replaced. When using options: Connect the temperature switch/ntb to the customer-provided control. Connect the flow switch to the customer-provided control. Connect the pressure sensor to the customer-provided control. Observe the following information. If a temperature switch/ntb is used, it must be integrated in the circuit in a way that a warning signal is issued and the main drive is switched off if the switching point of 90 C is reached. 1

14 2 Motor pump with pressure lubrication Installation/assembly 2.. Limit temperature for start-up of the motor pump To ensure a correct function of the motor pump, the gear unit oil must have at least the minimum oil viscosity. The viscosity depends on the used oil, and on the oil temperature in the oil pipes/hoses and in the oil pump. Observe chapter "Permitted lubricants" ( 2 19). When the motor pump is used at low ambient temperatures, it may be required to adjust the motor pump. Contact SEW EURODRIVE, if required Technical data of electrical/optical maintenance indicator The following figure shows the wiring diagram: 2 1 The following table shows the technical data: Max. voltage Max. switching current Max. switching capacity Degree of protection Contact type AC 250 V / DC 200 V 1.0 A 70W IP 65 in plugged and secured condition NO contact / NC contact 14

15 Motor pump with pressure lubrication Notes on checking the oil level Notes on checking the oil level Using an oil supply system might influence the oil level. The fill quantities specified on the nameplate are guide values and refer only to the gear unit. The mark on the oil sight glass, oil level glass or oil dipstick is the decisive indicator for the correct oil quantity. Observe the chapter "Checking the oil level" in the operating instructions for the X.. series industrial gear units Additionally required gear unit oil The following table shows the lubricant fill quantity for the motor pump which has to be filled into the gear unit additionally. Size ONP1 6 ONP1 8 ONP1 10 ONP1 12 ONP1 16 ONP1 20 ONP1 25 Lubricant fill quantity in liters

16 2 Motor pump with pressure lubrication Startup 2.5 Startup Notes NOTICE Improper startup of gear units with pressure lubrication can damage the gear unit. Possible damage to property. Note the following Prior to startup, make sure that monitoring devices (pressure switch, flow switch, temperature switch/ntb etc.) are fully operational. Do not start up the gear unit if the pressure switch is not connected. Before taking the gear unit into operation for the first time and after each oil change, run the oil pump at least 10 minutes to ensure that all oil chambers are filled with oil. After the 10 minutes, switch off the pump and adjust the oil level is required. Note that the pump must run 10 seconds before startup of the gear unit. An oil heater is mandatory when operating the gear unit with pump at low temperatures. For further information, refer to chapter Limit temperature for start-up of the cooling system Venting the oil pump WARNING Danger due to leaking and squirting gear unit oil. Serious injury. You must wear safety goggles. Be very careful when you vent the pump. If the pump does not supply oil immediately after the start, do the following: Fill the oil pump with oil. Vent the oil supply system on the pressure side during start, if possible at the highest point. 16

17 Motor pump with pressure lubrication Inspection/maintenance Flow switch Observe the following procedure: 1. Start up the pump. 2. Connect the flow switch.. Perform the high-flow adjustment, observe the notes in the manufacturer documentation (see attachment). 4. Set the switch-off point of the flow switch to LED 4 or 5 and observe the notes in the manufacturer documentation. 5. Integrate the switching point into the system in a way that the gear unit is switched off if the value is undercut. 2.6 Inspection/maintenance INFORMATION First read the operating instructions of the cooling system manufacturer Inspection and maintenance intervals Adhere to the following inspection and maintenance intervals. Time interval Depending on the operating conditions, at least every 12 months Varying (depending on external factors) What is to be done? Check the condition of the motor pump, replace filter element if necessary Check all hose pipes for tightness. The period of use of hose pipes should not exceed 6 years from the date of manufacture printed on them Checking hose pipes NOTICE Hoses and hose pipes are subject to natural aging even if they are properly stored and used. This is why the period of use is limited. The period of use of hose pipes should not exceed 6 years from the date of manufacture printed on them. The operator of the plant is responsible for making sure that hose pipes are replaced at adequate intervals even if they do not show any signs of safety-related defects. Have hose pipes checked by a specialist at least once a year to ensure operational safety. 17

18 2 Motor pump with pressure lubrication Malfunctions 2.7 Malfunctions Failure Possible cause Remedy No oil pump suction Air in the pipes Motor not running Wrong direction of rotation of the motor Not enough oil in the gear unit Wrong oil grade Fill the suction line and oil pump with oil Vent pressure pipe during startup Check electrical connections Check electrical connections Check oil level in gear unit Check oil grade (in particular when temperatures are low) Delivery rate of oil pump not sufficient Wrong motor speed Oil circulation clogged Negative pressure at pump suction side too high Wrong oil grade Check pump motor speed Open valves and plugs Increase cross section of suction line Decrease suction lift Check oil grade (in particular when temperatures are low) Pump excessively loud Negative pressure at pump suction side too high The pump delivers froth Leaky suction line Not enough oil in the gear unit Increase cross section of suction line Decrease suction lift Avoid distortion of the suction line Avoid reductions in the suction pipes Check screw fittings for leaks Check oil level in gear unit Pressure switch does not switch Air in the pipes Pressure switch connected incorrectly Pressure switch defective Fill the suction line and oil pump with oil Vent pressure pipe during startup Check the connection Replace pressure switch 18

19 Motor pump with pressure lubrication Permitted lubricants Permitted lubricants This chapter describes the permitted lubricants and the permitted temperatures for industrial gear units from SEW EURODRIVE. INFORMATION The standard for viscosity and oil grade is the type of oil that is specified by SEW EURODRIVE in the order (see order confirmation and nameplate). Contact SEW EURODRIVE if you use bio and food grade lubricants or polyglycol oils. Check the compatibility of the greases and oils used. The tables contain the lubricants approved by SEW EURODRIVE. Oils of the same viscosity class from different manufacturers do not have the same characteristics. In particular, the minimum permitted oil bath temperatures are manufacturer-specific. These temperatures are specified in the lubricant tables. The minimum permitted oil bath temperatures depend on the lubrication type used. These temperatures are specified in the lubricant tables. The values correspond to the maximum viscosity of the individual lubricants. The values specified in the lubricant tables apply as of the time of printing of this document. The data of the lubricants are subject to dynamic change on the part of the lubricant manufacturers. For the latest information about the lubricants, visit: Explanation of the structure of the tables and abbreviations Icons CLP CLP HC E Designation = Mineral oil = Synthetic polyalphaolefin (PAO) = Oil based on esters = Mineral lubricant = Synthetic lubricant = Lubricant for the food industry (NSF H1-compliant) Oil Oil = Biodegradable oil (lubricant for agriculture, forestry, and water management) 1) = Lubricants may only be used if service factor F s 1. RWDR = Radial oil seal 19

20 2 Motor pump with pressure lubrication Permitted lubricants Explanation of the various lubricants [5] [1] [2] [] [6] [4] xyz SEW [7] [1] Lowest cold start temperature in C for splash lubrication* [2] Lowest cold start temperature in C for drives with pumps up to a max. oil viscosity of 5000 cst* [] Lowest cold start temperature in C for drives with pumps up to a max. oil viscosity of 2000 cst* [4] Trade name [5] Manufacturer [6] Highest oil bath temperature in C. MUST NOT BE EXCEEDED. [7] Approvals *In case of low temperatures, the oil must be heated to the specified minimum temperature, for example by using an oil heater. The maximally permitted oil viscosity per pump type is specified in the following chapter Explanation of the oil supply systems and the oil viscosity The motor pump is designed for an oil viscosity of 5000 cst. 20

21 Motor pump with pressure lubrication Permitted lubricants Lubricant tables This lubricant table is valid when the document is published. Please refer to for the latest version of the table. Optigear BM 150 Alpha SP 150 Klüberoil GEM N S0 S0 S0 S S0 S0 ISO,SAE NLGI DIN (ISO) API VG 150 1) VG FUCHS Mobil LUBRICATION TO T A L Sh e ll TEXACO Renolin CLP 150 Plus Renolin HighGear 150 Mobilgear 600 XP 150 Meropa SEW Optigear BM 220 Alpha SP 220 Renolin CLP 220 Plus Renolin HighGear 220 Mobilgear 600 XP 220 Klüberoil GEM N Shell Omala Oil F 220 Meropa 220 Carter EP 220 S0 S0 S0 S SEW S S S S Optigear BM 20 Alpha SP 20 Renolin CLP 20 Plus Renolin HighGear 20 Mobilgear 600 XP 20 Klüberoil GEM 1-20 N Shell Omala Oil F 20 Meropa 20 Carter EP 20 S0 S0 S0 S SEW S S S S Optigear BM 460 Alpha SP 460 Renolin CLP 460 Plus Renolin HighGear 460 Mobilgear 600 XP 460 Klüberoil GEM N Shell Omala Oil F 460 Meropa 460 Carter EP 460 S0 S S0 S SEW S VG 20 CLP VG 460 VG 680 VG 1000 S0 S0 S Optigear BM 680 Alpha SP 680 Renolin CLP 680 Plus Renolin HighGear 680 Mobilgear 600 XP 680 Klüberoil GEM N Meropa 680 Carter EP 680 S0 S S0 S0 SEW S0 S0 S0 Optigear BM 1000 S

22 2 Motor pump with pressure lubrication Permitted lubricants This lubricant table is valid when the document is published. Please refer to for the latest version of the table. CLP HC DIN (ISO) API VG 1000 VG 680 VG 460 VG 20 VG 220 VG 150 1) VG 68 1) VG 2 1) ISO,SAE NLGI S0 S0 S0 SHC 69 SHC Gear 1000 Klübersynth EG S0 S0 S0 S0 S0 S0 S0 S0 Optigear Synthetic X 680 Renolin Unisyn CLP 680 HighGear Synth 680 SHC 66 SHC Gear 680 Klübersynth GEM N Omala S4 GX 680 Carter SH S0 S0 S0 S0 S0 S0 S0 S0 S0 S0 Alphasyn EP 460 Optigear Synthetic X 460 Renolin Unisyn CLP 460 HighGear Synth 460 SHC 64 SHC Gear 460 Klübersynth GEM N Omala S4 GX 460 Pinnacle EP 460 Carter SH S0 S0 S0 S0 S0 S0 S0 S0 S0 S0 Alphasyn EP 20 Optigear Synthetic X 20 Renolin Unisyn CLP 20 HighGear Synth 20 SHC 62 SHC Gear 20 Klübersynth GEM 4-20 N Omala S4 GX 20 Pinnacle EP 20 Carter SH S0 S0 S0 S0 S0 S S0 S0 S0 S0 Alphasyn EP 220 Optigear Synthetic X 220 Renolin Unisyn CLP 220 HighGear Synth 220 SHC 60 SHC Gear 220 Klübersynth GEM N Omala S4 GX 220 Pinnacle EP 220 Carter SH S0 S0 S0 S0 S0 S0 S0 S0 S0 Alphasyn EP 150 Optigear Synthetic X 150 Renolin Unisyn CLP 150 SHC 629 SHC Gear 150 Klübersynth GEM N Omala S4 GX 150 Pinnacle EP 150 Carter SH S0 S0 S0 S0 Renolin Unisyn CLP 68 SHC 626 Klübersynth GEM 4-68 N Omala S4 GX S0 SHC Mobil LUBRICATION TO T A L Sh e ll TEXACO FUCHS

23 Motor pump with pressure lubrication Permitted lubricants 2 This lubricant table is valid when the document is published. Please refer to for the latest version of the table. DIN (ISO) API CLP HC NSF H1 E ISO,SAE NLGI VG 68 1) VG 220 1) VG 460 1) VG 460 S0 S0 S Cassida Fluid HF Cassida Fluid GL Cassida Fluid GL 460 S0 S0 S Optileb HY 68 Optileb GT 220 Optileb GT FUCHS S0 S S0 Plantogear 460 S S0 S0 LUBRICATION Klüberoil 4UH1-68 N Klüberoil 4UH1-220 N Klüberoil 4UH1-460 N Klüberbio CA

24 Supplier documentation Supplier documentation Table of Contents 2 Transfer Gear Pumps - Operating and Maintenance Instructions Transfer Gear Pumps - Technical data Pressure Switch - Operating Instructions Bourdon tube pressure gauge - data sheet Bimetal thermometer - data sheet Flow switch - Operating instructions Flow switch - data sheet Pressure sensors - data sheet Single Filter - Operating instructions Duplex filter Pi Operating instructions Maintenance Indicators - Operating Instructions / EN 0/

25 Supplier documentation Transfer Gear Pumps Operating and Maintenance Instructions KF 4 80 Transfer Pumps 25

26 Supplier documentation List of Contents Safety 1 Safety Instruction Symbols 1 General Safety Instructions 1 Address of Manufacturer: 1 The Documentation 2 Description of Equipment 2 General 2 Specified Use Construction Technical Data 4 Explanation of Type Code 4 General Data 5 Overview of Nominal sizes 5 Overview of Materials 6 Overview of Operating Pressures 6 Pump installation and removal 6 Mechanical Installation 6 Alignment of the Coupling 7 Determining the Direction of Rotation 8 Suction Pipework 9 Pressure Line 9 Pump Removal 11 Commissioning 11 Special feature on sealing variants 4 and 7 (Double radial shaft sealing ring) 12 Pressure setting of the pressure relief valve 12 Maintenance 1 Seals 1 Maintenance of the seal variants 4 and 7 (Double radial shaft sealing ring) 1 Maintenance of the seal variants 5 and 6 (Slide ring seals) 1 Changing the direction of rotation of the pump 14 Tightening torque for cover fixing screws 14 Change in direction of rotation with sealing variant 5 (Slide ring sealing) 14 Repairs 14 Elimination of the Fault 14 Diagnosis 15 Detection and Elimination of Faults 15 26

27 Supplier documentation Safety Safety Instruction Symbols The safety notes contained in these operating instructions are identified by the following warning symbol. If these warnings are not heeded, the consequence can be danger to life and limb and damage to equipment.. Other notes, which do not warn of danger, but which provide tips for optimum operation, are symbolised by a hand. General Safety Instructions The operating safety of the pump supplied is only guaranteed if the pump is used as specified (see Description of equipment ). The stated limiting values (see Technical data ) must not be exceeded under any circumstances. Personnel having the responsibility for installing, operating or repairing the pump must possess the appropriate qualifications; these may have been obtained through training or appropriate instruction. Such personnel must be familiar with the contents of these operating instructions. During the execution of all work, the prevailing national regulations relating to accident prevention and safety at the work place and where appropriate, the internal regulations of the operator must be observed, even if the latter are not named in these operating instructions. Leakages of dangerous substances handled by the pump must be contained and disposed of in such a way that there is no danger to personnel or to the environment. In so doing, the relevant statutory regulations must be observed. During all work on the pump and prior to installation, the connecting pipework must be depressurised and the motor isolated! The operator must ensure that these operating instructions are accessible at all times to personnel concerned with the operation of the equipment. Address of Manufacturer: KRACHT GmbH Gewerbestrasse Werdohl Tel / Fax / BKF E 1 27

28 Supplier documentation The Documentation These operating instructions describe the installation, the operation and the repair of the KRACHT KF 4 80 tranfer gear pump. The equipment is manufactured in various versions. The specific version can be identified from the type label affixed to the pump. The format of the type designation and a detailed description of the individual versions and nominal sizes is to be found in the Technical data section (see Description of equipment ). Description of Equipment General KRACHT pumps in the KF Series are outside gear wheel pumps, which operate according to the displacement principle. Two gear wheels which are rotating in mesh with each other cause an increase in volume to occur as the spaces between the gear wheels are exposed at the pump inlet (suction side), so that the medium can flow into the pump. Simultaneously, a corresponding volume is displaced at the pump outlet (pressure side) through rotation of the gear teeth into the filled area vacated by the preceding teeth. The transport of fluid is achieved through the entrainment along the cavities between the gear teeth and the walls of the gear chambers. The so-called geometric delivery volume V g is displaced per revolution of the gearwheels. A value V gn, referred to as the nominal volume, is used in technical documentation to identify the pump size. Gear wheel pumps are self-priming over a wide envelope. The described displacement process is initially achieved without noticeable pressure rise. It is only after the burden of external loading is applied, for example if a delivery head is imposed, there is resistance at the pump outlet, pipeline components, etc., that a working pressure must be generated to overcome these resistances. Displacement pumps must never be operated against closed valves, since the uncontrollable pressure heads which occur in this case lead to damage to the pump and to the associated plant elements. As is usual in the case of so-called rigid pumps, i.e., pumps without compensation for axial play, the lateral play between the gear wheel contact surfaces is set such that the permissible operating pressure is safely controlled. The directions of rotation and supply of outside gear wheel pumps, when viewed on the end of the drive shaft, are given as in the following diagrams: p d p s p s p d Pressure side Suction side Suction side Pressure side Fig. 1 Fig. 2 Shaft rotating to left: Shaft rotating to right: Delivery from right to left Delivery from left to right 2 BKF E 28

29 Supplier documentation Specified Use The KF is a pump for the continuous delivery of fluids. The different types of seals available enable the pump to be used for various media. It must be ascertained that the medium to be delivered is compatible with the materials used in the construction of the pump (see Technical data ). The maximum permissible operating data given in the Technical data section must be unconditionally adhered to. Construction The drawing below illustrates the principle features of the KF pump. Fig. 1 Drive shaft gear wheel 2 Driven gear wheel Housing 4 End cover 5 Plain bearing bush 6 Radial shaft sealing ring (shaft seal varies to suit sealing requirements) 7 Retaining ring BKF E 29

30 Supplier documentation Technical Data Explanation of Type Code Example: KF 40 R F 1 D15 / Product name Nominal size V g = 4 / 5 / 6, / 8 / 10 / 12,5 16 / 20 / 25 cm³ V g = 2 / 40 / 50 / 6 / 80 cm³ Direction of rotation R = right L = left B = right and left U = universal (Direction of flow delivery remains the same as the angle of rotation changes) Mounting F = DIN flange without support bearing G = DIN flange with support bearing W = mounting angle without support bearing X = mounting angle with support bearing Seal type 1 = radial shaft sealing ring NBR 2 = radial shaft sealing ring FPM = radial shaft sealing ring PTFE 4 = double radial shaft sealing ring PTFE 5 = GLRD with FPM-secondary seals 6 = GLRD with PTFE-secondary seals 7 = double radial shaft sealing ring FPM Pressure relief valve D 15 adjustable over 0-15bar D 25 adjustable over 15-25bar Special Code - No. Code-No. for special design 4 BKF E 0

31 Supplier documentation General Data Type of construction Materials External gear pump see Materials overview Type of mounting Flange DIN ISO 019 Drive shaft end Pipe line connection Installed attitude Viscosity ν min ν max ISO R 775 short/cylindrical KF 4 to 25 Whitworth - pipe thread KF 2 to 80 SAE - flange connection Arbitrary* 12 mm²/s mm²/s Ambient temperature ϑ u min -20 C ϑ u max 60 C Filtering Filter fineness 60 µm * With exception of universal version (KF U ) Overview of Nominal sizes geom. Delivery Volume RPM Range perm. radial Force** V g n min n max F radial Nominal size cm³ 1/min 1/min N 4 4,0 5 5,05 6 6,8 8 8, , , , , ,10 2 2, , , , ,50 * see Type label on pump: KF ** Radial forces only on version with support bearing. F radial on central shaft journal. BKF E 5 1

