Carpeta Tecnica Equipamiento Flush by

Flush By II Equipamientos para Servicios al Pozo
50000 lbs
ISO 9001:2008
equipment Certificado: 01 10006 072663
Especificaciones Accesorios
Flush By II Equipamientos para Servicios al Pozo
50000 lbs
Indice equipment
ISO 9001:2008
Certificado: 01 10006 072663
A-Hidráulica
1.Bombas
2.Malacates
3.Mandos
4.Grúa Auxiliar
5.Llave hidráulica
6.BOP
7.Manometros
8.Bomba manual
9.Medidores de presión
10.Accesorios
B-Piping Alta Presión

1.Triplex
2-Roper
3-Caja tranferencia
4-Caja de cadenas
5-Dumper
6-Accesorios
C-Accesorios de Izaje
1.Gancho
2.Cable
3.Salvacaídas
4.Grilletes
5.Tensores
6.Eslingas
D-Registradores
1.Celda de carga
2.Medidor de nivel tanque de agua
3.Nivel TRIPLEX
4.PLC
5.Medidor-Termometro Tanque de aceite
E-Herramientas Petroleras
F-Herramientas
Especificaciones Accesorios
A-Hidráulica
T6DCM-045-017-1R00-B1
T Series Double The high performance T Series tion resistant and reliable pump.
? xed displacement vane pumps High pressure and speed capa-
have been specially designed to bilities, extremely low noise, and a
provide high ? ows within a small cartridge designed to prime in cold
envelope. The balanced design and weather conditions, make this ? uid
double lip vane technology are key power source ideal for mobile
features in providing a contamina- applications.
Pump Performance Data zp20
Double Pump Displacement, Max. Outlet Rated Drive Flow @1800 RPM Input Horsepower @ 1800
Model Series cc/rev* Pressure** Speed and 0 PSI* RPM and 2000 PSI*
T6CCM 21.6 - 200 4000 PSI 2800 RPM 10.3 - 95.1 GPM 16.9 - 115.9 HP
T6DCM 58.3 - 258 4000 PSI 2500 RPM 27.8 - 122.7 GPM 37.8 - 148.5 HP
T6ECM 143.1 - 327 4000 PSI 2200 RPM 68.1 - 155.6 GPM 86.9 - 187.0 HP
T6EDM 179.7 - 385 3500 PSI 2200 RPM 85.5 - 183.1 GPM 107.7 - 219.7 HP
* Available range based on various combinations of displacements
**Lower for larger displacements, see catalog
T Series Double Features/Bene? ts