32 Supplier documentation Overview of Materials Type of seal* Housing / Cover Gear Bearing Shaft seals O-Ring 1 NBR NBR 2 FPM FPM Carburising PTFE FEP 4 GG 25 steel P 10 PTFE FEP 5 (1.719) Carbonaceous (in synthetic resin), CrMo-Guß, FKM, SiC-Si, FFKM, FEP 7 FPM FPM * see Type label on pump: KF Overview of Operating Pressures Operating pressure Temperature of Type of Suction side Pressure side delivered medium sealing* p e min ** bar P e max bar p b bar p b max bar ϑ min C ϑ max C , * see Type label on pump: KF ** note restriction on p min. on universal version (KF U ) For certain operating conditions, the stated minimum and maximum values cannot be avoided! Thus, for example, the maximum operating pressure is not permissible in conjunction with low rpm and minimal viscosity. FP Pump installation and removal Mechanical Installation The pipeline components and connections used must be compatible with the anticipated operating pressure range. The relevant manufacturers specifications should be consulted! Prior to installation, the pump is to be inspected for possible damage and soiling during transportation. The respective coupling hubs must be mounted on the motor and pump shaft. When installing the coupling, the hub should be heated up and slid onto the shaft in the heated condition. The shaft must not be struck during the mounting operation! Each coupling hub must be secured on the respective shaft against axial displacement by means of the threaded pin, which presses on the adjusting spring! 6 BKF E 2

33 Supplier documentation Alignment of the Coupling When installing the coupling, care should be taken that the dimension E is precisely maintained, so that during operation the coupling is free to move axially. In order that the elastic toothed rim is not exposed to pressure on its face, for axial movement, the dimension E is to be taken as a minimum. Shaft with adjuster spring Shaft separation "E" sits in toothed rim (d w ) Fig. 4 Careful and exact alignment of the shaft prolongs the life of the coupling! Coupling Type /24 24/28 28/8 8/45 42/55 48/60 55/70 65/75 75/90 Dimn.* E Dimn.* s 2 2 2,5,5 4 4,5 5 Dimn.* d H Dimn.* d W max. axial disp,mt * max. radial offset * n=1500 1/min max. ang. offset * n=1500 1/min * dimensions in mm K a 1,2 1,4 1,5 1,8 2,0 2,1 2,2 2,6,0 K r 0,20 0,22 0,25 0,28 0,2 0,6 0,8 0,42 0,48 K w 1,2 0,9 0,9 1,0 1,0 1,1 1,1 1,2 1,2 BKF E 7

34 Supplier documentation The given permissible misalignment values for the couplings represent general guidelines which take the loading of the coupling into consideration up to the nominal torque T KN,an operating rpm n = 1500 and an ambient temperature of +0 C. For operating conditions outside these limits, KRACHT GmbH should be consulted. The misalignment values are individually applicable, in the case of a simultaneous occurrence they should be applied proportionately. The couplings can either take up a radial or an angular misalignment. If the shaft clearance dimension is less than the coupling dimension E, then one of the shaft ends can extend into the toothed rim section. The dimension d W corresponds to the maximum shaft diameter which, with the adjuster spring, is allowed to penetrate into the toothed rim, dimension d H. If it is possible to remove the adjuster spring, i.e., only the shaft penetrates into the toothed rim section, then the shaft dimension can be increased to up to 2 mm less than the given dimension d H, so that the axial freedom of movement of the toothed rim is not restricted. Rotating parts must be protected by the customer against unintentional contact! Mount the pump on the pump supports or feet. Before installing the pump, clean the pipework, removing dirt, sand, swarf, etc. Welded pipes, in particular, must be scoured or scavanged. Do not use cotton waste/rags for cleaning purposes. Remove the protective stoppers in the pump suction and pressure connections. Determining the Direction of Rotation The direction of rotation of the pump is determined as follows: When viewed on the end of the pump shaft, the direction of supply is from left to right when the shaft rotates clockwise When viewed on the end of the pump shaft, the direction of supply is from right to left when the shaft rotates anti-clockwise Without pressure relief valve suction side pressure side pressure side suction side Fig. 5 rotation to right rotation to left With pressure relief valve suction side pressure side pressure side suction side rotation to right rotation to left Fig. 6 8 BKF E 4

35 Supplier documentation Suction Pipework Provision of the suction pipework should be carried out with great care, since the operational behaviour of the pump is greatly affected by this factor. The suction pipe should be as short and as straight as possible. Additional sources of pipeline resistance, such as formed parts and valves, should be avoided. The reduced pressure in the suction pipe depends on the sum of all the resistances in the suction line and the suction head, taking account of the data specific to the medium in the line. The suction can be checked by installing a vacuum meter on the pump/suction connection. The permissible pressure at the pump inlet must not fall below the value p e min given in the Technical data section. The only exception to this is the start-up condition of the pump, when a pressure of bar (suction) is tolerable for up to 0 minutes. The nominal diameter of the suction line can be chosen to be considerably larger than that of the pump connection. If the permissible values (see Technical data ) are exceeded, the consequence is a reduction in the delivery volume (caused by reduced filling of the pump), higher noise level and cavitation. If hosing is used on the suction side of the pump, then this must be of adequate stability such that the hose does not deform and constrict the flow under the suction effect. The provision of a funnel-shaped suction opening or an oblique intersection at the end of the suction pipe are of value in increasing the cross-section on the suction side. When laying out the suction pipe in the medium container, attention should be paid to the achievement of unimpaired suction. There should be no partition walls adjacent to the opening of the suction pipe. Laying out the suction pipe as a siphon, whereby the pump is continually full after start-up, is a possible way of avoiding suction problems (see Fig. 7). Pressure Line The nominal diameter of the pressure pipe should be selected such that the velocity of flow does not exceed the values given in the following table. Pressure 10 bar 25 bar Flow velocity m/s,5 m/s Fig. 7 The pump pressure should be checked by a manometer installed as close as possible to the pump connection. KRACHT pumps are displacement pumps (see Equipment description section). This means that the use of a pressure relief valve or some other means of restricting pressure in the system is essential! In order to avoid overloading the pump due to pressure above the permissible value, a pressurelimiting valve, incorporating return flow to the reservoir, must be installed as near as possible to the pump pressure connection. An alternative method of limiting the pressure on KRACHT feed pumps is to install a pressurelimiting valve directly onto the pump. BKF E 9 5

36 Supplier documentation When operating a pump which is to feed, via a non-return valve, into a circuit which is under pressure (e.g. reserve pump in a lubrication circuit), suction difficulties can occur if the suction line is filled with air. In these cases, the pressure line should be vented directly before the non-return valve. This can be achieved, for example, by fitting a venting jet in the circuit (Fig. 8), or by providing a restricted by-pass (Fig. 9). Fig. 8 Fig. 9 The volume in the pressure line between the pump and the non-return valve must be at least 75% of the volume of the suction line. Connect the pipelines on the suction and pressure sides of the pump. In doing so, the instructions of the relevant manufacturer should be followed. Neither the suction nor the pressure side pipelines should transfer loads to the pump! The pipelines must connect with the pump supports in an absolutely stress-free condition. The pipelines are to be constructed in such a way, that even during operation, no stresses can be transferred through the pipelines, for example through changes in length due to temperature fluctuations. Damaged pipes and hoses must be replaced immediately! On installation, it must be ensured that no sealing material can enter the pipeline. Sealing materials such as hemp and mastic are not permissible, since they can lead to soiling and hence to operating failures. Fill the medium container with the prescribed fluid. Care should be taken that the cleanest possible conditions prevail when filling the fluid container! Clean filler plugs and caps on fluid transport and storage containers before opening. Check fluid containers and clean if necessary. The filter gauze on filling tubes and filter inserts on fitted filters must not be removed under any circumstances. Attention should be paid to adequate filling of the fluid container! 10 BKF E 6

37 Supplier documentation In order to achieve optimum noise protection, it is recommended that an anti-vibration flange is fitted between the pump and the pump supports and that damping elements are inserted between the electric motor and the installation. Likewise, the use of suction and pressure hoses reduces the noise level of an hydraulic installation. Pump Removal The cleanest possible conditions should be assured during all work. Prior to loosening screwed connections, their external surroundings should be cleaned. During all work on the pump and prior to removal, the connecting pipework must be depressurised and the motor isolated! In addition, precautions must be taken to ensure that the motor cannot run-up during work on the pump. Remove the depressurised pipelines from the pump. Leakages of dangerous media must be collected and disposed of in such a way that no danger results to personnel or to the environment. In so doing, the statutory regulations must be observed.. Secure the pump connections and pipelines against the ingress of dirt. Commissioning Commissioning is only to be carried out by appropriately trained and qualified personnel. Prior to starting up plant, it must be ascertained that an adequate quantity of the operating medium is available, in order to avoid dry running. Check the permissible operating values against the anticipated operating conditions. Check all fixing bolts on the pump. Check the direction of rotation. If the direction of rotation has to be changed, refer to the section on Maintenance. The pumps must only run in the direction of rotation indicated by the arrow / in the direction of rotation indicated by the symbol on the type plate. Operation of the pump in the opposite direction of rotation to that indicated will lead to failure of the slide ring sealing in the case of sealing version 5. Prior to commissioning, the pump must be filled with the fluid medium. BKF E 11 7

38 Supplier documentation Special feature on sealing variants 4 and 7 (Double radial shaft sealing ring) The sealing chamber (see Fig. 10) must be filled with a suitable barrier medium prior to initial operation of the pump. Sealing chamber Before commissioning, the sealing chamber must be filled with a barrier medium.. The pumps should be started up at either very low or zero pressure loading. The existing shut-off devices should be fully opened and the pressure relief valve, installed in the pressure line, should be adjusted to the lowest opening pressure setting. Pressure setting of the pressure relief valve Applies only to pumps with a built-in pressure relief valve (Pump Type Code: KF -D15 and KF -D25) Fig. 10 Response pressure lower Response pressure higher Fig Lock nut 2 Adjuster screw securing screw (do not loosen) CAUTION: The pressure relief valves on series DKF are purely safety valves! These valves only respond briefly! Continual drawing off of the conveyed fluid medium via the DKF will result in the destruction of the pump due to overheating! To adjust the pressure setting on the pressure relief valve (see Fig. 11): Loosen the lock nut (1). Set the adjuster screw (2) Rotation right = higher response pressure Rotation left = lower response pressure When the desired pressure has been set, re-lock the adjuster screw (2) with the lock nut (1). The securing screw () must not be loosened! 12 BKF E 8

39 Supplier documentation Start-up is achieved by repeated rapid switching on and off of the drive motor (inching mode), without reaching full rpm, until it is apparent that the pump is operating satisfactorily. The satisfactory operation being detectable either from manometer readings, or from the noise generated by the pump, and being achieved over a period of not longer than 0 seconds. This particularly applies when a cold pump must be started-up with a fluid medium that has already been warmed, in order to achieve a slow heating up of the pump and to prevent jamming of the pump due to heat shock. After switching on the motor, it is then allowed to run for a few minutes, under zero or low pressure. The pressure loading can then be increased in stages until the desired operating pressure is reached. On attaining the required operating values, the temperature of the medium and of the pump should be checked. The control points on the pump are the shaft bearing positions and the shaft seals. The temperatures reached on the surface of the pump housing should be approx. 10 C greater than the temperature of the medium. After several hours of running time, the final operating temperature should be checked (for maximum temperatures, see the section on Technical data ). Maintenance Assuming correct installation in accordance with the conditions of use and correct operation, KRACHT gear pumps are of such construction that a long and fault-free operational life should be obtained. They require a minimum of maintenance which, however, is necessary for reliable operation, since experience has shown that a high percentage of the faults and damage which can occur are attributable to the ingress of dirt and inadequate maintenance. The extent of servicing required and the service and inspection intervals are, in general, laid down by the manufacturer in an appropriate plan. The regular examination of all operating data, such as pressure, temperature, current consumption, degree of filter soiling, etc., contributes to the early detection of potential failure. Extreme cleanliness should be ensured during all work. Before loosening screwed connectins, the surrounding areas are to be cleaned. All openings are to be closed with protective covers, so that there is no ingress of dirt into the system. Leakages of dangerous media must be collected and disposed of in such a way that no danger results to personnel or to the environment. In so doing, the statutory regulations must be observed. Seals Maintenance of the seal variants 4 and 7 (Double radial shaft sealing ring) The filling level in the sealing chamber should be inspected at regular intervals and the barrier medium replenished if necessary. Maintenance of the seal variants 5 and 6 (Slide ring seals) The slide ring sealing is particularly subject to wear, depending on the application and accordingly, must be carefully checked. Too high an inlet pressure, incorrect direction of rotation or soiling, lead to increased wear and greater leakage. Low leakage rates are essential to the functioning of the slide ring sealing. The slide ring sealing should be renewed if the leakage rate increases. The installation instructions from the manufacturer of the slide ring sealing should be consulted. BKF E 1 9

40 Supplier documentation Changing the direction of rotation of the pump On pump types KF R and KF L, i.e. pure left or right rotating pumps, a change in the direction of rotation is only possible by re-building the pump. cover fixing scews cover fixing scews cover fixing scews cover fixing scews Tightening torque for cover fixing screws Nominal size** Tightening torque 25 Nm 49 Nm * see Type code on unit: KF If the direction of rotation of a pump is required to be changed, the cover and the pressure relief valve on the pump housing must be freed, in order that they can be rotated through 180 and refitted. On pumps without a pressure relief valve, the leakage oil bore on the inside of the cover must be on the suction side of the pump. On pumps with a pressure relief valve, the relief valve adjuster screw must point towards the pressure side of the pump (see the section on Mechanical installation, Fig. 6 on page 8). This conversion of the pump must only be carried out by appropriately trained and experienced personnel! Change in direction of rotation with sealing variant 5 (Slide ring sealing) A change in the direction of rotation on sealing variant 5 cannot be carried out immediately! In this case, in order to carry out the rotation of the cover and the relief valve, as detailed above, in addition the slide ring seal must be exchanged (note the direction of coiling of the spring). When exchanging the slide ring seal, the installation instructions of the seal manufacturer should be consulted. Repairs A repair comprises: Diagnostic examination, i.e. isolation of the fault. Determining and localising the cause of the fault. Elimination of fault, i.e. replacement or repair of defective components and elimination of the primary cause. Elimination of the Fault The elimination of the fault takes place on site, predominantly through exchange of the defective component/s. The repair of components is generally undertaken by the manufacturer.. 14 BKF E 40

41 Supplier documentation Repairs must only be carried out by trained specialist personnel. Given the appropriate know-how and adequate equipment, the repair may also be carried out by the end user or the initial equipper. Assistance in this is available in the form of spares lists and repair instructions. Diagnosis Lack of adequate sealing is a frequent source of failure. If this occurs at the pipeline connections, it may be eliminated by simply tightening the screwed fittings. In the case of a lack of sealing on the pump, the respective seals must be replaced (see spares list). Detection and Elimination of Faults The following list gives the causes of faults which are most frequently encountered during operational failures together with an indication of the problem areas to be rectified. In the event of the occurrence of a fault which cannot be identified, please request assistance from KRACHT. Fault Possible cause Increased noise Pump cavitation Suction level too high Suction filter blocked or too small Internal dia. Suction line too small Suction line too long Too many curves in suction line Too many local constrictions in suction line Suction line blocked or not sealed Viscosity too high Viscosity too high Formation of foam or Suction line not sealed Inclusion or air in Medium Fluid reservoir level too low Tank return line not sealed Incorrect container layout Lack of sealing, suction side or shaft seal Return line ends above level of fluid in reservoir Inadequate venting Mechanical vibrations Faulty aligned or loose coupling Faulty or inadequate pipeline fixing Mechanical vibrations Installation not optimised for noise (lack of damping elements) Pump installed in unfavourable position Pump worn out, tooth flank wear BKF E 15 41

42 Supplier documentation Fault Pump does not suck Insufficient supply flow Insufficient pressure Power consumption too high Operating tempertature too high Pump heat-up above Permissible level Leakage at the shaft sealing Coupling wear Possible cause Supply flow too low Working resistances in pressure line too low Fluid level in reservoir too low Incorrect direction of rotation Throttling element in suction line Foreign body in suction line Volume of the pressure linebetween pump and non-return valve too small, pump cannot compress the air found in the suction line into the pressure line Non-return valve in the pressure line not vented Throttling element in suction line Fluid level in reservoir too low Suction filter blocked or too small Viscosity too high Rpm too high Pressure too high Pressure relief valve set too low Pump sucks air Pump is worn out Viscosity too low Rpm too low Drive power too low Pump worn out Pressure too high Viscosity too high Drive power too low Motor winding defective Cooling and heat dissipation inadequate Fluid supply too low Fluid conveyed under load into the reservoir via pressure relief valve Built-in pressure relief valve set too low Pressure too high Viscosity too low Spectacle gland tightened excessively Pump worn out Inlet pressure above permissible value Incorrect direction of rotation Shaft radial loading too high Seal wear Seal temperature too high Incorrect seal material Incorrectly aligned or loose coupling Inadequate axial play in coupling Coupling overloaded Temperature too high 16 BKF E 42

43 Supplier documentation Transfer Gear Pumps KF

44 Supplier documentation Transfer Gear Pumps KF KRACHT GmbH Gewerbestr Werdohl, Germany fon +49(0)2 92/95-0 fax +49(0)2 92/ mail info@kracht.eu web 44

45 Supplier documentation Transfer Gear Pumps KF Contents Technical Data Page Applications / Suitable fluids Construction Variants / Direction of rotation ATEX version Materials / Characteristics Shaft end seals / Variants Shaft End Seals Version noise optimized for medias with increased air content Type key Technical data Discharge flow / Input power Dimension Sheets Flange-mounting version with pipe thread Nominal size Flange-mounting version with SAE-connection Nominal size Pump with mounting angle, pipe thread Nominal size Pump with mounting angle, SAE connection Nominal size Flange-mounting version with universal arrangement Nominal size Flange-mounting version with universal arrangement Nominal size Flange-mounting version with universal arrangement U Nominal size Flange-mounting version with universal arrangement U Nominal size 100/ Couplings Bell housing Nominal size Motor-pump assemblies with pipe thread Nominal size Motor-pump assemblies with SAE-connection Nominal size Motor-pump assemblies with SAE-connection Nominal size Threaded flange / Welding flange / Accessory liquid seal KRACHT GmbH Gewerbestr Werdohl, Germany fon +49(0)2 92/95-0 fax +49(0)2 92/ mail info@kracht.eu web 45

46 Supplier documentation Transfer Gear Pumps KF Applications, Suitable Fluids Applications Centrifuge construction, Coating machines, Compressors Engine construction Filling stations, Filter systems Generator construction Heat transfer systems, Heavy electrical machines Lubricant manufacturers, Lubricating oil systems Machine-building industry, Machine tools, Manufacture of apparatus, Marine engine construction, Metal-forming machines, Metering systems Paint industry, Plain metal bearing production, Printing machines, PUR machinery Refrigerators, Rubber and tire manufacturing Tank plant construction, Transmission building Turbine construction Vacuum machinery Waste oil - disposal - transport - treatment Suitable fluids Adhesives, Antifreeze Bore oils Cutting oils Diesel oils, Drawing compound Emulsions Fuel oils, L, EL, H Gear oils, Grease Hardening oils, Heat transfer media, Heavy oils, Hydraulic fluids Isocyanate Lubricating oils, Lacquers Motor oils Paint, Paraffins, Plastics, Polyols Printing inks, Processing oils Resins, Rolling oils Waste oils, Waxes 4 KRACHT GmbH Gewerbestr Werdohl, Germany fon +49(0)2 92/95-0 fax +49(0)2 92/ mail info@kracht.eu web 46

47 Supplier documentation Transfer Gear Pumps KF Construction Antriebswellenende Drive shaft end Wellendichtung Shaft seal Getriebe Gear Gehäuse Housing Lagerbuchse Plain bearing bushes Lagerdeckel End cover Product Features Transfer gear pumps KF are used for pumping a wide variety of fluids. Transfer gear pumps KF are distinguished especially by their wide range of variants which are assembled as required on the modular principle and also permit subsequent upgrade. The pumps are also suitable for media with low lubricating properties. The standard housing sections are of grey cast iron. The gear units are manufactured from high-strength case-hardening steel, hardened and mounted in special multi-compound plain bearing bushes. The standard drive shaft is sealed by rotary shaft lip-type seal. All pump sizes incorporate helical tooth system. This feature, combined with special gear geometry, results in extremely low noise levels and reduced pressure pulsation. Working Notes The fluids should ensure a certain minimum lubricating properties, should not contain solids and should be chemically compatible. Avoid dry operation. The pumps may only be operated in the specified direction of rotation, as otherwise the shaft seal will be destroyed. In order to prevent excessive overpressure, a safety valve should be provided in the system or on the pump. The pressure relief valve attached to the pump may only be used as safety valve for short-term operation. A separate pressure relief valve with return line to the reservoir must be foreseen, if a partial discharge flow has to be drained over a prolonged period. KRACHT GmbH Gewerbestr Werdohl, Germany fon +49(0)2 92/95-0 fax +49(0)2 92/ mail info@kracht.eu web

48 Supplier documentation Transfer Gear Pumps KF Variants Sealing of the drive shaft: Rotary shaft lip-type seal Double rotary shaft lip-type seal (Quench) Mechanical seal Outboard bearing to take up input drive-side radial load Pressure relief valve for pump and system Uniform discharge flow direction with changing direction of rotation by means of flange-mounting valve combi nation (universal device). Direction of Rotation The following should be note for direction of rotation: when looking at the pump shaft end, the direction of pumping is from left to right if the shaft rotates clockwise. when looking at the pump shaft end, the direction of pumping is from right to left if the shaft rotates counterclockwise. Without pressure relief valve Special Design Various shafts ends and gear units, as well as flange mounted versions, bearing alternatives, multi-stage pump combinations for your special application are available on request. Our Sales engineers will be pleased to advise you. suction side pressure side pressure side suction side pump running cw pump running ccw With pressure relief valve Accessories Connecting flanges Couplings Bell housing Quench tank Attenuation elements suction side pressure side pressure side suction side pump running cw pump running ccw 6 With universal device Direction of rotation right and left Direction of rotation consistent,see dimension sheets page 18 to 21. ATEX-Version KF 2, KF 2, with lip-type seal with double lip-type seal In Ex-area max. EX II 2G T4 suitable for category EX II 2D T15 C EX II 2G T4 Perm. working pressure inlet port in bar Perm. working pressure outlet port in bar Perm. viscosity in mm 2 /s Max. speed in 1/min (viscosity dependent)) Perm. mounting position Horizontal or shaft end toward bottom Horizontal quencher up Perm. media temperatures in C Perm. ambient temperatures in C Comments Vertical mounting with shaft end Not suitable up on request. for dust-ex. In executing with outboard bearing Execution with quench feed max. speed /min. and quencher. In dust Ex-area, permissible only with non-conductive dusts. Dust-proof capsuling of pump shaft and coupling required. Additional products available on request. KRACHT GmbH Gewerbestr Werdohl, Germany fon +49(0)2 92/95-0 fax +49(0)2 92/ mail info@kracht.eu web 48

49 Supplier documentation Transfer Gear Pumps KF Materials Housing and cover EN-GJL-250 (GG 25) EN-GJS (GGG 40) on request Gear Steel Plain bearing bushes DU (multi-layer friction-type bearings P 10, DP 4) Bearings free of nonferrous metal on request Shaft end seals NBR, FKM, PTFE, EPDM (other sealing materials on request. E.g. HNBR / CR) O-ring NBR, FKM, PTFE, EPDM (other sealing materials on request. E.g. HNBR / CR) Characteristics Nominal sizes cm Vg = 2.5 / 4/5/6/8/10/12/16/20/25/2/40/50/6/80/100/112/ 125 / 150 / 180 / 200 Mounting position KF... R/L/B... without Quench optional KF... R/L/B... with Quench horizontal, Quench connection above KF... U... horizontal, Pressure connection above KF... U2...optional Direction of rotation right or left right and left Fixing type flange Pipe connection KF Whitworth pipe thread, SAE flange KF SAE flange Drive shaft end ISO R 775 short-cylindrical Working pressure suction side see chart page 8 Working pressure pressure side Pn 25 bar (higher pressures on request) Speed KF /min KF /min KF /min Recommended speed The speed of the pump must be chosen in such a way that complete pump filling is guaranteed. This is given if the relative pressure at the pump inlet does not fall below -0.4 bar (-0.6 bar briefly e.g. during cold start). Viscosity (dependent on V min mm²/s (see table "permissible differential pressure") pressure and rotational speed) V max mm 2 /s Fluid temperature see chart page 8 Ambient temperature u = C 60 C (-- 4 F 140 F) 0 C C Sealing type 2 (KF ) 0 C C Sealing type 1 (KF ) Permissible Differential Pressure Bearing Δp max [bar] 1.4 mm²/s 6 mm²/s 12 mm²/s Multi-layer plain bearing containing lead (1) :DU,P Multi-layer plain bearing lead-free (2) : DP4 Polymer plain bearing (2) : Iglidur X 10 White metal plain bearing (2) (1) Standard (2) Is defined in the special number KRACHT GmbH Gewerbestr Werdohl, Germany fon +49(0)2 92/95-0 fax +49(0)2 92/ mail info@kracht.eu web

50 Supplier documentation Transfer Gear Pumps KF Shaft End Seals Sealing material Pressure suction Fluid temperature side * (bar) C F KF 2, KF Pump with single rotary shaft lip NBR/ max /min NBR NBR FKM max /min max /min FKM FKM max /min max /min FKM (low temperature) ** **...02 EPDM PTFE Pump with outboard bearing NBR/ max /min NBR NBR and single rotary shaft lip FKM max /min max /min FKM FKM max /min max /min PTFE Pump with double rotary shaft seal NBR/ max /min NBR NBR with connection borehole FKM max /min for liquid seal (quench) max /min FKM FKM max /min max /min PTFE Pump with double rotary shaft seal NBR for vacuum operation with FKM connection borehole for liquid seal (quench) PTFE Pump with triple rotary shaft seal for vacuum and normal operation with connection borehole for liquid seal (quench) NBR/ max /min NBR NBR FKM max /min max /min FKM FKM max /min max /min Pump with mechanical seal FKM PTFE EPDM Pump with mechanical seal and FKM connection borehole for liquid seal (quench) Speed: KF /min KF /min KF /min The indicated maximum values are dependent upon the remaining working conditions. ** short term during start-up status: bar ** only in connection with housing and cover material EN-GJS-400 (GGG 40) In case of universal devices, pay attention to limitation of Pe min. Other sealing materials on request. 8 KRACHT GmbH Gewerbestr Werdohl, Germany fon +49(0)2 92/95-0 fax +49(0)2 92/ mail info@kracht.eu web 50

51 Supplier documentation Transfer Gear Pumps KF Variants Shaft End Seals Pump with single rotary shaft lip Fixing type: F/W Sealing materials: NBR = sealing type 1 FKM = sealing type 2 PTFE = sealing type EPDM = sealing type 9 FKM low temperature = sealing type 2/1 Pump with outboard bearing and single rotary shaft lip Fixing type: G/X Sealing materials: NBR = sealing type 1 FKM = sealing type 2 PTFE = sealing type Pump with double rotary shaft seal with connection borehole for liquid seal (quench) Fixing type: F/W Sealing materials: NBR = sealing type 19 FKM = sealing type 7 PTFE = sealing type 4 EPDM = sealing type 2 Pump with double rotary shaft seal for vacuum operation with connection borehole for liquid seal (quench) Fixing type: F/W Sealing materials: NBR = sealing type 19 FKM = sealing type 7 PTFE = sealing type 4 EPDM = sealing type 2 Special number: 74 Pump with triple rotary shaft seal for vacuum and normal operation with connection borehole for liquid seal (quench) Fixing type: F/W Sealing materials: NBR = on request FKM = on request Pump with mechanical seal Fixing type: F/W Sealing materials: FKM = sealing type 5 PTFE = sealing type 6 mechanical seal = sealing type 40 Pump with mechanical seal and connection borehole for liquid seal (quench) Fixing type: F/W Sealing materials: FKM = sealing type 5 Special number: 198 Pump without shaft sealing Fixing type: F/W Sealing material: FKM o-ring = sealing type 0 KRACHT GmbH Gewerbestr Werdohl, Germany fon +49(0)2 92/95-0 fax +49(0)2 92/ mail info@kracht.eu web

52 Supplier documentation Transfer Gear Pumps KF KF noise optimized for medias with increased air content The noise optimized pumps in the KF series are designed for conveying for medias with increased air content, predominantly for use as lubricating oil pumps in transmissions. Special measures prevent the otherwise normally increased noise present in auriferous transmission oil. The noise levels do not exceed or only barely exceed the measurements with non-auriferous oils. Also, there is no noise spectrum shift to higher, unpleasant frequencies. In applications without auriferous portions in the media, it is not recommended to use this version as it will not bring about noise reduction effects there. The noise optimized version of the KF pump is marked with the special number 197 at the end of the type key. Pumps with the special number 197 are built as pumps in combination with an electric motor or as mounted pumps. The pump in combination with an electric motor (Fig. 1) does not have an outboard bearing, so it has to be driven via an elastic coupling. The mounted pump (Fig. 2) comes equipped with an outboard bearing to absorb the centrifugal forces such as those which arise when using a flying pinion. Pumps for electric motor drives and mounted pumps are sealed at the shaft end using a lip-type shaft seal. Fig. 1 Fig. 2 Pump with single rotary shaft lip Fixing type: F/W Sealing materials: NBR = sealing type 1 FKM = sealing type 2 Special number: 197 Pump with outboard bearing and single rotary shaft lip Fixing type: G/X Sealing materials: NBR = sealing type 1 FKM = sealing type 2 Special number: 197 The noise optimized version is also available in a ductile cast iron version. We can supply these pumps in the ATEX version also. Note Dimensions conformable standard pumps 10 KRACHT GmbH Gewerbestr Werdohl, Germany fon +49(0)2 92/95-0 fax +49(0)2 92/ mail info@kracht.eu web 52

53 Supplier documentation Transfer Gear Pumps KF Type Key (Ordering example) KF 40 R F 1 - /... - D15 Type of seal see below Special No. see below Housing and cover material not specified EN-GJL-250 (GG 25) GJS EN-GJS-400 (GGG 40) Valve type D 15 adjustable from 0 15 bar D25 adjustable from bar (only for one direction of rotation) Mounting F DIN flange without outboard bearing G DIN flange with outboard bearing W Mounting angle without outboard bearing X Mounting angle with outboard bearing Direction of rotation R right L left B right and left Nominal size Product name U universal Note direction of rotation right and left, direction of discharge consistent Type of seal 1 Rotary shaft seal BABSL NBR 2 Rotary shaft seal BABSL FKM Rotary shaft seal PTFE 4 Double rotary shaft seal PTFE 5 Mechanical seal with FKM secondary seals (C2S2V1GG1) 6 Mechanical seal with FFKM secondary seals Q2Q2K1G (KF ) Q2B2K1G (KF ) 7 Double rotary shaft seal BABSL FKM 9 Rotary shaft seal EPDM (not resistant to mineral oils) 19 Double rotary shaft seal BABSL NBR 2 Rotary shaft seal MSS-1 FKM (low temperature) (KF ) 0 Without shaft seal (1) O-ring FKM 1 Rotary shaft seal BABSL FKM (low temperature) (KF ) 2 Double rotary shaft seal EPDM (not resistant to mineral oils) 6 Without shaft seal (1) O-ring NBR 40 Mechanical seal with FKM secondary seals (AQ2VFF) (1) Leak oil discharged through the gland pocket Special No. 74 Double rotary shaft seal (for vacuum operation) Connection bore G 1/8" (for liquid seal) 158 KF : Flange connection SAE ¾ KF 16 25: Flange connection SAE Noise-optimized version for aerated oils and vacuum (1) 198 Mechanical seal KF : Connection bore G 1/8" (for liquid seal) KF 2 80: Connection bore G ¼" (for liquid seal) 22 KF : Flange connection SAE 2 KF : Flange connection SAE 2 ½ KF : Flange connection SAE KF : Flange connection SAE ½ 04 Polymer plain bearing iglidur X (free from non-ferrous metals), Δp max = 10 bar 17 Noise-optimized version for aerated oils and vacuum (1) Polymer plain bearing iglidur X (free from non-ferrous metals), Δp max = 10 bar 22 Triple rotary shaft seal (for normal operation + for vacuum operation) Connection bore G 1/8" (for liquid seal) Polymer plain bearing iglidur X (free from non-ferrous metals), Δp max = 10 bar KF 50 80: Flange connection SAE 2 5 Noise-optimized version for aerated oils and vacuum (1) Multi-layer plain bearing DP4 (lead-free) 55 Polymer plain bearing iglidur X (free from non-ferrous metals), Δp max = 10 bar Housing connection: KF : as special number Version for low-viscous media (housing and cover material = GJS) Polymer plain bearing iglidur X (free from non-ferrous metals), Δp max = 10 bar Housing connection: KF : as special number 158 KF : as special number Noise-optimized version for aerated oils and vacuum (1) Housing connection: KF : as special number Shaft end with centre hole DIN 22-D Outboard bearing with steel cage (1) There can be a reduction in pumping capacity. Measures for noise optimisation are only feasible for one rotational direction and only effective for aerated oils or vacuum. KRACHT GmbH Gewerbestr Werdohl, Germany fon +49(0)2 92/95-0 fax +49(0)2 92/ mail info@kracht.eu web

54 Supplier documentation Transfer Gear Pumps KF Technical Data Nominal geom. Working Maximum Speed range Permissible Sound level size displace- pressure* pressure load ** db (A) ment (pressure (n = /min) peaks) Vg p b p max n min n max F radial p = p = p = cm /r bar bar 1/min 1/min N 5 bar 15 bar 25 bar Remark ** Working pressure p b = perm. sustained pressure (higher pressures on request) ** Permissible load only for version with outboard bearing. F radial at centre of shaft end. For certain working condi tions, the minimum or maximum characteristics should not be used. For example, the max. working pressure is not permissible in combination with low speed and low viscosity. In such limit ranges, please consult us. Sound level measured in db(a) at 1 m distance Sound level measured with drive motor, installation site: Works hall, quiet sound level = 40 db(a) Pump assembly on rigid fastening angle, Suction and pressure conduits: Hose Measured with transmission oil, Oil viscosity ν = 4 mm 2 s, Speed n = /min. 12 KRACHT GmbH Gewerbestr Werdohl, Germany fon +49(0)2 92/95-0 fax +49(0)2 92/ mail info@kracht.eu web 54

55 Supplier documentation Transfer Gear Pumps KF Power Consumption Speed n = 950 1/min Discharge Q in l/min Pressure p b in bar Nominal size Pressure p b in bar Power consumption P in KW Discharge Q in l/min Speed n = /min Pressure p b in bar Nominal size Pressure p b in bar Power consumption P in KW The ratings refer to a mineral oil with a viscosity of 4 mm 2 /s. Margin of error for the flow Q % % of the tabular value. For viscosity < 0 mm 2 /s, take a reduction of the rated flow Q into account. The output of the drive motor should be selected 20 % higher than tabular value P. For viscosity > 100 mm 2 /s, an increase in the required power is necessary, in this case proceed as per description on page 15. KRACHT GmbH Gewerbestr Werdohl, Germany fon +49(0)2 92/95-0 fax +49(0)2 92/ mail info@kracht.eu web

56 Supplier documentation Transfer Gear Pumps KF Discharge Flow / Input Power Calculation P 1Pu = P tab n fν Q P 1Pu = pump power consumption (kw) P tab = power consumption per table (kw) at /min n = speed (1/min) dependent on viscosity! (see speed recommendation) f ν = viscosity factor (see diagram) [ ] kw l/min Q = discharge flow (l/min) with Q = V g = geometrical displacement (cm /r) Vg n 1000 Example: Pump type KF 80 Viscosity ν = 000 mm 2 /s Working pressure p = 15 bar at P tab =.6 kw n = 500 1/min kw f ν = l/min Q = = 40 l/min 1000 becomes P 1Pu = ( ) kw P 1Pu = 1.92 kw Motorpower output: P 2Mot = 1.2 P 1Pu = 2. kw Select helical geared motor with P =.0 kw n = 500 1/min Conversion factors 1 bar ^= 14.5 lb in 2 = 14.5 psi 1 l gal ^= min min = [U.K.] 1 l gal ^= min min = [US] Input Power ν Diagramm: n, fν = f(ν) Note: To determine the power consumption, always take the max. working viscosity at starting state into consideration. The power of the drive motor should be selected 20 % higher than the value determined. 14 ν KRACHT GmbH Gewerbestr Werdohl, Germany fon +49(0)2 92/95-0 fax +49(0)2 92/ mail info@kracht.eu web 56

57 Supplier documentation Transfer Gear Pumps KF Flange-Mounting Version with Pipe Thread KF J 80 F ø ø85 80 ø6 5 14,2 j6 ø14 h a 16 b 25 KF with pressure reliev valve 95 J1 80 F ø ø85 80 ø6 14,2 ø14 j6 h a 16 b 25 Nominal size Suction and pressure connection Weight in kg without with a b F J J 1 valve valve 2, G 4 17 deep G1 19 deep Ø Ø (Dimensions in mm) KRACHT GmbH Gewerbestr Werdohl, Germany fon +49(0)2 92/95-0 fax +49(0)2 92/ mail info@kracht.eu web

58 Supplier documentation Transfer Gear Pumps KF Flange-Mounting Version with SAE-Connection KF KF with pressure reliev valve Nominal Sp.- SAE Seal Suction- and Pump sizes Shaft end Weight in kg size No. pressure connection without with a b e f C D E F G J J 1 K L M R S h8 i Y d j6 l m n t u valve valve " M deep , " deep M " / " " / " M /112 2" 20deep /112 2" / " / " / " / " / " / " /200 " 28 1 M16-180/200 " deep / " / " (Dimensions in mm) 16 KRACHT GmbH Gewerbestr Werdohl, Germany fon +49(0)2 92/95-0 fax +49(0)2 92/ mail info@kracht.eu web 58

59 Supplier documentation Transfer Gear Pumps KF Pump with Mounting Angle, Pipe Thread KF 2, J F 95 7 b a R j6 ø6 ø14 h8 14, ø Nominal Suction and size pressure connection Weight in kg a b F J 2, G 4 17 deep G1 19 deep (Dimensions in mm) Ø ,2 Ø ,8 Pump with Mounting Angle, Pipe Thread, SAE connection KF J 44 F ,7 R ø24 j ,9 8 ø h M tief 18 ø Nominalsize F J Weight in kg SAE / 80 SAE (Dimensions in mm) KRACHT GmbH Gewerbestr Werdohl, Germany fon +49(0)2 92/95-0 fax +49(0)2 92/ mail info@kracht.eu web

60 Supplier documentation Transfer Gear Pumps KF Flange-Mounting Version with Universal Arrangement KF A 80 F Ø 10 5 Ø 85 4 Ø 6 h G /4 /4-17 deep tief B G 1/ deep tief 25 Ø 14 j6 Ordering code KF. UF. Seals Nominal Weight Perm. manometr. low pressure size in kg at the pump suction connection A B F p e bar (Dimensions in mm) Mounting position horizontal, Pressure connection above KRACHT GmbH Gewerbestr Werdohl, Germany fon +49(0)2 92/95-0 fax +49(0)2 92/ mail info@kracht.eu web 60

61 Supplier documentation Transfer Gear Pumps KF Flange-Mounting Version with Universal Arrangement KF B 44 77,8 298 F 28 MM deep tief Ø 50 42, A 1 7 Ø 80 h8 42,9 6 M deep tief Ø 24 j6 77,8 8 1 Ø Ø 10 Ø 50 Ordering code KF. UF. Seals 1 2 Nominal Weight Perm. manometr. low pressure size in kg at the pump suction connection A B F p e bar (Dimensions in mm) Mounting position horizontal, Pressure connection above 0.5 KRACHT GmbH Gewerbestr Werdohl, Germany fon +49(0)2 92/95-0 fax +49(0)2 92/ mail info@kracht.eu web

62 Supplier documentation Transfer Gear Pumps KF Flange-Mounting Version with Universal Arrangement U2 KF 2 80 Suction and pressure port equally sized Nominal displacement A B Weight in kg (Dimensions in mm) Mounting position optional 20 KRACHT GmbH Gewerbestr Werdohl, Germany fon +49(0)2 92/95-0 fax +49(0)2 92/ mail info@kracht.eu web 62