Performance Characteristics • Low noise
• SAE or ISO standards
• One-piece shaft (no internal torque
limitations)
• One inlet
• 32 porting orientations available
• Wide displacement possibility
• High power to weight ratio
• Wide range of options for shafts,
threads and pilots
• Mobile cartridge design for cold
start conditions
Refer back to tables on pages 34
Truck 37
T Series Double
Performance Characteristics
A B
D
E
G
C.G.
F
Dimensions, mm (inch)
Series A B Max D E F Weight, kg (lb)
T6CCM 265.7 (10.46) 71.4 (2.81) 174.5 (6.87) 84.1 (3.31) 73.2 (2.88) 26.0 (57.3)
T6DCM 286.0 (11.26) 83.6 (3.29) 212.3 (8.36) 88.9 (3.50) 74.2 (2.92) 36.7 (80.7)
T6ECM 331.7 (13.06) 90.9 (3.58) 213.1 (8.39) 102.4 (4.03) 88.9 (3.50) 55.0 (121.0)
T6EDM 361.2 (14.22) 90.9 (3.58) 213.1 (8.39) 102.4 (4.03) 88.9 (3.50) 66.1 (145.5)
38 Truck
Model Ordering Code
T – – – – –
High Size Shaft Severe Delivery Delivery Rotation Design Seal Mounting
Performance Seal Duty (P1) (P2) Level Class w/Connection
Vane Pump Shaft Shaft Porting Variables
(T6CC only)
Code
6CC Code Seal Class Modi? cations
Code Porting Combinations*
(Code entered
6DC 1 S1 (Buna N)
00 Standard at factory)
6EC *Many other combinations are 4 S4 (EPDM)
6ED Code Severe Duty available. See catalog on CD. 5 S5 (VITON)
Omit Standard
W* Severe Duty Code Rotation*
R CW Code Deslgn Level
*Available on T6CCM and
T6DCM only. D T6CC only
L CCW
*As viewed from shaft end. C All Others
Code Shaft Seal
M Mobile 1 Seal
Shaft (See catalog on CD for severe duty options)
P Mobile 2 Seals
Code 6DCP 6ECM
6CCM 6CCP 6DCM
6ECP, 6EDP 6EDM
Keyed Keyed Keyed
1
(non SAE) SAE C SAE CC
Delivery
(See Table Below) Keyed Keyed
Size 2
(non SAE) (non SAE)
P1 P2
Splined Splined Splined Splined Splined
Use Codes Use Codes 3
6CC SAE BB (non SAE) SAE C (non SAE) SAE C
for 6C for 6C
Splined Splined Splined
6DC SAE BB (non SAE) SAE CC
for 6D for 6C
Splined
6EC SAE B
for 6E for 6C
Splined
6ED (non SAE)
for 6E for 6D
Splined
T
SAE J718c
Delivery
6C Deivery* 6D Delivery* 6E Delivery*
Codes (GPM) Codes (GPM) Codes (GPM)
B03 3.42 B14 15.09 042 41.94
B05 5.45 B17 18.45 045 46.15 Connection
Variables
B06 6376 B20 20.93 050 50.25 Code
T6CC
B08 8.36 B24 25.20 052 52.25
P1 P2 S
B10 10.81 B28 28.44 062 62.36
00 1" 1" 3"
B12 11.76 B31 31.16 066 67.62
01 1" ³/₄
" 3"
B14 14.58 B35 35.19 072 72.00
10 1" 1" 2½"
B17 18.48 B38 38.14
B20 20.23 B42 43.12
11 1" ³/₄
" 2½"
B22 22.28 B45 46.19 P = Pressure Port; S = Suction Port

B25 25.14 B50 50.09
B28 27.90 = Omit if not required
B31 31.70
= Not Available
*At 0 PSI and 1200 RPM.
Truck 39
MOTORES ORBITALES
Motores hidráulicos MLHS y MLHSY

standard y reforzados UE
ISO 9001
Reemplaza a MLHS
DANFOSS “OMS”
CHAR LYNN serie 2000
PARKER “TF”
GEOLINK “GLS/GLC”
También
disponible
en versión
europea. MLHS
Con válvula
Pérdida de carga de retención
Prad
daN
Recomendaciones:
F 14
12
-
-
-
La operación intermitente puede ocurrir por máx. 10% de cada minuto.
La operación pico puede ocurrir sólo 1% máximo de cada minuto.
Para velocidades menores a 5 RPM, consultar.
24 10 - Presión y velocidad intermitentes no pueden ocurrir simultaneamente.
8 - Grado de contaminación recomendado ISO 4406 20/16 o filtración nominal de
25 µm o mejor.
6
- Utilizar fluídos hidráulicos de base mineral.
4 - Viscosidad mínima 70 SUS (13 mm2) a 50ºC.
- Temperatura de operación máxima 82ºC.
2
- Para garantizar una óptima vida útil del motor, llene la carcaza con aceite
0 antes de rodar y haga trabajar al motor con cargas moderadas y a baja
10 20 30 40 50 60 70 80 90 Q lpm velocidad durante 10 - 15 minutos.
ESPECIFICACIONES TECNICAS MLHSY

TIPO S 80 S 100 S 125 S 160 S 200 S 250 S 315 S 400 S 475 160 200 250 315 400
CILINDRADA (cm3/rev) 80,5 100 125,7 159,7 200 250 314,9 397 474,6 159,7 200 250 314,9 397
VELOCIDAD MÁXIMA cont. 800 757 600 474 378 303 240 191 160 470 375 300 240 185
(RPM) int. 987 908 722 569 454 363 288 229 190 560 450 360 285 225
TORQUE MÁXIMO cont. 20 25 32 34 40 45 54 58 58 45 56,6 70,8 90 94
(da Nm) int. 24 30 38 48 50 54 63 69 68 51,5 64,5 80,6 100 104
pico 26 32 40 51 65 69 84 85 84
POTENCIA MÁXIMA cont. 16 17,5 15,5 14 12,5 11,5 10 8,4 19,1 19,2 18 15,5 11,4
(Kw) int. 19 21 21 17,5 15 13,5 13 11,3 25,0 24,7 23 17 12
PRESIÓN DIFERENCIAL cont. 175 140 125 120 100 85 200 170
(bar) int. 210 175 155 140 120 100 225 190
pico 225 225 200 185 140 115
CAUDAL MÁXIMO cont. 65 75,7 75 75
(l/min.) int. 79,5 90,9 90 90
PRESIÓN MÁXIMA cont. 210 210
(bar) int. 250 250
pico 300
PRESIÓN MÁXIMA cont. 0-100 rpm 100 100 100
EN LÍNEA DE RETORNO cont. 100-300 rpm 50 50 50
SIN DRENAJE cont >600 rpm 20 - 20
(bar) int. 0-máx rpm 100 100 100
PRESIÓN MÁXIMA (bar) cont. 140 140
EN LÍNEA DE RETORNO int. 175 175
CON DRENAJE pico 210
PRESIÓN MÁXIMA (bar)
12 10 8 8
DE ARRANQUE SIN CARGA
TORQUE DE ARRANQUE máx.pres. dif. cont. 16,5 20,5 26 28 33 36 44 47 37,0 46,5 58,2 74,2 76,0
MÍNIMO (da Nm) máx. pres. dif. int. 19,5 25 31 39 41 44 52 55 41,8 52,4 65,0 80,5 83,0
RPM MÍNIMA 10 8 6 5 8 6 5
PESO MLHS (F) 9,8 10 10,3 10,7 11,1 11,6 12,3 13,2 14 10,8 11,2 11,7 12,4 13,3
(Kg) MLHSB 10,3 10,5 10,8 11,2 11,6 12,1 12,8 13,7 14,5 11,3 11,7 12,2 12,9 13,8
MLHSS(Z) 7,8 8 8,3 8,7 9,1 9,6 10,3 11,2 12 11,2 11,6 12,1 12,8 13,7
MLHSV 5,7 5,9 6,2 6,6 7 7,5 8,2 9,1 9,9 17,8 18,2 18,7 19,4 20,3
MLHSW(E) 10,2 10,4 10,7 11,1 11,5 12 12,7 13,6 14,4
MLHSBD 16,8 17,0 17,3 17,7 18,1 18,6 19,3 20,2 21
Para mayor información consultar a nuestro departamento técnico.

Calle 89 Int. A. Campos 1617/23 • B1650BFA San Martín • Bs As • Argentina • Tel.: (011) 4754-0044 (5 líneas rotativas) • Fax: (011) 4755-7167 • E-mail: [email protected] • http://www.verion.com.ar
MOTORES ORBITALES
UE
ISO 9001
MLHS
VERSIONES
2-6 3-9 4-8 5-7
C 2xM10 2xM10 2x 3/8 -16UNC 2x 3/8 -16UNC
P(A,B) 2xG 1/2 2xM22x1,5 2x 7/8 -14UNC 2x 1/2 -14NPTF
T G 1/4 M14x1,5 7
/16 -20UNF 7
/16 -20UNF
Brida SAE A
Conecciones
laterales
versión 2 3 5 R
Brida de rueda
F
25
Brida SAE B
Versión 4
Dimensiones para motor MLHS