63 Supplier documentation Transfer Gear Pumps KF Flange-Mounting Version with Universal Arrangement U2 KF 100/112 Suction and pressure port equally sized Nominal displacement A B Weight in kg 12,5 247, (Dimensions in mm) Mounting position optional KRACHT GmbH Gewerbestr Werdohl, Germany fon +49(0)2 92/95-0 fax +49(0)2 92/ mail info@kracht.eu web

64 Supplier documentation Transfer Gear Pumps KF Accessory Couplings Version A Version B Gear rim Ordering code Coupling Weight Moment Pre Finished Dimensions (in mm) size of bore bore inertia min. max. kg kgm 2 part part part part part part l E s b L M DH D D 1 dh Version A RA 19-Z25/..-Z25/ RA 24-Z0/..-Z0/ RA 28-Z0/..-Z0/ RA 19/24-Z25/..-Z25/.. 19/ RA 24/28-Z0/..-Z0/.. 24/ Version B RA 28/8-Z5/..-Z5/.. 28/ RA 8/45-Z45/..-Z45/.. 8/ RA 42/55-Z50/..-Z50/.. 42/ RG 42/55-Z50/..-Z75/.. 42/ / / Type Key KF Coupling Ordering example R.* 8 - Z 45/8 - Z 45/8.* Hub material A AL Coupling size Pump side cylindrical Motor side cylindrical coupling hub lengt and hub bore G GG Working temperature: --20 C to +80 C (-- 4 F to 176 F) (short duration temperature peaks up to 120 C / 248 F are permissible). Weights and mass moments of inertia refer to max. finish machined bore without slot. Finish-machined bores to ISO Fit H7, parallel key slots in accordance with DIN 6886 Sh KRACHT GmbH Gewerbestr Werdohl, Germany fon +49(0)2 92/95-0 fax +49(0)2 92/ mail info@kracht.eu web 64

65 Supplier documentation Transfer Gear Pumps KF Bell Housing KF 2, Aluminum bell housing Motor size Bell housing Coupling Dimensions (in mm) Weight KF 2,5 25 KF 2 80 KF A B C D E F G K L M N P kg 71 S 71 PT160-A RA19-Z25/14-Z25/ M8 1 M S 80 PT200-A RA19-Z25/14-Z25/ M8 16 M S 90 L PT200-A RA19/24-Z25/14-Z25/ M8 16 M LS 100 L PT250-A RA24/28-Z0/14-Z0/ M8 19 M M 80 S 80 PT200-A RA19/24-Z25/24-Z25/ M8 16 M S 90 L PT200-A RA24-Z0/24-Z0/ M8 16 M LS 100 L PT250-A RA24/28-Z0/24-Z0/ M8 19 M M 12 S 12 M PT00-A RA28/8-Z5/24-Z5/ M8 20 M M 160 L PT50-A RA8/45-Z45/24-Z45/ M8 26 M L RA24/28-Z0/28-Z0/28 PT250-A M * RS24/28-Z0/24-Z0/ M12 18 M S PT00-A RA28/8-Z5/28-Z5/ M1220M12 12 M * PT00-A * RS28/8-Z5/24-Z5/8 * 144 * ** PT00-A ** RS28-Z5/24-Z60/8 160 M RA8/45-Z45/28-Z45/42 PT50-A L * RS8/45-Z45/24-Z45/ M12 26 M M RA42/55-Z50/28-Z50/48 PT50-A L * RG42/55-Z50/24-Z75/ M12 26 M ** RG42/55-Z50/24-Z50/48 * Version seal 1 (KF ) ** Version seal 1 (KF ) KRACHT GmbH Gewerbestr Werdohl, Germany fon +49(0)2 92/95-0 fax +49(0)2 92/ mail info@kracht.eu web

66 Supplier documentation Transfer Gear Pumps KF Motor-Pump Assemblies with Pipe Thread KF with pressure relief valve KF Pump sizes (in mm) Nominal size Pump sizes F J J KRACHT GmbH Gewerbestr Werdohl, Germany fon +49(0)2 92/95-0 fax +49(0)2 92/ mail info@kracht.eu web 66

67 Supplier documentation Transfer Gear Pumps KF Motor-Pump Assemblies with Pipe Thread KF Frame Power Speed Power Speed Bell housing Coupling Total weight * size Motor 6 pole Motor 4 pole kg Nominal size kw 1/min kw 1/min PT160-A RA19-Z25/14-Z25/ PT200-A RA19-Z25/14-Z25/ S L PT200-A RA19/24-Z25/14-Z25/ PT250-A RA24/28-Z0/14-Z0/ * with pressure relief valve add, weight 0.8 kg KF Dimensions Frame size Dimensions (in mm) L 1* L 1* L 2* L 2* L i a 1 a b c* e* f* g* h o* p* q* ø s* w S L Note: Flange connection same outer dimensions as for pipe connection Note * Dimensions dependent on motor typ (drawing: manufacture ADDA). Other manufactures motors can be supplied on request. Motor frame sizes are based on DIN 4267/677. All pump and motor sizes can be combined. KRACHT GmbH Gewerbestr Werdohl, Germany fon +49(0)2 92/95-0 fax +49(0)2 92/ mail info@kracht.eu web

68 Supplier documentation Transfer Gear Pumps KF Motor-Pump Assemblies with SAE-Connection KF with pressure relief valve KF Pump sizes (in mm) Nominal size F J J / KRACHT GmbH Gewerbestr Werdohl, Germany fon +49(0)2 92/95-0 fax +49(0)2 92/ mail info@kracht.eu web 68

69 Supplier documentation Transfer Gear Pumps KF Motor-Pump Assemblies with SAE-Connection KF Frame Power Speed Power Speed Bell housing Coupling Total weight * size Motor 6 pole Motor 4 pole kg Nominal size kw 1/min kw 1/min PT200-A RA19/24-Z25/24-Z25/ S L PT200-A RA24-Z0/24-Z0/ PT250-A RA24/28-Z0/24-Z0/ S M PT00-A RA28/8-Z5/24-Z5/ L M L PT50-A RA8/45-Z45/24-Z45/ * with pressure relief valve add. weight 1.8 kg KF Dimensions Frame size Dimensions (in mm) L 1* L 1* L 2* L 2* L i a 1 a b c* e* f* g* h o* p* q* ø s* w S L S M M L Note * Dimensions dependent on motor typ (drawing: manufacture ADDA). Other manufactures motors can be supplied on request. Motor frame sizes are based on DIN 4267/677. All pump and motor sizes can be combined. KRACHT GmbH Gewerbestr Werdohl, Germany fon +49(0)2 92/95-0 fax +49(0)2 92/ mail info@kracht.eu web

70 Supplier documentation Transfer Gear Pumps KF Motor-Pump Assemblies with SAE-Connection KF with pressure relief valve KF Pump sizes (in mm) Nominalsize F J J 1 100/ / / KRACHT GmbH Gewerbestr Werdohl, Germany fon +49(0)2 92/95-0 fax +49(0)2 92/ mail info@kracht.eu web 70

71 Supplier documentation Transfer Gear Pumps KF Motor-Pump Assemblies with SAE-Connection KF Frame Power Speed Power Speed Bell housing Coupling Total weight * size Motor 6 pole Motor 4 pole kg Nominal size kw 1/min kw 1/min 100/ / / L RA24/28-Z0/28-Z0/ L PT250-A **RA24/28-Z0/24-Z0/ M S PT00-A RA28/8-Z5/28-Z5/8 12 M **PT00-A **RA28/8-Z5/24-Z5/8 12 L M RA8/45-Z45/28-Z45/ PT50-A L **RA8/45-Z45/24-Z45/ M RA42/55-Z50/28-Z50/ PT50-A L **RG42/55-Z50/24-Z50/ **with pressure relief valve KF add. weight 2.7 kg ** Sealing version 1 KF Dimensions Frame size 100/ / / / / /200 Dimensions (in mm) L 1* L 1* L 1* L 2* L 2* L 2* L a 1 a b c* e* f* g* h o* p* q* ø s* w S M M L M L Note * Dimensions dependent on motor typ (drawing: manufacture ADDA). Other manufactures motors can be supplied on request. Motor frame sizes are based on DIN 4267/677. All pump and motor sizes can be combined. KRACHT GmbH Gewerbestr Werdohl, Germany fon +49(0)2 92/95-0 fax +49(0)2 92/ mail info@kracht.eu web

72 Supplier documentation Transfer Gear Pumps KF Accessory Connections SAE-Threaded Flange Screw SAE-Welding Flange Screw O-ring O-ring 0 SAE-Threaded Flange Dimensions (in mm) Nominal size A B C D* E F* G H* L Screws O-ring Working pressure Weight SAE DN max. min max.** ca. [kg] /4" 1 G 1/2" M 10 x x G /4" G 1/2" " 19 G /4" M 10 x x G 1" G /4" /4" 25 G 1" M 10 x x G 1 1/4" G 1 " /2" 2 G 1 1/4" M 12 x x G 1 1/2" G1" " 2 G1 1/4" M 12 x x G 1 1/2" G 2" /2" 51 G 2" M 12 x x G 2 1/2" " 64 G 2 1/2" M 16 x x G " /2" 76 G " M 16 x x G 1/2" SAE-Welding Flange Dimensions (in mm) Nominal size A* B C D* E F* G H* Screws O-ring Working pressure Weight SAE DN max max.** ca. [kg] /4" M 10 x x " M 10 x x /4" M 10 x x /2" M 12 x x " M 12 x x /2" M 12 x x " M 16 x x /2" M 16 x x * Dimensions depending on the manufacturer ** O-ring material with hardness 90 Shore A Material: Steel S55J2G or equivalent Stainless steel or equivalent 16L KRACHT GmbH Gewerbestr Werdohl, Germany fon +49(0)2 92/95-0 fax +49(0)2 92/ mail info@kracht.eu web 72

73 Supplier documentation Transfer Gear Pumps KF Accessory Quench Chamber Quench tank Adapter for screw size tap G 1 8 KRACHT GmbH Gewerbestr Werdohl, Germany fon +49(0)2 92/95-0 fax +49(0)2 92/ mail info@kracht.eu web 1 7

74 Supplier documentation Product Portfolio Transfer Pumps Transfer pumps for lubricating oil supply equipment, low pressure filling and feed systems, dosing and mixing systems. Mobile Hydraulics Single and multistage high pressure gear pumps, hydraulic motors and valves for construction machinery, vehicle-mounted machines. Flow Measurement Gear and turbine flow meters and electronics for volume and flow metering techno logy in hydraulics, processing and laquering technology. Industrial Hydraulics / Test Bench Construction Cetop directional control and proportional valves, hydraulic cylinders, pressure, quantity and stop valves for pipe and slab construction, hydraulic accessories for industrial hydraulics (mobile and stationary use). Technology Test benches / Fluid Test benches. KF /GB/06.14 KRACHT GmbH Gewerbestraße Werdohl, Germany fon +49 (0) 2 92 / 95-0 fax +49 (0) 2 92 / mail info@kracht.eu web 74

75 Supplier documentation Bedienungsanleitung Operating Instructions Für künftige Verwendung bitte aufbewahren Please keep carefully for future use Membran-/ Kolbendruckschalter mit Gerätesteckdose Baureihe 0184 Baureihe 0185 D GB Pressostat à membrane/ ou à piston avec connecteur Série 0184 Série 0185 Einbau und Inbetriebnahme sind nach dieser Bedienungsanleitung und nur von autorisiertem Fachpersonal vorzunehmen. Installation and commissioning must be carried out in accordance with these Operating Instructions and by authorized, qualified personnel only. Montage et mise en service sont à entreprendre d après le présent mode d emploi et par le personnel autorisé seulement. SUCO Robert Scheuffele GmbH & Co. KG Keplerstraße Bietigheim-Bissingen, Germany Telefon: / Telefax: / info@suco.de SUCO Robert Scheuffele GmbH & Co. KG Keplerstraße Bietigheim-Bissingen, Germany Phone: Fax: info@suco.de SUCO Robert Scheuffele GmbH & Co. KG Keplerstraße Bietigheim-Bissingen, Germany Téléphone: Fax: info@suco.de Funktion und Anwendung Operation and use Fonctionnement et applications The series 0184/0185 switch opens or closes an electrical circuit when a certain (adjustable) pressure is reached. A diaphragm or piston is moved by the increase in pressure. The amount of diaphragm deflection or piston travel depends on the force of the pressure applied and the (adjustable) spring tension. At a predetermined deflection of the diaphragm or movement of the piston, a microswitch is actuated which opens or closes the electrical contacts (changeover). Der Druckschalter überwacht einen eingestellten Druckwert. Le pressostat contrôle une valeur de pression pré-réglée! Consignes relatives à la mise en service Allgemeine, stets zu beachtende Hinweise für den ordnungsgemäßen und sicheren Einsatz des Druckschalters: The following general instructions are to be observed at all times to ensure the correct, safe use of the pressure switch: Beachten Sie unbedingt die Warnungen und Hinweise in der Bedienungsanleitung. Observe without fail the warning notices and other instructions laid down in the operating instructions. Impérativement respecter les avis et les remarques données dans le mode d emploi. Beachten Sie die Vorschriften der Berufsgenossenschaften, des Technischen Überwachungsvereins (TÜV) oder die entsprechenden nationalen Bestimmungen. Observe the applicable safety regulations laid down by the regulatory bodies in the country of use. Toujours respecter les prescriptions et directives des Chambres syndica les, des Services de contrôle technique ainsi que les dispositions légales nationales. Use the switch only for monitoring fluid and gaseous medias. Der Druckschalter ist für die Überwachung von flüssigen und gasförmigen Medien bestimmt. Use the product only in its original condition. Do not carry out any unauthorized modifications. Verwenden Sie das Produkt nur im Originalzustand. Nehmen Sie keine eigenmächtige Veränderung vor. Remove all items providing protection in transit such as foils, caps or cartons. Entfernen Sie alle Transportvorkehrungen wie Schutzfolien, Kappen oder Kartonagen. Disposal of the above-named materials in recycling containers is permitted. Tous les matériaux susmentionnés sont recyclables et peuvent être déposés dans des conteneurs prévus à cet effet! Media temperatures other than room temperature (20 C): Extreme Temperatureinflüsse (abweichend von der Raumtemperatur) können zu einer starken Schaltpunktabweichung oder zum Ausfall des Druckschalters führen. Protection against overpressure: The static overpressure safety is included in the technical data. The overpressure safety corresponds to the hydraulic, pneumatic part of the pressure switch. The dynamic rating of the overpressure safety is smaller than 0 to 50%. Rated operating voltage Ue Rated operating current I e Utilization category 250 Volt AC 50/60 Hz 4 Ampere AC Volt AC 50/60 Hz 1 Ampere AC 14 0 Volt DC 4 / 4 Ampere DC 12 / DC 1 50 Volt DC 2 / 1 Ampere DC 12 / DC 1 Bemessungsbetriebsstrom I e Gebrauchskategorie 250 Volt AC 50/60 Hz 4 Ampere AC Volt AC 50/60 Hz 1 Ampere AC 14 0 Volt DC 4 / 4 Ampere DC 12 / DC 1 75 Volt DC 1 / 0.5 Ampere DC 12 / DC Volt DC 0. / 0.2 Ampere DC 12 / DC 1 50 Volt DC 2 / 1 Ampere DC 12 / DC 1 75 Volt DC 1 / 0,5 Ampere DC 12 / DC Volt DC 125 Volt DC 0, / 0,2 Ampere DC 12 / DC 1 Rated insulation voltage Ui 00 Volt DC 12 / DC 1 Rated surge capacity Uimp: 2.5 kv 2,5 kv Schaltüberspannung: < 2,5 kv Bemessungsfrequenz: DC und 50/60 Hz Nennstrom der Kurzschlusseinrichtung: bis 5 Ampere Bedingter Kurzschlussstrom: < 50 Ampere IP-Schutzart nach EN :1991: IP65 mit Stecker Anzugsdrehmoment der Anschlussschrauben: < 0.5 Nm Anschlussquerschnitt: 0,5 bis 1,5 mm2 Bitte wenden Technische Änderungen zur Produktverbesserung vorbehalten. Zeichenerklärung: Hinweis, Bemerkung Recycling Gefahr Art.- No.: A 08 / Volt 5 Ampere Pressostat à piston: Les pressostats à piston ne sont pas appropriés à la manipulation de fluides gazeux, l oxygène en particulier. Soupape de surpression: La valeur admise de surpression statique est exprimée dans les caractéristiques techniques. Elle se réfère à la valeur hydraulique ou pneumatique du pressostat. La valeur dynamique est de 0% jusqu à 50% inférieure. Technical data Technische Daten Bemessungsstoßspannungsfestigkeit Uimp: Utilisation avec l oxygène: Pressostat à membrane: Pour la manipulation d oxygène, la réglementation afférente à la Sécurité de Travail et à la Prévention d Accidents devra impérativement être respectée. Nous conseillons en outre de ne pas dépasser une pression de service de 10 bar maximum. Piston Pressure Switch: Piston Pressure Switches are not suitable for gaseous media, particulary oxygen. Kolbendruckschalter: Kolbendruckschalter sind für gasförmige Medien, insbesondere für Sauerstoff, nicht geeignet. Konventioneller thermischer Strom I the: Indice de protection IP65: Cet indice est fortement dépandant de l environnement dans lequel travaille le pressostat. L utilisateur est tenu de vérifier si le connecteur répond aux prescriptions et règlements autres que ceux indiqués dans la notice, ou s il peut être utilisé pour des applications non prévues par nous. Diaphragm Pressure Switch: If oxygen is used, the applicable accident prevention regulations must be observed. In addition, we recommend a maximum operating pressure of 10 bar, which should not be exceeded. Membrandruckschalter: Beim Einsatz von Sauerstoff sind die einschlägigen Unfallverhütungsvorschriften zu beachten. Außerdem empfehlen wir, einen maximalen Betriebsdruck von 10 bar nicht zu überschreiten. 0,25 / 0,2 Ampere En présence de températures des fluides autres que la température ambiante (20 C): Des températures ambiantes extrêmes peuvent provoquer une forte dérive du point de commutation ou une défaillance du pressostat. Use with oxygen: Sauerstoffeinsatz: Überdrucksicherheit: In den Technischen Daten ist die statische Überdrucksicherheit angegeben. Sie bezieht sich auf den hydraulischen bzw. pneumatischen Teil des Druckschalters. Der dynamische Wert ist 0 bis 50% niedriger. Conditions d utilisation Type of protection IP65: Type testing does not apply to all ambient conditions without limitations. The user is responsible for verifying that the plug-and-socket connection complies with the specified rules and regulations of CE, or whether it may be used for specialized purposes other than those intended by us. Schutzart IP65: Die Typenprüfung ist nicht uneingeschränkt auf alle Umweltbedingungen übertragbar. Die Überprüfung, ob die Steckverbindung anderen als den angegebenen Bestimmungen und Vorschriften entspricht bzw. ob diese in speziellen, von uns nicht vorgesehenen Anwendungen eingesetzt werden kann, obliegt dem Anwender _A_08-08.indd 1 Retirer tous les éléments de protection nécessaire pour le transport, telles que emballages, capuchons ou cartons. The effects of extreme temperatures (relative to room temperature) can lead to pronounced variations in the switching point or the failure of the pressure switch. Bei Medientemperaturen außerhalb der Raumtemperatur (20 C): Achtung N utiliser le produit que dans son état original. Ne jamais entreprendre des modifications quelconques sur celui-ci. Operating conditions Betriebsbedingungen Veillez à ce que le pressostat ne soit jamais soumis à des fortes accélérations, vibrations, et des chocs forts / 0.2 Ampere Caractéristiques techniqus Tension de assignées d emploi Ue DC 12 / DC 1 Intensité de service de référence I e Catégorie de service 250 V CA 50/60 Hz 4 Ampère CA V CA 50/60 Hz 1 Ampère CA 14 0 V CC 4 / 4 Ampère 50 V CC 2 / 1 Ampère CC 12 / CC 1 75 V CC 1 / 0,5 Ampère CC 12 / CC V CC 0, / 0,2 Ampère 0,25 / 0,2 Ampère CC 12 / CC 1 CC 12 / CC 1 Rated thermal current Ithe: 5 Ampere 250 V DC Switching overvoltage: < 2.5 kv Tension d isolement de référence Ui: Rated frequency: DC und 50/60 Hz Rated current of short-circuit protective decvice: Up to 5 Ampere Résistance de référence aux ondes 2,5 kv de surtension Uimp: Rated short-circuit current: < 50 Ampere IP-protection to EN :1991: IP65 with plug Tightening torque for terminal screws: < 0.5 Nm Connection size: 0.5 to 1.5 mm2 PTO Continuing development sometimes necessitates specification changes without notice. Key to drawings: Caution Note Recycling CC 12 / CC 1 00 V Courant thermique nominal Ithe: 5 Ampère Surtension de commutation: < 2,5 kv Fréquence de référence: CC et 50/60 Hz Courant nominal de protection contre les court-circuits: jusqu à 5 Ampère Danger Référence: A 08 / 08 Die Entsorgung der einzelnen Werkstoffe in Recycling-Sammelbehältern ist möglich. 250 Volt DC Tenir compte des conditions environnantes rencontrées (température ambiante, humidité atmosphérique, pression atmosphérique, etc.). Never expose the pressure switch to severe side impacts or vibrations. Setzen Sie den Druckschalter niemals starken Stößen oder Vibrationen aus. Bemessungsisolationsspannung Ui: Utiliser le pressostat exclusivement avec des fluides liquides ou gazeux. Respecter les valeurs seuils indiquées (pressions, forces, moments, températures, par exemple). Give due consideration to the prevailing ambient conditions (temperature, atmospheric humidity, atmospheric pressure, etc.). Berücksichtigen Sie die vorherrschenden Umgebungsbedingungen (Temperatur, Luftfeuchte, Luftdruck etc.). Bemessungsbetriebsspannung Ue Remarques d ordre général, mais dont il faut toutefois toujours tenir compte, pour obtenir un fonctionnement fiable et sûr du pressostat: Do not exceed the specified limits for e.g. pressures, forces, moments or temperatures under any circumstances. Halten Sie die angegebenen Grenzwerte wie z.b. Drücke, Kräfte, Momente und Temperaturen ein. Art.- Nr.: A 08 / 08 F Les séries 0184/0185 ouvrent ou ferment un circuit électrique dès qu une valeur de pression pré-réglée est atteinte. La montée en pression agit sur une membrane ou un piston. L ampleur de la déformation subie par la membrane ou la course du piston dépend de la pression exercée et de la précontrainte pré-réglée sur un ressort. Par une déformation de la membrane ou une course du piston donnée, le microrupteur est actionné; il ouvre ou il ferme le circuit électrique (inverseur). The pressure switch monitors a preset pressure. Conditions governing the use of the product Voraussetzungen für den Produkteinsatz Mode d emploi A conserver pour toute utilisation ultérieure Diaphragm-/ Piston Pressure Switch with connector Series 0184 Series 0185 Die Baureihe 0184/0185 öffnet oder schließt einen elektrischen Stromkreis beim Erreichen eines einstellbaren Druckwerts. Durch das Ansteigen des Drucks wird eine Membrane bzw. ein Kolben bewegt. Die Auslenkung der Membrane bzw. der Hub des Kolbens hängt von der Druckkraft und der einstellbaren Federvorspannung ab. Bei einer definierten Auslenkung der Membrane bzw. einem definierten Hub des Kolbens wird ein Mikroschalter betätigt, der die elektrischen Kontakte öffnet bzw. schließt (Wechsler). Courant de court-circuit conditionnel: < 50 Ampère Protection IP selon EN :1991: IP65 avec connecteur Couple de serrage des vis de raccordement: < 0,5 Nm Section de raccordement: 0,5 à 1,5 mm2 T.S.V.P. Soucieux d apporter une amélioration constante à nos produits, les caractéristiques peuvent évoluer sans préavis. Explication des symboles: Attention Nota, remarque Recyclage Danger :1:20 Uhr 75

76 Supplier documentation Presse-étoupe: Pg 9 Connecteur DIN 4650 lumineux à LED: Pg 11 Diamètre du câble: Pg 9: 6 à 9 mm Pg 11: 6 à 11 mm Fréquence de commutation: < 200 min -1 Hystérésis: 10 à 0% réglable en usine Durée de vie mécanique 10 6 cycles de manoevre Version à membrane (0184): (pour des pressions de commutation jusqu à 50 bar) Version à piston (0184): 10 6 cycles de manoevre Corps: acier zinguè, nickelè (Fe//ZnNi(12)6//A/T2) Tenue à la temperature: NBR -40 C à +100 C EPDM -0 C à +120 C FKM -5 C à +120 C Securité de surpression Pressostat à membrane (0184): 100 bar (0, à 1,5 bar) 00 bar (autres plages) Pressostat à piston(0185): 600 bar Cable screw coupling: Pg 9 Connector with LED: Pg 11 Cable size: Pg 9: 6 to 9 mm Pg 11: 6 to 11 mm Operating frequency: < 200 min -1 Switching hysteresis: 10 to 0% adjustable by the factory Mechanical life 10 6 operating cycles Diaphragm type (0184): (at a trip pressures up to 50 bar) Piston type (0184): 10 6 operating cycles Body material: Zinc-plated steel (Fe//ZnNi(12)6//A/T2) Temperature range: NBR -40 C to +100 C EPDM -0 C to +120 C FKM -5 C to +120 C Overpressure safety Diaphragm Pressure Switch (0184): 100 bar (0. to 1.5 bar) 00 bar (restidual pressure) Piston Pressure Switch (0185): 600 bar Kabelverschraubung: Pg 9 Gerätesteckdose mit LED: Pg 11 Klemmbereich: Pg 9: 6 bis 9 mm Pg 11: 6 bis 11 mm Schalthäufigkeit: <200 min -1 Schalthysterese: 10 bis 0% im Werk einstellbar Mechanische Lebensdauer Membranausführung (0184): 10 6 Schaltspiele (bei Schaltdrücken bis 50 bar) Kolbenausführung (0184): 10 6 Schaltspiele Gehäusewerkstoff: verzinkter Stahl (Fe//ZnNi(12)6//A/T2) Temperaturbeständigkeit: NBR -40 C bis +100 C EPDM -0 C bis +120 C FKM -5 C bis +120 C Überdrucksicherheit Membrandruckschalter (0184): 100 bar (0, bis 1,5 bar) 00 bar (restl. Druckbereiche) Kolbendruckschalter (0185): 600 bar Eléments de manoeuvre et de raccordement Fig. 1 Fig. 2 Operating controls and connections Fig. 1 Fig. 2 Bedienteile und Anschlüsse Bild. 1 Bild Fig. max. 0,5 Nm Fig. max. 0.5 Nm Bild. max. 0,5 Nm (1) Raccordement hydraulique/ pneumatique (2) Raccordement électrique () Vis de réglage du point de commutation (4) Vis de fixation (5) Boîtier du connecteur (6) Joint profilé (7) Embase de montage (8) Raccord Pg, avec joint et bague d appui Fig. 4 P (1) Pressure connection (2) Electrical connection () Adjusting screw (4) Fastening screw (5) Plug housing (6) Gasket (7) Terminal board (8) Pg gland Fig. 4 P (1) Hydraulischer/Pneumatischer Anschluss (2) Elektrischer Anschluss () Einstellschraube für den Schaltpunkt (4) Befestigungsschraube (5) Steckergehäuse (6) Profildichtung (7) Anschlussplatte (8) Pg-Verschraubung mit Dichtring Fig. 4 P Montage Mécanique, pneumatique, hydraulique: A l aide d une clé plate de 27 (DIN 894 ou analogue), visser par l embout 6 pans le pressostat dans le raccord de pression prévu (couple dynamométrique: voir le tableau suivant). L étanchéité du système est assurée par une bague en cuivre, aux dimensions correspondantes. Attention: ne jamais serrer le pressostat en le saisissant par ses parties en plastique! Risque de détérioration! Filetage du raccord Couple dynamométrique M10 x 1 conique et NPT 1/8 Visser jusqu à ce que le systéme soit hermétique M10 x 1 cylindrique 5 Nm Autres 45 Nm Electrique: N utiliser que le connecteur fourni par nos services. S assurer que le câble électrique soit exempt - d écrasements, - de coudes trop prononcés - qu il soit installé de manière à ne pas pouvoir s allonger. Câblage avec le connecteur: 1. Oter la vis de fixation (4) présente à l extrémité (la conserver en lieu sûr). 2. Démonter l embase de montage (7) ainsi liberée (Fig. 2).. Raccorder les conducteurs (section maxi: 1,5 mm 2 ) sur les bornes prévues à cet effet (Fig. 4). 4. Réengager l embase de montage (7) dans le boîtier (5), remettre la vis de fixation (4) en place. Engager la prise de courant sur le pressostat et serrer fermement la vis de fixation (4). 5. Procéder aux vérifications suivantes: - Le câblage correspond-il au schéma de la figure 4? - Les câblages sont-ils posés sans risque d écrasement? - Les couples dynamométriques (Fig. ) sont-ils respectés? Veiller à ce que le joint profilé (6) soit correctement positionné et à ce que le raccord Pg (8) soit en place comme il faut, faute de quoi l indice de protection spécifié (IP65) ne serait pas obtenu. Mise en service 1. Dévisser la vis de fixation (4) et la retirer. 2. Relier les bornes 1 et 4 avec un multimètre (Fig. 4). Si l on se sert d une lampe en tant que contrôleur de passage, il faut veiller à respecter la puissance de commutation maximale admise (voir caractéristiques techniques).. Tout d abord visser la vis de réglage () à fond. Utiliser pour cela un tournevis avec une largeur de lame de 2,5 mm. 4. Alimenter le pressostat avec la pression de commutation souhaitée (un manomètre de contrôle est nécessaire). Tenir compte du fait que la vis de réglage (4) n a une butée que pour le serrage. 5. Dévisser la vis de réglage () jusqu à ce que le pressostat commute (la lampe de contrôle réagit). 6. Corriger le cas échéant la pression de commutation en agissant en conséquence sur la vis de réglage (). 7. Engager finalement la prise de l appareil sur le pressostat (respecter le schéma de raccordement). Le réglage des seuills de contact selon les points, 4, 5 et 6 ci-dessus peut également être entrepris, la prise de courant étant engagée sur le pressostat. Pour cela, oter la vis de fixation (4). On aura ainsi accès à la vis de réglage (), avec un tournevis d une largeur de lame de 2,5 mm, introduit par cet orifice à l intèrieur de la prise. Procéder comme décrit points, 4, 5 ci-dessus. A la mise en service du pressostat, tenir compte des prescriptions et directives correspondantes données par les Chambres syndicales concernées, ainsi que les dispositions nationales respectives. Le réglage de l hystérésis est fait par l usine. Une utilisation abusive pourrait endommager le pressostat. Installation Mechanical, pneumatic, hydraulic With a size 27 open-ended wrench (to DIN 894 or similar), install the pressure switch, by means of the hexagon connector, in the corresponding pressure socket (for torque specification, see following table). For sealing the system, use a standard copper gasket of the appropriate dimensions. Caution: Do not secure the pressure switch by means of the plastic components under any circumstances; otherwise they may be damaged beyond further use. Commecting thread Torque M10 x 1 tap. and NPT 1/8 Tighten until system is hermetically sealed M10 x 1 cyl. 5 Nm Remaining 45 Nm Electrical: Use the connector supplied. Take care to ensure that the cable is laid in such a way that it is not: - pinched - kinked - under tension. Connection to the connector: 1. Remove the fastening screws (4) from the head end (set aside for later use). 2. Remove the released terminal board (7) (Fig. 2).. Connect the cable (max. lead cross-section 1.5 mm 2 ) to the screw terminals provided (Fig. 4). 4. Reinstall the terminal board (7) in the plug housing (5). Install the fastening screw (4). Install the connector on the pressure switch and tighten the fastening screw (4). 5. Pay attention to the following points: - Wiring in accordance with connection diagramm (Fig. 4) - Cabling laid free of pinchin, chafing, etc. - Torque specifications (Fig. ) Take care to ensure that the gasket (6) and Pg gland (8) are correctly installed, otherwise the conditions specified for protection category IP65 will not be achieved. Entry into service 1. Remove out the connector. 2. Using a continuity tester, wire up the electrical connections 1 and 4 (Fig. 4). If using a testing lamp as a continuity tester, observe the maximum permissible switching capacity (see Technical Data).. First screw in the adjusting screw () as far as it will go.to adjust the pressure switch, use a screwdriver with a 2,5 mm wide blade. 4. Adjust the pressure switch to the desired switching pressure (a test pressure gauge required). Take care to ensure that the adjusting screw () does not seize at any point other than when it is fully tightened down. 5. Ease off the adjusting screw () to a sufficient extent to cause the pressure switch to trip (continuity tester reacts). 6. If necessary, adjust the trip pressure setting by turning the adjusting screw (). 7. Push the connector onto the pressure switch (observe the connection diagram). Adjustment of the trip pressure setting in accordance with points, 4, 5 and 6 can also be carried out with the connector installed. In this case, first remove the fastening screw (4). With a screwdriver (Bladewidth 2,5 mm), you can now reach the adjusting screw () through the aperture in the connector. Now proceed in accordance with points, 4, 5 and 6 above. When putting the pressure switch into service, please observe the applicable safety regulations laid down by the governing bodies in the country of use. The adjustment of hysteresis can only be carried out in the factory. If this is unexpertly undertaken, damage may be caused to the pressure swich. Einbau Mechanisch, pneumatisch, hydraulisch: Drehen Sie den Druckschalter an dem sechskantförmigen Ansatz mit einem Maulschlüssel der Schlüsselweite 27 (nach DIN 894 o.ä.) in den vorgesehenen Druckanschluss (Anzugsdrehmomente siehe nachfolgende Tabelle). Zum Abdichten des Systems verwenden Sie einen Standard-Kupferdichtring mit den entsprechenden Abmessungen. Achtung: niemals den Druckschalter an den Kunststoffteilen mechanisch belasten. Zerstörungsgefahr! Anschlussgewinde Drehmoment M10 x 1 kegl. und NPT 1/8 Einschrauben bis System abgedichtet ist M10 x 1 zyl. 5 Nm Restliche 45 Nm Elektrisch: Verwenden Sie die mitgelieferte Gerätesteckdose. Stellen Sie sicher, dass das Kabel - quetschfrei, - knickfrei, - dehnungsfrei verlegt ist. Verkabelung des Gerätesteckdose: 1. Lösen Sie die Befestigungsschraube (4), und ziehen Sie diese am Kopf ende ganz heraus (gut aufbewahren) 2. Demontieren Sie die gelöste Anschlussplatte (7) (Bild 2).. Schließen Sie die Kabel (max. Leistungsquerschnitt 1,5 mm 2 ) an den dafür vorgesehenen Schraubklemmen an (Bild 4). 4. Anschlussplatte (7) wieder in das Steckergehäuse (5) schieben. Befestigungsschraube (4) montieren. Gerätesteckdose auf den Druckschalter stecken und Befestigungsschraube (4) anziehen. 5. Achten Sie auf folgende Punkte: - Verkabelung nach Anschlussbild (Bild 4) - quetschfreie Kabelführung - Anzugsdrehmomente (Bild ) Achten Sie auf die ordnungsgemäße Lage der Profildichtung (6) und auf eine sachgemäße Montage der Pg-Verschraubung (8), da sonst die Schutzart IP65 nicht erreicht wird. Inbetriebnahme 1. Lösen Sie die Befestigungsschraube (4), und ziehen Sie die Gerätesteckdose ab. 2. Verkabeln Sie die elektrischen Anschlüsse 1 und 4 mit einem Durchgangsprüfer (Bild 4). Bei Verwendung einer Prüflampe als Durchgangsprüfer: Achten Sie auf die max. zulässige Schaltleistung(siehe technische Daten).. Drehen Sie die Einstellschraube () zunächst ganz ein. Verwenden Sie zum Einstellen des Druckschalters einen Schraubendreher mit 2,5 mm Klingenbreite. 4. Beaufschlagen Sie den Druckschalter mit dem gewünschten Schaltdruck (Kontrollmanometer erforderlich). Beachten Sie bitte, dass die Einstellschraube () nur beim Eindrehen einen Anschlag besitzt. 5. Drehen Sie die Einstellschraube () so weit heraus, bis der Druckschalter umschaltet (Durchgangsprüfer reagiert). 6. Korrigieren Sie gegebenenfalls den Schaltdruck durch Verdrehen der Einstellschraube (). 7. Schieben Sie die Gerätesteckdose auf den Druckschalter (Anschlussbild beachten). Das Einstellen des Schaltpunkts nach den Punkten, 4, 5 und 6 kann auch mit aufgesetzter Gerätesteckdose durchgeführt werden. Hierzu entfernen Sie bitte die Befestigungsschraube (4). Nun können Sie mit einem Schraubendreher (Klingenbreite 2,5 mm) durch die Durchgangsbohrung der Gerätesteckdose die Einstellschraube () erreichen. Verfahren Sie nun wie in Punkt, 4, 5 und 6 des Kapitels Inbetriebnahme beschrieben. Bei Inbetriebnahme des Druckschalters beachten Sie bitte die entsprechenden Sicherheitsvorschriften der Berufsgenossenschaft oder die entsprechenden nationalen Bestimmungen. Démontage Removing the pressure switch Die Einstellung der Hysterese ist nur werkseitig durchführbar. Bei unsachgemäßer Vorgehensweise kann der Druckschalter beschädigt werden. Avant de démonter le pressostat il est très important de tenir compte des points suivants: Il est impératif que le système sur lequel le pressostat est monté soit au préalable mis hors pression et hors tension. A l aide d une clé plate de 27 (DIN 894 ou analogue), dévisser par l embout 6 pans le pressostat du raccord de pression sur lequel il a été monté. De même, les prescriptions inhérentes à la sécurité doivent impérativement être respectées. Ne jamais dévisser le pressostat en le saisissant par ses parties en plastique, faute de quoi on encourt le risque de l endommager _A_08-08.indd 2 When removing the pressure switch, observe the following important instructions: The pressurized system from which the pressure switch is intended to be removed must be entirely relieved of pressure. All the relevant safety regulations must be observed. Use a size 27 open-ended wrench (to DIN 894 or similar), to remove the pressure switch. Do not attempt to turn the switch by means of the plastic collars, otherwise it could be damaged beyond further use. Ausbau Beachten Sie folgende wichtige Punkte beim Ausbau des Druckschalters: Das Drucksystem, aus dem der Druckschalter ausgebaut werden soll, muss sich im drucklosen Zustand befinden. Es müssen alle relevanten Sicherheitsbestimmungen beachtet werden. Drehen Sie den Druckschalter mit einem Maulschlüssel der Schlüsselweite 27 (nach DIN 894 o.ä.) aus dem Druckanschluss. Drehen Sie den Druckschalter niemals an den Kunststoffansätzen heraus, da Zerstörungsgefahr für den Druckschalter besteht :1:45 Uhr 76