L L2 L1
TIPO
F mm mm mm
Brida Magneto MLHS(F,B) 80 166 121 11
MLHS(F,B) 100 169 125 14,4
MLHS(F,B) 125 174 129 18,8
Conecciones MLHS(F,B) 160 180 135 24,8
traseras MLHS(F,B) 200 187 142 31,8
versión 6 8 9 MLHS(F,B) 250 195 151 40,5
MLHS(F,B) 315 207 162 51,8
MLHS(F,B) 400 221 176 66,4
W
L L2
Brida rueda TIPO
mm mm
MLHSW 80 129 84
MLHSW 100 132 88
MLHSW 125 137 92
Versión 7 MLHSW 160 143 98
MLHSW 200 150 105
MLHSW 250 158 114
MLHSW 315 169 125
MLHSW 400 184 140
L L2 L1
E TIPO
mm mm mm
Brida rueda
MLHSW 80 131 88,5 11
MLHSW 100 135 91,9 14,4
MLHSW 125 139 96,3 18,8
MLHSW 160 145 102,3 24,8
MLHSW 200 152 109,3 31,8
MLHSW 250 161 118 40,5
MLHSW 315 172 129,3 51,8
MLHSW 400 187 143,9 66,4

MOTORES ORBITALES
UE
ISO 9001
MLHSS, MLHSV y MLHSZ
Brida corta S
Conecciones
laterales
versión 2 3 5
F
26
Brida corta Z
(con alojamiento para rodamiento a agujas)
versión 4
Brida muy corta V
Dimensiones para motor MLHSS, MLHSV y MLHSZ

L L2 TIPO L L2 L3 L1
*
TIPO
mm mm mm mm mm mm
MLHSS(Z) 80 123 80 MLHSV 80 89 49,0 21,0 11,0
MLHSS(Z) 100 127 84 MLHSV 100 92 52,5 15,0 14,4
MLHSS(Z) 125 131 87 MLHSV 125 97 57,0 23,0 18,8
MLHSS(Z) 160 137 93 MLHSV 160 103 63,0 17,0 24,8
MLHSS(Z) 200 144 100 MLHSV 200 110 70,0 20,0 31,8
MLHSS(Z) 250 153 109 MLHSV 250 118 78,5 21,5 40,5
MLHSS(Z) 315 164 120 MLHSV 315 130 90,0 20,0 51,8
MLHSS(Z) 400 179 135 MLHSV 400 144 105 25 66,4

MOTORES ORBITALES
UE
ISO 9001
C D*
ø 31,75; con chaveta 5/16” x 5/16” x 11/4” BS46 ø 25,4; con chaveta 1/4” x 1/4” x 1” BS46
torque máximo 77 daNm torque máximo 44 daNm
G
14T estriado; ø 31,75 ANS B92.1-1976
M
ø 32; con chaveta A10x8x45 DIN 6885
F
torque máxino 77 daNm torque máximo 77 daNm 27
S* T
ø 25,4; SAE 6B estriado Bs2509 ø 31,75; SAE J501cónico
torque máxino 44 daNm con chaveta 5/16” x 5/16” x 1” BS46
torque máximo 77 daNm
P
ø 34,85; p.t.o. DIN 9611 Form 1
torque máxino 77 daNm
Cara de montaje del motor.

No se deberá exceder los
torque máximos indicados.

MOTORES ORBITALES
UE
ISO 9001
Carga radial Prad para MLHS
Los ejes de salida están montados sobre un par de rodamientos Prad
cónicos lo que permite absorber altas cargas radiales y axiales. daN 1
Pa max= 0 daN
La curva “1” muestra la carga radial máxima. Cargas mayores a 2500
las permitidas disminuirán la vida útil del motor. 2000
Las otras dos curvas muestran las cargas radiales admisibles 1500 Pa max= 500 daN
para que los rodamientos B10 alcancen una vida de 3.000 1000
horas a 200 RPM. 500

0
20 40 60 80 100 mm
Dirección de la rotación
F
28
DESIGNACIÓN PARA ORDENAR:

MOTOR
M L H S
ROTACIÓN
BAJA VUELTAS
ALTO TORQUE
- = STANDARD R= ROTACIÓN INVERSA
APLICACIONES ESPECIALES
MODELO
SIN SÍMBOLO= NINGUNA LL= BAJAS FUGAS
Y= MOTOR CON ELEMENTOS REFORZADOS
SIN SÍMBOLO= STANDARD
LSV= VÁLVULA PARA BAJAS VUELTAS FR= GIRO LIBRE
CONEXIONES
BRIDA DE MONTAJE
SIN SÍMBOLO= SAE A, 4 AGUJEROS 2= LATERAL, 2XG1/2, G1/4, BSP ROSCA, ISO 228
B = SAE B, 2 AGUJEROS 3= LATERAL, 2XM22X1,5, M14X1,5, ROSCA MÉTRICA, ISO 262
E = MOTOR RUEDA “E” 4= LATERAL, 2X7/8-14 UNF, O-RING 7/16-20 UNF
F = MAGNETO, 4 O 6 AGUJEROS, STANDARD 5= LATERAL, 2X1/2-14 NPTF, 7/16-20 UNF
S = CORTO 6= TRASERA, 2XG1/2, G1/4, BSP ROSCA, ISO 228
V = MUY CORTO 7= TRASERA, 2X7/8-14 UNF, O-RING 7/16-20 UNF
W = MOTOR RUEDA 8= TRASERA, 2X1/2-14 NPTF, 7/16-20 UNF
Z = CORTO CON RODAMIENTO A RODILLOS 9= TRASERA, 2XM22X1,5, M14X1,5, ROSCA MÉTRICA, ISO 262
SENTIDO DE ROTACIÓN (SÓLO PARA MLHSBD)
BD = MOTOR DE RUEDA CON FRENO
R = MOTOR DE RUEDA T/TRW R = DERECHA L = IZQUIERDA
EJES (*SÓLO PARA MOTORES TIPO “S”)
DESPLAZAMIENTO
C= 31,75 MM CILÍNDRICO CON CHAVETA P= 34,85 MM ESTRIADO,
80 125 200 315
D*=25,4 MM CILÍNDRICO CON CHAVETA P.T.O. DIN 9611 FORM 1
100 160 250 400
G=31,75 14T ESTRIADO S*=25,4 SAE 6B ESTRIADO
475 525 565
M=32 MM CILÍNDRICO CON CHAVETA T=31,75 J501 CÓNICO

THE INTRAVENT
PL5
PLANETARY HYDRAULIC WINCH
DESIGN REVISION EFFECTIVE FROM SERIAL # 75036
INSTRUCTION
AND
PARTS
MANUAL
READ THIS MANUAL BEFORE INSTALLING, OPERATING OR

SERVICING THIS PRODUCT. THIS MANUAL CONTAINS IMPORTANT
INFORMATION. MAKE THIS MANUAL AVAILABLE TO ALL PERSONS
RESPONSIBLE FOR THE OPERATION, INSTALLATION, SERVICING
AND MAINTENANCE OF THIS PRODUCT.
PML THE LOGICAL

CHOICE
PULLMASTER LIMITED WARRANTY
Effective 1/1/2002
SUPERSEDES ALL PRIOR WARRANTIES
Seller warrants that each article sold under this order shall at the time of shipment (i) conform to applicable
specifications, and (ii) be free from defects in material and workmanship during normal and ordinary use and
service (the “Warranty”).
Buyer’s exclusive remedy and Seller’s sole obligation under this Warranty shall be, at Seller’s option, to repair
or replace any article or part thereof which has proven to be defective, or to refund the purchase price of such
article or part thereof.
This Warranty shall expire one (1) year from the date the article is first shipped by Seller. Notice of claimed
breach of this Warranty must be given by Buyer to Seller within the applicable period. Such notice shall
include an explanation of the claimed warranty defect and proof of date of purchase of the article or part
thereof for which warranty coverage is sought. No allowances shall be made by Seller for any transportation,
labor charges, parts, “in and out” costs, adjustments or repairs, or any other work, unless such items are
authorized in writing and in advance by Seller. Nor shall Seller have any obligation to repair or replace items
which by their nature are expendable.
If an article is claimed to be defective in material or workmanship, or not to conform to the applicable