77 Supplier documentation Mechanical pressure measurement Bourdon tube pressure gauge Model 21.5, liquid filling, stainless steel case WIKA data sheet PM for further approvals see page 2 Applications For measuring points with high dynamic pressure loads or vibrations For gaseous and liquid media that are not highly viscous or crystallising and will not attack copper alloy parts Hydraulics Compressors, shipbuilding Special features Vibration and shock resistant Especially sturdy design NS 6 and 100 with German Lloyd and Gosstandart approval Scale ranges up to ,000 bar Bourdon tube pressure gauge, model , lower mount Description Design EN 87-1 Nominal size in mm 50, 6, 100 Accuracy class NS 50, 6: 1.6 NS 100: 1.0 Scale ranges NS 50: to bar NS 6, 100: to ,000 bar or all other equivalent vacuum or combined pressure and vacuum ranges Pressure limitation NS 50, 6: Steady: /4 x full scale value Fluctuating: 2/ x full scale value Short time: Full scale value NS 100: Steady: Full scale value Fluctuating: 0.9 x full scale value Short time: 1. x full scale value Permissible temperature Ambient: C Medium: +60 C maximum Temperature effect When the temperature of the measuring system deviates from the reference temperature (+20 C): Max. ±0.4 %/10 K of the span Ingress protection IP 65 per EN / lec WIKA data sheet PM /2015 Page 1 of Data sheets showing similar products: Standard version with liquid filling; model 11.5; see data sheet PM

78 Supplier documentation Standard version Process connection Copper alloy, lower mount (LM) or back mount (BM), NS 50, 6: G ¼ B (male), 14 mm flats NS 100: G ½ B (male), 22 mm flats Pressure element NS 50: Copper alloy, C-type or helical type NS 6: 400 bar: Copper alloy, C-type or helical type > 400 bar: Stainless steel 16L, helical type NS 100: < 100 bar: Copper alloy, C-type 100 bar: Stainless steel 16L, helical type Movement Copper alloy Dial NS 50, 6: Plastic ABS, white, with pointer stop pin NS 100: Aluminium, white, black lettering Pointer NS 50, 6: Plastic, black NS 100: Aluminium, black Window Plastic, crystal-clear Case Natural finish stainless steel, with blow-out device with NS 50: in case back, 12 o clock NS 6, 100: at case circumference, 12 o clock O-ring seal between case and connection. Scale ranges bar with compensating valve to vent case. Bezel ring Crimp ring, glossy finish stainless steel, triangular bezel Filling liquid Glycerine Options Other process connection Sealings (model , see data sheet AC 09.08) Measuring system and movement from stainless steel (model 2.5) NS 100: Zero adjustment (in front) Increased medium temperature with special soft solder - NS 50, 6: 100 C - NS 100: 150 C Ambient temperature resistant C with silicone oil filling NS 50: Higher scale ranges up to ,000 bar Panel mounting flange, stainless steel, for back connection Surface mounting flange, stainless steel (not NS 50) Mounting clamp (for back connection) CE conformity Pressure equipment directive 97/2/EC, PS > 200 bar, module A, pressure accessory Approvals GL, ships, shipbuilding (e.g. offshore), Germany EAC, import certificate, customs union Russia/Belarus/ Kazakhstan GOST, metrology/measurement technology, Russia KBA, automotive, European Community CRN, safety (e.g. electr. safety, overpressure,...), Canada Certificates 1) 2.2 test report per EN (e.g. state-of-the-art manufacturing, material proof, indication accuracy).1 inspection certificate per EN (e.g. indication accuracy) 1) Option Approvals and certificates, see website Page 2 of WIKA data sheet PM /

79 Supplier documentation Dimensions in mm Standard version Lower mount (LM) NS 50, 6, centre back mount (CBM) NS 100, lower back mount (LBM) NS Dimensions in mm Weight in kg a b ±0.5 b 2 ±0.5 D 1 D 2 e f G h ±1 SW G ¼ B G ¼ B G ½ B Process connection per EN 87-1 / 7. Ordering information Model / Nominal size / Scale range / Connection size / Connection location / Options 2008 WIKA Alexander Wiegand SE & Co. KG, all rights reserved. The specifications given in this document represent the state of engineering at the time of publishing. We reserve the right to make modifications to the specifications and materials. 0/2015 EN WIKA data sheet PM /2015 Page of WIKA Alexander Wiegand SE & Co. KG Alexander-Wiegand-Straße Klingenberg/Germany Tel Fax info@wika.de 79

80 Supplier documentation Mechanical temperature measurement Bimetal thermometer Model 52, industrial series WIKA data sheet TM for further approvals see page 6 Applications A wide range of applications in machine building, vessel, piping and apparatus construction Heating technology Special features Scale ranges from C Large choice of nominal sizes from mm Case and stem from stainless steel 5 different connection designs Fig. left: model A52.100, back mount Fig. right: model R52.100, lower mount Description The model 52 bimetal thermometer is the entry-level model among process thermometers. The target markets of this thermometer are air-conditioning and machine building. Model 52 is manufactured in accordance with EN 1190 and already offers a stainless steel case and accuracy class 1 for nominal sizes > 60 mm. Especially noteworthy is the large number of stem lengths and nominal sizes. This enables the individual adaptation to the target applications. WIKA data sheet TM /2016 Page 1 of 6 80

81 Supplier documentation Standard version Measuring element Bimetal coil Nominal size in mm 25,, 40, 50, 6, 80, 100, 160 Connection designs S Standard (male threaded connection) 1 Plain stem (without thread) 2 Male nut 1) Union nut 1) 4 Compression fitting (sliding on stem) 1) 1) Not for NS 25,, 40, 50 Model overview Model NS Design A Back mount (axial) A52.0 A A A A A A R Lower mount (radial) R R R Window Instrument glass NS : polycarbonate Pointer NS 25,, 40: Aluminium, black NS 50, 6, 80, 100, 160: Aluminium, black, adjustable pointer Permissible operating pressure at the stem NS 25,, 40, 50: max. 6 bar, static NS 6, 80, 100, 160: max. 25 bar, static Ingress protection NS 25,, 40: IP54 per EN / IEC 529 NS 50, 6, 80, 100, 160: IP4 per EN / IEC 529 Options Scale range F, C/ F (dual scale) Other scale ranges Other connection types Accuracy class NS 25, : ±5 % of scale range NS 40, 50: 2 per EN 1190 NS 6, 80, 100, 160: 1 per EN 1190 Working range Continuous loading: Measuring range per EN 1190 Short time (24 h max.): Scale range per EN 1190 Case, bezel ring, stem, process connection and spacer Stainless steel Elbow behind the case Aluminium, only with lower mount version Dial Aluminium, white, black lettering Page 2 of 6 WIKA data sheet TM /

82 Supplier documentation Scale ranges, measuring ranges 2), error limit (EN 1190) Scale graduation per WIKA standard Scale range in C Measuring range in C Scale spacing in C Error limit ± C up to NS 6 from NS 80 up to NS 50 from NS ) ) ) ) ) ) The limits of the measuring range are indicated on the dial by two triangular marks. Only within this range is the stated error limit valid per EN ) Not for NS 4) Not for NS 25 to NS 50 Connection designs Standard design (male thread connection) Standard insertion length l 1 = 6, 100, 160, 200, 250 mm Nominal size Process connection Dimensions in mm NS G i SW Ø d 4 Ø d 25, M8 x G ⅛ B G ¼ B , 50 M8 x Legend: G Male thread i Thread length Ø d 4 Diameter of the sealing collar SW Ø d l 2 Spanner width Stem diameter Active length G ⅛ B G ¼ B G ½ B , 80, 100, 160 G ¼ B or 8 G ½ B or 8 M18 x or 8 ½ NPT or 8 Bauform 1, Anschluss glatt (ohne Gewinde) Standard-Einbaulänge I 1 = 45, 6, 100, 140, 160, 200, 240, 290 mm Nominal size Dimensions in mm NS d 1 Ø d 25, , , 80, 100, or 8 Legend: Ø d 1 Bunddurchmesser Ø d Stem diameter l 2 Active length WIKA data sheet TM /2016 Page of 6 82

83 Supplier documentation Design 2, male nut Standard insertion length l 1 = 80, 140, 180, 20 mm Nominal size Process connection Dimensions in mm NS G i SW Ø d 6, 80, 100, 160 G ½ B or 8 M18 x or 8 Legend: G Male thread i Thread length incl. collar SW Spanner width Ø d l 2 Stem diameter Active length Design, union nut Standard insertion length l 1 = 89, 126, 186, 226, 276 mm Nominal size Process connection Dimensions in mm NS G i SW Ø d 6, 80, 100, 160 G ½ or 8 G ¾ or 8 Legend: G 1 Female thread i Thread length SW Spanner width Ø d l 2 Stem diameter Active length Design 4, compression fitting (sliding on stem) Insertion length l 1 = variable Length L = l mm Nominal size Process connection Dimensions in mm NS G i SW Ø d 4 Ø d 6, 80, 100, 160 G ¼ B or 8 Sealing ring G ½ B or 8 M18 x or 8 ½ NPT or 8 G ¾ B or 8 Legend: G Male thread i Thread length Ø d 4 Diameter of the sealing collar SW Ø d l 2 Spanner width Stem diameter Active length ¾ NPT or 8 Page 4 of 6 WIKA data sheet TM /2016 8

84 Supplier documentation Dimensions in mm Back mount (BM) (up to 250 C) Back mount with spacer (from 00 C or on request) Lower mount (LM) NS Dimensions in mm Weight in kg b 1 b 2 b b 4 b 5 Ø D F R RD U ) ) ) ) 57 42, ) from 00 C or on request R Back mount (BM) RD Back mount with spacer U Lower mount (LM) Thermowell In principle, the operation of a mechanical thermometer without a thermowell with low process-side loading (low pressure, low viscosity and low flow velocities) is possible. However, in order to enable exchanging the thermometer during operation (e.g. instrument replacement or calibration) and to ensure a better protection of the instrument and also the plant and the environment, it is advisable to use a thermowell from the extensive WIKA thermowell portfolio. For further information on the calculation of the thermowell, see Technical information IN WIKA data sheet TM /2016 Page 5 of 6 84

85 Supplier documentation Approvals Logo Description Country GOST (option) Russia Metrology, measurement technology - CRN (option) Safety (e.g. electr. safety, overpressure,...) Canada Certificates (option) 2.2 test report Approvals and certificates, see website Ordering information Model / Connection design / Scale range / Process connection / Stem diameter, material / Insertion length / Options 2004 WIKA Alexander Wiegand SE & Co. KG, all rights reserved. The specifications given in this document represent the state of engineering at the time of publishing. We reserve the right to make modifications to the specifications and materials. Page 6 of 6 WIKA data sheet TM / /2016 EN WIKA Alexander Wiegand SE & Co. KG Alexander-Wiegand-Straße Klingenberg/Germany Tel Fax info@wika.de 85

86 Supplier documentation Operating instructions Flow monitors SI5000 SI5001 UK / 0 08 /

87 Supplier documentation Contents 1 Safety instructions 2 Functions and features Application area Operating principle flow monitoring 4 Installation 5.1 Installation location 5.2 Sources of interference in the pipe system 6.. Mounting operation 6 4 Electrical connection 7 5 Operating and display elements 7 6 Set-up and settings for water Change the switch point (optional) High flow adjustment (optional) 9 7 Additional settings (optional) Low flow adjustment Configure the switching output 9 7. Restore the factory setting (reset) Lock / unlock the unit 10 8 Error during adjustment 10 9 Operation Maintenance Scale drawing Technical data

88 Supplier documentation Preliminary note An instruction is indicated by : Example: Check whether the unit operates correctly. A reaction to the action is indicated by ">": Example: > LED 9 lights. 1 Safety instructions Please read the product description prior to set-up of the unit. Ensure that the product is suitable for your application without any restrictions. The unit conforms to the relevant regulations and EC directives. Improper or non-intended use may lead to malfunctions of the unit or to unwanted effects in your application. That is why installation, electrical connection, set-up, operation and maintenance of the unit must only be carried out by qualified personnel authorised by the machine operator. For the scope of validity culus: The device shall be supplied from an isolating transformer having a secondary Listed fuse rated as noted in the following table. UK Overcurrent protection Control-circuit wire size Maximum protective device rating AWG (mm 2 ) Ampere 26 (0.1) 1 24 (0.20) 2 22 (0.2) 20 (0.52) 5 18 (0.82) 7 16 (1.) 10 88

89 Supplier documentation 2 Functions and features 2.1 Application area The unit monitors the flow of liquid and gaseous media. 2.2 Operating principle flow monitoring The unit detects the flow speed to the calorimetric measuring principle and switches the output: -- output closed if medium is flowing / output open if no medium is flowing. This applies to the unit on delivery: output = normally open. In case of need you can change the output to normally closed ( 7.2). It then applies: output open if medium is flowing. If the flow speed increases, the switching status changes when the switch point is reached. If the flow speed falls again, the switching status changes if the value "SP minus hysteresis" is reached. The hysteresis changes with the flow speed and it is essentially influenced by the set monitoring range. It is cm/s for the setting cm/s (= factory setting), it increases with higher flow speeds. The typical response time of the unit is s. It can be influenced by the setting of the switch point: -- Low switch point = quick reaction with rising flow. --High switch point = quick reaction with falling flow. 4 89

90 Supplier documentation Installation Using process adapters the unit can be adapted to different process connections. Adapters have to be ordered separately as accessories. A correct fit of the unit and ingress resistance of the connection are only ensured using ifm adapters. For small flow rates ifm adapter blocks are available..1 Installation location General The sensor tip is to be completely surrounded by the medium. Insertion depth of the sensor: minimum 12 mm. 12mm UK Recommended For horizontal pipes: mounting from the side. For vertical pipes: mounting in the rising pipe. Conditional Horizontal pipe /mounting from the bottom: if the pipe is free from build-up. Horizontal pipe /mounting from the top: if the pipe is completely filled with medium. To avoid The sensor tip must not be in contact with the pipe wall. Do not mount in downpipes that are open at the bottom! 5 90

91 Low Flow High Setpoint Low Flow High Setpoint Supplier documentation.2 Sources of interference in the pipe system Components integrated in the pipes, bends, valves, reductions, etc. lead to turbulence of the medium. This affects the function of the unit. Recommendation: Adhere to the distances between sensor and sources of interference: x D...5 x D S S D = pipe diameter; S = sources of interference.. Mounting operation Ensure that the system is free of pressure during installation. Ensure that no media can leak at the mounting location during installation. 1 2 A í ì î Grease the threads of the process connection (1), adapter (2) and nut (). Note: The sensor tip (A) must not be in contact with grease. Screw the suitable adapter into the process connection. Place the flow monitor onto the adapter and tighten the nut. Tightening torque 25 Nm. Ensure that the unit is correctly oriented. 6 91

92 Supplier documentation 4 Electrical connection The unit must be connected by a qualified electrician. The national and international regulations for the installation of electrical equipment must be adhered to. Voltage supply to EN 50178, SELV, PELV. Disconnect power. Connect the unit as follows: 1 BN 1 BN 2 L+ L+ 4 1 BK 4 BK A B 4 BU BU L L UK A: SI5000 (positive switching); B: SI5001 (negative switching) Core colours of ifm sockets: 1 = BN (brown), = BU (blue), 4 = BK (black) 5 Operating and display elements 1 Low Flow Setpoint High 2 1: Operation display The green LEDs indicate the current flow (the LEDs 0 to 9 represent the range between no flow and maximum flow). A lighting LED indicates the position of the switch point (orange = output closed, red = output open). 2, : Setting buttons for adjustment and configuration 7 92

93 Supplier documentation 6 Set-up and settings for water (For media other than water 7.1: Low flow adjustment). Switch on the supply voltage. > > All LEDs light and go out again step by step. During this time the output is closed (if configured as normally open). The unit is in the operating mode. Let the normal flow circulate in the installation. Check the display and determine further actions. 1 2 Low Flow High Low Flow High Low Flow High The factory setting is suitable for the application. No further settings are required. Your normal flow is below the representation range of the display. 2 setting options: Change the switch point ( 6.1). Carry out high flow adjustment ( 6.2). Your normal flow exceeds the representation range of the display (LED 9 flashes). Carry out high flow adjustment ( 6.2). You can restore the factory setting any time. ( 7.). 6.1 Change the switch point (optional) For the factory setting the switch point is at LED 7. A change makes sense if: the display shows example 2. the flow fluctuates much or pulsates. if a faster response time of the unit is requested (low switch point = fast response with rising flow, high switch point = fast response with falling flow). Briefly press the pushbutton or. > > The switch point LED flashes. Press the pushbutton or as often as required. Each press of the pushbutton shifts the LED by one position in the indicated direction. Note: If no pushbutton is pressed for 2 s, the unit returns to the operating mode with the newly set value. 8 9

94 Supplier documentation 6.2 High flow adjustment (optional) The unit determines the existing flow as normal flow and adapts the display representation (all LEDs except the switch point LED light green). Let the normal flow circulate in the installation. Press the pushbutton and keep it pressed. > > LED 9 lights, after approx. 5 s it flashes. Release the pushbutton. The unit is now adapted to your flow conditions. It passes into the operating mode, the display should now show example 1. UK Note: The adjustment affects the switch point: It is increased proportionally (maximum up to LED 7). 7 Additional settings (optional) 7.1 Low flow adjustment If the unit is used in media other than water, you should additionally adapt the unit to the minimum flow. Note: The following adjustment must only be carried out after the high flow adjustment. Let the minimum flow circulate in the installation or ensure flow standstill. Press the pushbutton and keep it pressed. > > LED 0 lights, after approx. 5 s it flashes. Release the pushbutton. The unit adopts the new value and passes into the operating mode. 7.2 Configure the switching output The unit is delivered as normally open. In case of need you can change the output to normally closed: Press the pushbutton for at least 15 s. > > LED 0 lights, after approx. 5 s it flashes. > > After 10 s the current setting is displayed: LEDs light orange (= output normally open). > > After approx. 15 s LEDs flash orange. Release the pushbutton. The output is changed to normally closed operation. For a new changeover repeat the operation. 9 94

95 Supplier documentation 7. Restore the factory setting (reset) Press the pushbutton for at least 15 s. > > LED 9 lights, after approx. 5 s it flashes. > > After approx. 15 s LEDs flash orange. Release the pushbutton. All settings are reset to the factory setting: -- operating area: cm/s for water -- switch point: LED 7 -- output function: NO -- unlocked. 7.4 Lock / unlock the unit The unit can be locked electronically to prevent unintentional settings. Press both setting pushbuttons simultaneously for at least 10 s in the operating mode. > > The indication goes out, the unit locks or unlocks. On delivery: unlocked. 8 Error during adjustment If no adjustment is possible, all LEDs flash red. The unit then passes into the operating mode with unchanged values. Possible cause /aid: Error during installation. The difference between maximum flow and minimum flow is too small. The sequence high flow /low flow adjustment was not adhered to. Read chapter Installation. Check whether all requirements have been met. Increase the flow difference and carry out the adjustment once again. Carry out the two adjustment operations again in the right sequence

96 Supplier documentation 9 Operation After every power on all LEDs light and go out again step by step (during this time the output is closed if configured as normally open). The unit is then ready for operation. In case of power failure or interruption all settings remain. Operating indicators Interference indicators Display OFF (no LED lights): Green LED bar: Current flow within the representation range. Indication of the switch point (SP): - LED orange: output closed. - LED red: output open. LED 9 flashes: current flow above the representation range. LED 0 flashes: current flow far below the representation range. Short circuit at the switching output: The operating indicator and red LEDs light alternately. If the short circuit has been rectified, the unit immediately passes into the normal operating state. The current operating state is displayed. Operating voltage too low (< 19 V) or failed. Ensure a correct voltage supply. UK 10 Maintenance Recommended maintenance: Check the sensor tip for build-up from time to time. Clean it using a soft cloth. Stubborn build-up (e.g. lime) can be removed using a common vinegar cleaning agent

97 Supplier documentation 11 Scale drawing M12 x ,7 1: LED bar display 2: set button : tightening torque 25 Nm 12 Technical data Application area...liquids and gases Operating voltage [V] DC 1) Current rating [ma] Short-circuit protection, pulsed; reverse polarity / overload protection Voltage drop [V]...< 2.5 Current consumption [ma]...< 60 Power-on delay time [s]... 10, optically indicated 12 97

98 Supplier documentation Liquids Medium temperature [ C] Setting range [cm/s] Greatest sensitivity [cm/s] Temperature gradient [K/min]...00 Gases Medium temperature [ C] Setting range [cm/s] Greatest sensitivity [cm/s] Switch point accuracy [cm/s]...± 2...± 10 2) Hysteresis [cm/s] ) Repeatability [cm/s] ) Temperature drift [cm/s x 1/K] ) Response time [s] Pressure resistance [bar]...0 Operating temperature [ C] Protection rating... IP 67 Protection class...iii Shock resistance [g] (DIN / IEC , 11 ms) Vibration resistance [g] (DIN / IEC , Hz) Housing materials...stainless steel 16L / ; stainless steel 04 / 1.401; PC (Makrolon); PBT-GF 20; EPDM/X (Santoprene) Materials (wetted parts)... stainless steel 16L / ; O-ring: FPM 8x1.5 gr 80 Shore A EMC EN ESD:... 4 kv CD / 8 kv AD EN HF radiated: V/m EN Burst:... 2 kv EN HF conducted: V 1) to EN50178, SELV, PELV; 2) for water; cm/s; 25 C (factory setting) ) for water; cm/s; C The sensor conforms to the standard EN UK More information at

99 Supplier documentation SI5000 SID10ABBFPKG/US-100 Flow sensors 1: LED display 2: setting pushbutton : tightening torque 25 Nm Product characteristics Flow monitor Compact type for adapter Process connection: internal thread M18 x 1.5 for adapter Probe length: 45 mm Setting range:...00 cm/s (liquids) Application Application Pressure rating [bar] Medium temperature [ C] Electrical data Electrical design Operating voltage [V] Current consumption [ma] Protection class Reverse polarity protection Outputs Output function Current rating [ma] Voltage drop [V] Short-circuit protection Overload protection Measuring / setting range Liquids Setting range [cm/s] Greatest sensitivity [cm/s] Gases Setting range [cm/s] Greatest sensitivity [cm/s] liquids and gases DC PNP DC < 60 III yes normally open / closed programmable 250 < 2.5 pulsed yes

100 Supplier documentation SI5000 SID10ABBFPKG/US-100 Accuracy / deviations Switch point accuracy Hysteresis Repeatability Temperature drift Max. temperature gradient of medium Reaction times Power-on delay time Response time Software / programming Adjustment of the switch point Environment Ambient temperature Storage temperature Protection Tests / approvals EMC Shock resistance Vibration resistance MTTF Mechanical data Process connection Materials (wetted parts) Housing materials Probe length L Weight [cm/s] [cm/s] [cm/s] [cm/s x 1/K] Displays / operating elements Function display Electrical connection Connection Wiring [K/min] [s] [s] [ C] [ C] [Years] [mm] [kg] LED EN ESD: EN HF radiated: EN Burst: EN HF conducted: DIN IEC : DIN EN ± 2...± 10 *) *) *) 0.1 **) pushbuttons IP 67 4 kv CD / 8 kv AD 10 V/m 2 kv 10 V g (11 ms) 20 g ( Hz) internal thread M18 x 1.5 for adapter stainless steel 16L / ; O-ring: FKM 8 x 1.5 gr 80 Shore A stainless steel 16L / ; stainless steel / 01 / 1.410; PC (polycarbonate); PBT-GF 20; EPDM/X LEDs, three-colour M12 connector Flow sensors Remarks Remarks Pack quantity [piece] *) for water; cm/s; 25 C (factory setting) **) for water; cm/s; C 1 100

101 Supplier documentation SI5000 SID10ABBFPKG/US-100 Flow sensors ifm electronic gmbh Friedrichstraße Essen We reserve the right to make technical alterations without prior notice. GB SI

102 Supplier documentation PT540 Seite 1 von PT540 PT-025-SEG14-A-ZVG/US/ /W Pressure sensors 1: Process connection sealing FKM / DIN 869 Product characteristics Electronic pressure sensor for industrial applications Process connection: G ¼ A (according to DIN EN ISO ) Analog output Measuring range: bar Application Application Pressure rating [bar] Bursting pressure min. [bar] 600 Vacuum resistance [mbar] Medium temperature [ C] Electrical data Electrical design Operating voltage Insulation resistance Protection class Reverse polarity protection Outputs Output Output function Short-circuit proof Overload protection Analog output Max. load Measuring / setting range [V] [MΩ] [Ω] Type of pressure: relative pressure Group 2 fluids according to the Pressure Equipment Directive (PED), group 1 fluids on request 65 (static) Measuring range [bar] Accuracy / deviations DC DC > 100 (500 V DC) III yes Analog output ma analog yes yes ma (Ub V) / 21.5 ma; 720 at Ub = 24 V file:///d:/notesdata/vstemp/pt540.hta

103 Supplier documentation PT540 Seite 2 von Accuracy / deviations (in % of the span) Characteristics deviation *) < ± 0.5 Linearity Step response time analogue [ms] output 1 Ambient temperature [ C] Storage temperature [ C] MTTF [Years] 686 [Nm] < ± 0.1 (BFSL) / < ± 0.2 (LS) Hysteresis < ± 0.2 Repeatability **) < ± 0.05 Long-term stability ***) < ± 0.1 Temperature coefficients (TEMPCO) in the temperature range C (in % of the span per 10 K) Greatest TEMPCO of the zero point + span Reaction times Environment Protection Tests / approvals Pressure equipment directive EMC DIN EN DIN EN < 0.1 ( C) / < 0.2 ( C) IP 67 / IP 69K sound engineering practice Shock resistance DIN EN g (11 ms) Vibration resistance DIN EN g ( Hz) Mechanical data Process connection G ¼ A (according to DIN EN ISO ) Process connection sealing FKM (to DIN 869) Materials (wetted parts) (17-4 PH / 60)² Housing materials Min. pressure cycles Tightening torque Restrictor element integrated (17-4 PH / 60)²; stainless steel (16L / ); PEI 60 millions in the course of the lifetime (at 1.2 times the nominal pressure) (recommended tightening torque¹) Weight [kg] Electrical connection Connection Wiring no M12 connector Core colors BN brown WH white OUT: ma The following pin connection is available on request: pin 1: L+, pin : OUT Colours to DIN EN Remarks Remarks file:///d:/notesdata/vstemp/pt540.hta *) incl. drift when overtightened, zero point and span error, non-linearity, hysteresis **) with temperature fluctuations < 10 K ***) in% of the span / 6 months

104 Supplier documentation PT540 Seite von ¹) Depends on lubrication, seal and pressure rating ²) Characteristics similar to stainless steel (e.g. 04/1.401) but higher strength. BFSL = Best Fit Straight Line / LS = Limit Value Setting Pack quantity [piece] 1 ifm efector, inc Atwater Drive Malvern PA 1955 We reserve the right to make technical alterations without prior notice. US PT file:///d:/notesdata/vstemp/pt540.hta

105 Supplier documentation Low Pressure Filter Pi 200 Nominal pressure 2/6 bar (460/910 psi), nominal size up to Features. -. Quality filters, easy to service Equipped with highly efficient glass fibre PS filter elements Beta rated elements according to ISO multipass test Elements with high differential pressure stability and dirt holding capacity Other connections on request Worldwide distribution._ High performance filters for modern hydraulic systems Provided for pipe installation Modular system Compact design Minimal pressure drop through optimal flow design Visual/electrical/electronic maintenance indicator Threaded connections 105

106 Supplier documentation Low Pressure Filter Pi 200 up to NG Flow rate/pressure drop curve (filter housing incl. element)

107 Supplier documentation y = differential pressure p [bar] x = flow rate V [l/min] Calculation of individual filter under Separation grade characteristics 4. Filter performance data tested according to ISO (multipass test) PS elements with PS vst elements with max. p 20 bar max. p 210 bar PS β5(c) 200 PS vst β5(c) 200 PS 6 β7(c) 200 PS vst 6 β7(c) 200 PS 10 β10(c) 200 PS vst 10 β10(c) 200 PS 25 β20(c) 200 PS vst 25 β20(c) 200 values guaranteed up to 10 bar differential pressure values guaranteed up to 20 bar differential pressure y = beta-value x = particle size [µm] determined by multipass tests (ISO 16889) calibration according to (NIST) 5. Quality assurance MAHLE filters and filter elements are produced according to the following international standards: Norm Designation DIN ISO 2941 Hydraulic fluid power filter elements; verification of collapse/burst resistance DIN ISO 2942 Hydraulic fluid power filter elements; verification of fabrication integrity DIN ISO 294 Hydraulic fluid power filter elements; verification of material compatibility with fluids DIN ISO 72 Hydraulic fluid power filter elements; method for end load test DIN ISO 724 Hydraulic fluid power filter elements; verification of flow fatigue characteristics ISO 968 Hydraulic fluid power-filters-evaluation of pressure drop versus flow characteristics ISO Fatigue pressure testing of metal containing envelopes in hydraulic fluid applications ISO Hydraulic fluid power filters-multipass method for evaluation filtration performance of a filter element Low Pressure Filter Pi 200 up to NG

108 Supplier documentation 6. Symbols 7. Order numbers Example for ordering filters: 1. Filter housing 2. Filter element V = 80 l/min and visual/electrical maintenance indicator Type: Pi Order number: PS vst Type: Pi 2208 PS vst Order number: Housing design Order number Type Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi no options with bypass valve and electrical indicator with visual indicator with electrical indicator Low Pressure Filter Pi 200 up to NG Nominal size NG [l/min] with bypass valve and with visual bypass valve indicator

109 Supplier documentation 7.1 Housing design Nominal size 600 with bypass valve and electrical with visual with electrical bypass valve indicator indicator indicator indicator Order NG [l/min] 450 with with bypass valve and visual number Type Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi no options When filter with non bypass configuration is selected, the collapse pressure of the element must not be exceeded. 7.2 Filter elements (a wider range of element types is availble on request) Nominal size NG [l/min] Order number max. p Type Filter material Filter surface [cm²] [bar] Pi 2105 PS PS Pi 5105 PS 6 PS Pi 105 PS 10 PS Pi 4105 PS 25 PS Pi 2205 PS vst PS vst Pi 5205 PS vst 6 PS vst Pi 205 PS vst 10 PS vst Pi 4205 PS vst 25 PS vst Pi 2108 PS PS Pi 5108 PS 6 PS Pi 108 PS 10 PS Pi 4108 PS 25 PS Pi 2208 PS vst PS vst Pi 5208 PS vst 6 PS vst Pi 208 PS vst 10 PS vst Pi 4208 PS vst 25 PS vst Pi 2111 PS PS Pi 5111 PS 6 PS Pi 111 PS 10 PS Pi 4111 PS 25 PS Pi 2211 PS vst PS vst Pi 5211 PS vst 6 PS vst Pi 211 PS vst 10 PS vst Pi 4211 PS vst 25 PS vst Pi 2115 PS PS Pi 5115 PS 6 PS Pi 115 PS 10 PS Pi 4115 PS 25 PS 25 Low Pressure Filter Pi 200 up to NG

110 Supplier documentation 7.2 Filter elements (a wider range of element types is availble on request) Nominal size NG [l/min] Order number max. p Type Filter material [bar] Filter surface [cm²] Pi 2215 PS vst PS vst Pi 5215 PS vst 6 PS vst Pi 215 PS vst 10 PS vst Pi 4215 PS vst 25 PS vst Pi 210 PS PS Pi 510 PS 6 PS Pi 10 PS 10 PS Pi 410 PS 25 PS Pi 220 PS vst PS vst Pi 520 PS vst 6 PS vst Pi 20 PS vst 10 PS vst Pi 420 PS vst 25 PS vst Pi 2145 PS PS Pi 5145 PS 6 PS Pi 145 PS 10 PS Pi 4145 PS 25 PS Pi 2245 PS vst PS vst Pi 5245 PS vst 6 PS vst Pi 245 PS vst 10 PS vst Pi 4245 PS vst 25 PS vst Pi 2160 PS PS Pi 5160 PS 6 PS Pi 160 PS 10 PS Pi 4160 PS 25 PS Technical specifications Pi in-line filter 10^7 load changes 6 bar (900 psi) 10^7 load changes 25 bar (60 psi) 2x 10^6 load changes 2 bar (460 psi) Test pressure: Pi bar (170 psi) Pi bar (690 psi) Temperature range: -0 C to +120 C survival temperature -40 C (other temperature ranges on request) Bypass setting: p.5 bar ± 10 % Filter head material: Filter housing material: Sealing material: Maintenance indicator setting: Electrical data of maintenance indicator: Max. voltage: Max. current: Max. current: Type of protection: Contact: Cable sleave: GDAL AL/St NBR/AL p 2.2 bar ± 10 % 250 V AC/200 V DC 1A 70 W IP 65 in inserted and secured status normally open/closed M20x1.5 The switching function can be changed by turning the electric upper part by 180 (normally closed contact or normally open contact). The state on delivery is a normally closed contact. By inductivity in the direct current circuit the use of suitable protection circuit should be considered. Further maintenance indicator details and designs are available in the maintenance indicator data sheet. We draw attention to the fact that all values indicated are average values and do not always occur in specific cases of application. Our products are continually being further developed. Values, dimensions and weights can change as a result of this. Our specialized department will be pleased to offer you advice. We recommend you to contact us concerning applications of our filters in areas governed by the EU Directive 94/9 EC (ATEX 95). The standard version can be used for liquids based on mineral oil (corresponding to the fluids in Group 2 of Directive 97/2 EC Article 9). If you consider to use other fluids please contact us for additional support. Subject to technical alteration without prior notice. Low Pressure Filter Pi 200 up to NG Design: Nominal pressure: Pi

111 Supplier documentation 9. Dimensions In Inlet Out Outlet *1 Housing design for NG 600 All dimensions except C in mm. Type A B Pi Pi Pi 2011 C* F G SW D E P Weight [kg] G½ H 80 I 95 K 45 M 1.0 M8x10 N O G¾ M8x G¾ M8x Pi G1¼ M12x Pi G1¼ M12x Pi G1¼ M12x Pi G1¼ M12x * NPT and SAE connections on request Low Pressure Filter Pi 200 up to NG

112 Supplier documentation 10. Installation, operating and maintenance instructions 10.1 Filter installation When installing the filter make sure that sufficient space is available to remove filter element and filter housing. Preferably the filter should be installed with the filter housing pointing downwards. The maintenance indicator must be visible Connecting the electrical maintenance indicator The electrical indicator is connected via a 2-pole appliance plug according to DlN EN with poles marked 1 and 2. The electrical section can be inverted to change from normally open position to normally closed position or vice versa. The state on delivery is a normally closed contact. 10. When should the filter element be replaced? 1. Filters equipped with visual and electrical maintenance. EER _ 10.4 Element replacement 1. Stop system and relieve filter from pressure. 2. Unscrew the filter housing by turning counter-clockwise. Clean the housing using a suitable cleaning solvent.. Remove element by pulling down carefully. 4. Check O-ring on the filter housing for damage. Replace, if necessary. 5. Make sure that the order number on the spare element corresponds to the order number of the filter name-plate. To ensure no contamination occurs during the exchange of the element first open the plastic bag and push the element over the spigot in the filter head. Now remove plastic bag. 6. Lightly lubricate the threads of the filter housing a little bit and screw into the filter head. Maximum tightening torque for NG 50 to 110 = 60 Nm, for NG 150 to 600 = 100 Nm. MAHLE Industriefiltration GmbH Schleifbachweg 45 D-7461 Öhringen Phone Fax industrialfiltration@mahle.com / Spare parts list Order numbers of spare parts Position Type Order number Seal kit for filter Pi Pi NBR FPM EPDM Pi Pi 2060 NBR FPM EPDM Maintenance indicator Visual PiS 098/2, Electrical PiS 097/2, Electrical upper section only Seal kit for maintenance indicator NBR FPM EPDM Low Pressure Filter Pi 200 up to NG indicator: During cold starts, the indicator may give a warning signal. Press the red button of the visual indicator once again only after operating temperature has been reached. lf the red button immediately pops up again and/or the electrical signal has not switched off after reaching operating temperature, the filter element must be replaced after the end of the shift. Filters without maintenance indicator: The filter element should be replaced after the trial run or flushing of the system. Afterwards follow instructions of the manufacturer. Please always ensure that you have original MAHLE spare elements in stock: Disposable elements cannot be cleaned.

113 Supplier documentation Duplex Filter Pi 210 Nominal pressure 2/6 bar (460/900 psi), nominal size up to Features._ User-optimized one-hand-operation Equipped with highly efficient glass fibre PS filter elements Beta rated elements according to ISO multipass test Elements with high differential pressure stability and dirt holding capacity Other connections on request Worldwide distribution.high performance filters for modern hydraulic systems Modular system Compact design Minimal pressure drop through optimal flow design Visual/electrical/electronic maintenance indicator Threaded connections Change over valve on upstream side Ergonomic switch-over handle with safety lock and pressure compensation 11

114 Supplier documentation 2. Flow rate/pressure drop curve complete filter Duplex Filter Pi 210 up to NG

115 Supplier documentation y = differential pressure p [bar] x = flow rate V [l/min] Calculation of individual filter under Separation grade characteristics 4. Filter performance data tested according to ISO (multipass test) PS elements with PS vst elements with max. p 20 bar max. p 210 bar PS β5(c) 200 PS vst β5(c) 200 PS 6 β7(c) 200 PS vst 6 β7(c) 200 PS 10 β10(c) 200 PS vst 10 β10(c) 200 PS 25 β20(c) 200 PS vst 25 β20(c) 200 values guaranteed up to 10 bar differential pressure values guaranteed up to 20 bar differential pressure y = beta-value x = particle size [µm] determined by multipass tests (ISO 16889) calibration according to (NIST) 5. Quality assurance MAHLE filters and filter elements are produced according to the following international standards: Norm Designation DIN ISO 2941 Hydraulic fluid power filter elements; verification of collapse/burst resistance DIN ISO 2942 Hydraulic fluid power filter elements; verification of fabrication integrity DIN ISO 294 Hydraulic fluid power filter elements; verification of material compatibility with fluids DIN ISO 72 Hydraulic fluid power filter elements; method for end load test DIN ISO 724 Hydraulic fluid power filter elements; verification of flow fatigue characteristics ISO 968 Hydraulic fluid power-filters-evaluation of pressure drop versus flow characteristics ISO Fatigue pressure testing of metal containing envelopes in hydraulic fluid applications ISO Hydraulic fluid power filters-multipass method for evaluation filtration performance of a filter element Duplex Filter Pi 210 up to NG

116 Supplier documentation 6. Symbols 7. Order numbers Example for ordering filters: 1. Housing design 2. Filter element V = 80 l/min and visual/electrical indicator PS vst Type: Pi Order number: Type: Pi 2208 PS vst Order number: Housing design Order number Type Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi Pi with bypass valve and electrical indicator with visual indicator with electrical indicator When filter with non bypass configuration is selected, the collapse pressure of the element must not be exceeded. Duplex Filter Pi 210 up to NG Nominal size NG [l/min] with bypass valve and visual indicator

117 Supplier documentation 7.2 Filter elements* Nominal size NG [l/min] max. p Order number Type Filter material Filter surface [cm²] [bar] Pi 2105 PS PS Pi 5105 PS 6 PS Pi 105 PS 10 PS Pi 4105 PS 25 PS Pi 2205 PS vst PS vst Pi 5205 PS vst 6 PS vst Pi 205 PS vst 10 PS vst Pi 4205 PS vst 25 PS vst Pi 2108 PS PS Pi 5108 PS 6 PS Pi 108 PS 10 PS Pi 4108 PS 25 PS Pi 2208 PS vst PS vst Pi 5208 PS vst 6 PS vst Pi 208 PS vst 10 PS vst Pi 4208 PS vst 25 PS vst Pi 2111 PS PS Pi 5111 PS 6 PS Pi 111 PS 10 PS Pi 4111 PS 25 PS Pi 2211 PS vst PS vst Pi 5211 PS vst 6 PS vst Pi 211 PS vst 10 PS vst Pi 4211 PS vst 25 PS vst Pi 2115 PS PS Pi 5115 PS 6 PS Pi 115 PS 10 PS Pi 4115 PS 25 PS Pi 2215 PS vst PS vst Pi 5215 PS vst 6 PS vst Pi 215 PS vst 10 PS vst Pi 4215 PS vst 25 PS vst Pi 210 PS PS Pi 510 PS 6 PS Pi 10 PS 10 PS Pi 410 PS 25 PS Pi 220 PS vst PS vst Pi 520 PS vst 6 PS vst Pi 20 PS vst 10 PS vst Pi 420 PS vst 25 PS vst Pi 2145 PS PS Pi 5145 PS 6 PS Pi 145 PS 10 PS Pi 4145 PS 25 PS Pi 2245 PS vst PS vst Pi 5245 PS vst 6 PS vst Pi 245 PS vst 10 PS vst Pi 4245 PS vst 25 PS vst *a wider range of element types is availble on request Duplex Filter Pi 210 up to NG

118 Supplier documentation 7.2 Filter elements* Nominal size NG [l/min] 600 max. p Order number Type Filter material Pi 2160 PS PS Pi 5160 PS 6 PS Pi 160 PS 10 PS Pi 4160 PS 25 PS 25 [bar] Filter surface [cm²] *a wider range of element types is availble on request 8. Technical specifications line mounting filter 10^7 load changes 6 bar (900 psi) 10^7 load changes 25 bar (60 psi) 2x 10^6 load changes 2 bar (460 psi) Pi Pi 2160 Test pressure: Pi Pi 2111 Pi Pi 2160 Temperature range: 95 bar (170 psi) 48 bar (690 psi) -10 C to +120 C survival temperature -40 C (other temperature ranges on request) Bypass setting: Filter head material: Filter housing material: Sealing material: Maintenance indicator setting: Electrical data of maintenance indicator: Max. voltage: Max. current: Contact load: Type of protection: Contact: Cable connection: p.5 bar ± 10 GAL AL/St NBR/AL p 2.2 bar ± 10 % The switching function can be changed by turning the electric upper part by 180 (normally closed contact or normally open contact). The state on delivery is a normally closed contact. By inductivity in the direct current circuit the use of suitable protection circuit should be considered. Further maintenance indicator details and designs are available in the maintenance indicator data sheet. We draw attention to the fact that all values indicated are average values which do not always occur in specific cases of application. Our products are continually being further developed. Values, dimensions and weights can change as a result of this. Our specialized department will be pleased to offer you advice. We recommend to contact us concerning applications of our filters in areas governed by the EU Directive 94/9 EC (ATEX 95). The standard version can be used for liquids based on mineral oil (corresponding to the fluids in Goup 2 of Directive 97/2 EC Article 9). If you consider to use other fluids please contact us for additional support. Subject to technical alteration without prior notice. 250 V AC/200 V DC 1A 70 W IP 65 in inserted and secured status normally open/closed M20x1.5 Duplex Filter Pi 210 up to NG Design: Nominal pressure: Pi Pi 2111

119 Supplier documentation 9. Dimensions In Inlet Out Outlet *H Minimum clearance required for element change *1 Lever locking and arresting *2 Venting screws All dimensions except "J" in mm Type øa * Optional fixing for NG 150 to 600 (WB version) *4 Optional fixing for NG 50 to 110 (WB version) *5 Housing version NG 600 B C D F G Pi M8x16 E H 80 Pi M8x Pi M8x Pi M10x Pi M10x Pi M10x Pi M10x J* K L** M SW N O Type øi Wt. [kg] Pi G Pi G Pi G Pi G1½ Pi G1½ Pi G1½ Pi G1½ * SAE flange connections (000 psi), NPT and SAE connections on request ** Not shown drain screw at NG 450 and NG 600 is part of dimension "L" Duplex Filter Pi 210 up to NG

120 Supplier documentation 10.1 Filter installation When installing the filter make sure that sufficient space is available to remove filter element and filter housing. Preferably the filter should be installed with the filter housing pointing downwards. The maintenance indicator must be visible Connecting the electrical maintenance indicator The electrical indicator is connected via a 2-pole appliance plug ac Element replacement Note: Elements may only be replaced by people who are familiar with the function of the filter. When replacing elements, appropriate safety clothing (protective goggles, gloves, safety shoes) must be worn. Note: The maintenance indicator monitors the filter side in operation, which is identified by the position of the switching lever catch. The change-over transfer valve must be switched prior filter servicing. cording to DlN EN with poles marked 1 and 2. The electrical section can be inverted to change from normally open position to normally closed position or vice versa. The state on delivery is a normally closed contact. 10. When should the filter element be replaced? 1. Filters equipped with visual and electrical maintenance indicator: During cold starts, the indicator may give a warning signal. Now the signal of the maintenance indicators cancelled and the red button can be repressed again. 1. Operate and hold pressure equalizing lever located behind switching lever. Pull catch knob and swivel switching lever. Engage the catch on the clear filter side. Place through or drip pan underneath to collect leaving oil. 2. Loosen vent screw of the filter side not in use by 2- turns; max. until contact is made with the safety stop.. Unscrew filter housing by rotating same counter-clockwise and clean with a suitable medium. Press the red button of the visual indicator once again only after operating temperature has been reached. lf the red button immediately pops up again and/or the electrical signal has not switched off after reaching operating temperature, the filter element must be replaced after the end of the shift. Please always ensure that you have original MAHLE spare elements in stock: Disposable elements cannot be cleaned. Warning: The shift lever may not, from now until the screwing back in of the filter housing (7.), be activated under any circumstances! Remove filter element with a side-to-side motion. Check O-ring on the filter house for damage. Replace, if necessary. Make sure that the order number on the spare element corresponds to the oder number of the filter name-plate. Lightly lubricate the threads of the filter housing and screw into the filter head. Maximum tightening torque for NG 50 to 110 = 60 Nm, for NG 150 to 600 = 100 Nm. To refill the filter chamber, operate only the pressure equalizing lever (leave the switching lever arrested in its catch) long enough for the medium to emerge bubble- free from the vent bore. Tighten vent screw. Check filter for leaks by operating the pressure equalizing lever once again Duplex Filter Pi 210 up to NG Installation, operating and maintenance instructions

121 Supplier documentation 11. Spare parts list Order number for spare parts Position Type Order number Seal kit for housing Pi Pi NBR FPM EPDM Pi Pi 2160 NBR FPM EPDM Seal kit for maintenance indicator - NBR FPM EPDM Maintenance indicator Duplex Filter Pi 210 up to NG 600 Visual PiS 098/ Electrical PiS 097/ Electrical upper section only

122 Supplier documentation MAHLE Industriefiltration GmbH Schleifbachweg 45 D-7461 Öhringen Phone Fax /2015 Duplex Filter Pi 210 up to NG

123 Supplier documentation Maintenance Indicators 1. Features - - Filter elements are economically used only if their dirt holding capacity is fully exploited. This is achieved by using filter housings with a maintenance indicator. MAHLE manufactures maintenance indicators of the following designs: - Differential pressure indicators Pressure indicators/switches/gauges Vacuum switches/gauges - With any filter element the collection of dirt particles continously reduces the number of open pores or, in other words: The open cross section for allowing the liquid to flow is continously reduced. Thus the pressure on the upstream side of the element (dirt side) increases continously. - With pressure filters, the pressure is measured upstream and downstream of the filter element (differential pressure). With return line filters the pressure is measured only on the upstream side because, depending on the tank design, atmospheric pressure exits on the downstream side of the filter element is measured analog. With suction filters the vacuum is measured downstream. - A piston with attached magnet is moved against the force of a spring, with which the indicating point is determined by the piston surface. A homopolar poled magnet is fitted in the outer part in the indicating button. - The closer the pole-springs move towards each other, the stronger is the force with the magnets mutually repel, until finally the red button on the indicator pops out. - - This red button remains visible until it is pushed in during the daily check which is to be performed while the plant is at operating temperature. If the button pops out immediately after being pushed in, the filter element must be replaced latest at the end of the shift. - This optical function may also be used for generating contactless electrical signals. For this purpose an electrical upper part is pushed over the hydraulic/optical part. This upper part incorporates all electrical switching elements. - Optical and electrical indicator with standard check function Normally open/normally closed combination - standard feature Electrical function, easy to install at a later time Two-step indication, at 75 % and 100 % optional Signal lock out up to approx. 0 C optional Rugged, non-bypass design Optimal element exploitation Worldwide distribution 12

124 Supplier documentation 2. Differential pressure indicators Fig. 1 Fig. 2 Fig. Fig. 4 Fig * = 40 mm wide Differential pressure indicators Nominal pressure [bar] [ C] Type Order number Indicator setting [bar] Indication Contact Maintenance Indicators 2 type* PiS visual - 1 PiS visual/electr a PiS Fig. visual/electr a (15) Temper-ature Material lower section Al Material upper section PiS visual/elektr a Al PA PiS visual - 2 PiS visual/electr a PiS visual/electr a PiS visual/electr a PiS visual/electr. 4 + a PiS visual/electr. 5 + a PiS /2.2 visual/electr. 6 + a PiS visual/electr a PiS visual/electr a PiS visual/electr a PiS visual PiS visual/electr a PiS visual - 2 PiS visual/electr a PiS visual/electr a PiS visual/electr a PiS visual/electr. 4 + a PiS visual/electr a PiS /5.0 visual/electr. 5 + a PiS visual/electr. 6 + a PiS visual/electr a PiS visual/electr a Al PA 6 PA 6 Al PA 6 Al Al PA 6 PA 6 Al PA 6 124

125 Supplier documentation Differential pressure indicators Nominal pressure [bar] Temperature [ C] Type Order number Indicator setting [bar] Indication Contacttype* Fig. PiS visual - 2 PiS visual/electr a PiS visual/electr a PiS visual/electr a PiS visual/electr. 4 + a PiS visual/electr. 5 + a PiS /2.2 visual/electr. 6 + a PiS visual/electr a PiS visual/electr a PiS visual/electr a PiS visual - 2 PiS visual/electr a PiS visual/electr a PiS 115 M visual/electr a PiS visual/electr a PiS visual/electr. 4 + a PiS visual/electr a PiS /5.0 visual/electr. 5 + a PiS visual/electr. 6 + a PiS visual/electr a PiS visual/electr a PiS visual - 2 PiS visual/electr a PiS visual/electr a PiS visual - 2 PiS visual/electr a PiS visual/electr. 7 + a PiS visual - 2 PiS visual/electr a PiS electrical 7 + a Material Material lower upper section section CuZn PA 6 CuZn PA 6 CuZn PA 6 CuZn PA 6 CuZn PA PA PA 6 *Contact type 1 Normally open/normally closed; 1 setting point; wiring box DIN EN ; max. 250 V AC/200 V DC; max. 1 A 2 Normally closed; 2 setting points; wiring box DIN EN ; max. 150 V; max. 1 A Change-over contact; 1 setting point; wiring box DIN EN ; max. 150 V; max. 1 A 4 Change-over contact; 2 setting points; LED; Mercedes Benz Norm DBL 9666 EA; wiring box DIN EN ; max V; max. 1 A 5 Change-over contact; 2 setting points; LED; signal surpression; time delay; wiring box DIN EN ; 10-0 V; max. 1 A 6 Change-over contact; 2 setting points; LED; signal surpression; wiring box DIN EN , 10-0 V; max. 1 A 7 Analog signal 4-20 ma; 2 setting points; LED; signal cold start; wiring box DIN EN ; 24 V; max. 1 A 8 Normally open/normally closed; 2 setting points; LED; signal surpression; plug connection M12x1; 10-0 V; max. 1 A 9 Normally open/normally closed; 2 setting points; LED; plug connection M12x1; 10-0 V; max. 1 A 10 Change-over contact;1 setting point; plug connection M12x1; 150 V; max. 1 A 11 Normally closed/normally closed; 2 setting points; LED; plug connection M12x1; 150 V; max. 1 A Maintenance Indicators 125

126 Supplier documentation. Pressure indicators/pressure switches Fig. 5 Fig. 6 Fig. 7 Fig. 8 40* = 40 mm wide Pressure indicators/pressure switches Nominal Temperature Indicator Material Material pressure Order setting Contact lower upper [bar] [ C] Type number [bar] Indication type* Fig. section section PiS visual PiS visual/electr a PA 66 PA 6 PiS visual/electr a PiS visual/electr a /1.2 PA 66 PA 6 PiS visual/electr a PiS visual - 6 PiS visual/electr a PiS visual/electr a PA 66 PA 6 PiS 125 M visual/electr a PiS opt./elektr a PiS visual/electr a PiS visual/electr a PiS /2.2 visual/electr a PA 66 PA 6 PiS visual/electr a PiS visual/electr a PiS visual/electr a DSS/ electrical norm. open DSO/ electrical n. closed 5 delivered DSS/ electrical norm. open 5 galvanized with 2.2 DSO/ electrical n. closed 5 steel protection DSS/ electrical norm. open 5 cap DSO/ electrical n. closed 5 *Contact type see remarks below 2. Differential pressure indicators Maintenance Indicators 4 126

127 Supplier documentation 4. Vacuum/pressure gauges Fig. 9 Fig. 10 Fig. 11 *1 = Green area/*2 = Red area * = Metering level Vacuum/pressure gauges Nominal size [NG] Type 40 Vacuum gauge Pressure gauge Order number Indicating range [bar] Connection size Fig. Class Dial face R1/8 conical 9 Red/Green area G1/8 9 sep. line bar R¼ conical 10 min. 2.5 white Red/Green area R¼ conical 11 sep. line 2.2 bar 5. Vacuum switches Fig. 12 Fig. 1 *G = Connection HES/HEO only for fluids, LES/LEO only for air Vacuum switches Permissible overpressure [bar] Temperature [ C] Type Order number Switch setting[mbar] Contact type Fig. Connection *G single pole G¼ changeover switch, G1/ PiS snap-in joint short-term +120 HES 2200 BP HEO 2200 BP LES 250 I LEO 250 I normally open -200 ±10 normally closed 1 normally open -50 ±4 normally closed G1/8 outside M10x1 inside Material Material lower upper section section GD-Al PA 6 GD-ZnAl PC Maintenance Indicators 5 127

128 Supplier documentation 6. Vacuum indicators/air filters Fig. 14 *1 = Indication: position of display in mbar *V1 = Version 1 *V2 = Version 2 Vacuum indicators/air filters Temperature [ C] Type Order number Indicator setting ±10 % [mbar] Indication type Fig. Version TB TB 745/ optical self locking 14 2 TB 746/ Accessories 7.1 Seal kits Order Type NBR FPM EPDM Designation number Order number Electrical upper section change-over contact M12x1für PiS 084, 087, 09, 098, 19 (contact type 10) PiS 092, 09, 102, 105, , 12, 142, 152, 155, Electrical upper section 2SP-LED-M12x1-SU (contact 192, 19, 158 type 8) spare part for 2 setting points indicator! PiS 012, 097, 098, 116, Electrical upper section 2SP-LED-M12x1 (contact type 119, 11, 141, 151, 154, ) spare part for 2 setting points indicator! Electrical upper section W-2SP-LED-SU-VERZ (contact type 5) spare part for 2 setting points indicator! PiS 084, 085, 10, 106, , 1, 14, 15, 156, Electrical upper section W-2SP-LED-SU (contact type 159 6) spare part for 2 setting points indicator! PiS 086, 087, Electrical upper section W-2SP/Ö-LED-M12x1 (contact type 11) spare part for 2 setting points indicator! 7.2 Electrical expansion kit/spare parts Electrical upper section normally closed with signal Order surpression PiS Designation number Electrical upper section normally open with signal surpression PiS Electrical upper section normally open/closed for PiS , 087, 09, 098, 19 (contact type 1) Wiring box with lamp insert V for electrical upper section normally open (acc. to DIN EN ) Electrical upper section change-over contact for PiS 084, 087, 09, 098, 19 (contact type ) Wiring box with 2 LEDs 10-0 V for electrical upper section change over contact (acc. to DIN EN ) Maintenance Indicators 6 128

129 Supplier documentation 7. Mounting block for differential pressure indicators (M20x1.5) Order Designation number Mounting block (St) Mounting block (1.401), 450 bar Protection cap Designation Protection cap for all visual pressure and differential pressure indicators, -20 C to +80 C Resistant to: gasoil, purifying agent, insolation, dust, salt, water, concret Order number R = clean side S = dirt side 8. Function The magnetic field as previously described, contactless operates reed contacts in the electrical upper part. The desired contact type is selected by inverting upper part. Another option keeping the electrical signal electronically suppressed up to 0 C operating temperature is also available. This eliminates false electrical signal during the cold start phase. For efficient servicing it is desirable to have a pre-warning device (so that the filter element can be replaced, e.g. with the next tool change). For this purpose electrical upper parts with two indicating points, i.e. at 75 % and at 100 % of the indicator setting are available. Pressure/vacuum gauges give an analog reading of the existing state of contamination of the filter elements. They require continous control to ensure that the service time and reserve capacity are not unduly exceeded. If the contamination signal is disregarded, the filter element may collapse or, if a bypass valve is installed, part of the contamination fluid may reach the hydraulic components via the bypass valve and cause failure of the hydraulics. Pressure/vacuum switches are provided with snap action switches, which ascertains that signal are issued only when the limit values have been fully reached. Dirt holding capacity - p curve x = dirt holding capacity [g] y = differential pressure p [bar] *1 = signal step maintenance indicator 100 % *2 = signal step maintenance indicator 75 % Maintenance Indicators 7 129

130 Supplier documentation 9. Technical specifications 9.1 Contact type normally open/normally closed 9.2 Contact type normally closed or open with signal suppression Contact type 1 Contact type normally closed Types PiS 085, 086, 092, 097, 192 Type PiS 00 (expansion kit) Max. voltage: 250 V AC/ 200 V DC Contact type normally open Max. current: 1 A Type PiS 002 (expansion kit) Contact load: 70 W Type of protection: IP 65 in inserted and secured status Signal suppression by thermorelay Contact type : normally open/normally closed Signal is released at +0 C Cable sleave: M20x1.5 Wiring box: DIN EN for further technical details see The switching function can be changed by turning the electric upper part by 180 (normally closed contact or normally open contact). The state on delivery is a normally closed contact. By inductivity in the direct current circuit the use of suitable protection circuit should be considered. Electrical parts are insulated (plastic material housing) Contact type normally closed 2 setting points 9.4 Contact type Change-over contact Contact type 2 Contact type Types PiS 105, 106, 119 Types PiS 115, 116, setting point at 75 % of the indicating pressure 2. setting point at 100 % of the indicating pressure Max. voltage: 150 V AC/DC Max. voltage: 150 V AC/DC Max. current: 1 A Max. current: 1 A Contact load: 20 VA/20W Contact load: 20 VA/20W - for further technical details see 9.1 for further technical details see Maintenance Indicators 8 10

131 Supplier documentation 9.17 Pressure switch DSS 9.18 Pressure switch DSO Contact type normally open Contact type normally closed - Electrical connection: AMP 6, DIN for further technical details see 9.17 bushings DIN switch type 2 pole Max. voltage: 42 V Max. current: 2 A Contact load: 100 VA Duty classification: 200/min - Maintenance indicators PiS 084, 087, 09, 098, 19 can be mounted in We draw attention to the fact that all values indicated are average values which do not always occur in specific cases of application: Our products are continually being further developed. Values, dimensions and weights can change as a result of this. Our specialized departement will be pleased to offer you advice. - When using our filters in areas which are to be classified according to EU directive 94/9 EG (ATEX), we recommend prior discussion with us. The standard version can be used for liquids based on mineral oil /corresponding to the fluids in Group 2 of Directive 97/2 EG Articlel 9). Please consult with us if using other media. - Subject to technical alterations without prior notice MAHLE Industriefiltration GmbH Schleifbachweg 45 D-7461 Öhringen Phone Fax industrialfiltration@mahle.com /2014 Maintenance Indicators 12 11

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136 SEW-EURODRIVE Driving the world SEW-EURODRIVE GmbH & Co KG Ernst-Blickle-Str BRUCHSAL GERMANY Tel Fax