specifications, Seller will either examine the article at Seller’s site or issue shipping instructions for return to
Seller. This Warranty shall not extend to any articles or parts thereof which have been installed, used, or
serviced otherwise than in conformity with Seller’s applicable specifications, manuals, bulletins, or instructions,
or which shall have been subjected to improper installation, operation, or usage, misapplication, neglect,
overloading, or employment for other than normal and ordinary use and service.
This Warranty shall not apply to any articles or parts thereof furnished by Seller to Buyer’s specifications and/
or furnished by Buyer or acquired from others at Buyer’s request.
SELLER MAKES NO EXPRESS WARRANTIES AND NO IMPLIED WARRANTIES OF ANY KIND, OTHER
THAN THE WARRANTY EXPRESSLY SET FORTH ABOVE. SUCH WARRANTY IS EXCLUSIVE AND IS
MADE AND ACCEPTED IN LIEU OF ANY AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS
FOR A PARTICULAR PURPOSE.
The remedies for this Warranty shall be only those expressly set forth above, to the exclusion of any and all
other remedies of whatsoever kind. The limited remedies set forth above shall be deemed exclusive, even
though they may fail their essential purpose. No agreement varying or extending the foregoing Warranty,
remedies, exclusions, or limitations shall be effective unless in a writing signed by an executive officer of
Seller and Buyer. This Warranty is non-transferable.
Under no circumstances shall Seller be liable (i) for any damage or loss to any property other than the
warranted article or part thereof, or (ii) for any special, indirect, incidental, or consequential damage or loss,
even though such expenses, damages, or losses may be foreseeable.
The foregoing limitations on Seller’s liability in the event of breach of warranty shall also be the absolute limit
of Seller’s liability in the event of Seller’s negligence in manufacture, installation, or otherwise, with regard to
the articles covered by this Warranty, and at the expiration of the Warranty period as above stated, all such
liabilities shall terminate.
WARNING
PULLMASTER planetary winches/drives are not designed for operations involving lifting or moving
personnel. The PULLMASTER WINCH CORPORATION cannot be held liable or responsible
for any accident resulting from such use of PULLMASTER planetary winches/drives.
Note: Specifications contained in this Instruction and Parts Manual are subject to change without notice.
SAFETY RECOMMENDATIONS
Definition: Caution indicates a potentially
DANGER hazardous situation which, if not avoided may
result in minor or moderate injury.
FAILURE TO COMPLY WITH THE FOLLOWING Definition: Warning indicates a potentially
SAFETY RECOMMENDATIONS AND LOCAL RULES hazardous situation which, if not avoided could
result in death or serious injury.
AND REGULATIONS WILL RESULT IN PROPERTY
DAMAGE, SEVERE INJURY OR DEATH. Definition: Danger indicates a potentially
hazardous situation which, if not avoided will
PULLMASTER planetary hydraulic winches are made for hoisting and lowering loads and are to be operated by
trained and professional personnel. They are not designed for operations involving lifting or moving personnel.
The winches are powered by hydraulic power. The ropes / cables for hoisting operations are not supplied by
PULLMASTER WINCH CORPORATION. The winches are always assembled in an application, they do not function
as an independent machine and it is not allowed to use them as such.
The winches are to be used within the specifications as listed in the manual under “SPECIFICATIONS”. Other
use as foreseen in the functional description of the hydraulic winch is not allowed without written permission
from PULLMASTER WINCH CORPORATION.
1. Do not install, operate or service winch before 18. Use only recommended hydraulic oil and gear
reading and understanding manufacturer’s lubricant.
instructions.
19. Keep hydraulic system clean and free from
2. The winch described herein is not designed for contamination at all times.
operations involving lifting or moving personnel.
20. Maintain winch and equipment in good operating
3. Do not lift or carry loads over people. condition. Perform scheduled maintenance regularly.
4. Do not exceed recommended operating pressure 21. Keep hands clear when winding wire rope onto the
(psi) and operating volume (gpm). winch drum.
5. Do not jerk the winch. Always smoothly accelerate 22. Do not use the wire rope as a ground for welding.
and decelerate load.
23. Rig the winch carefully. Ensure that the wire rope
6. Do not operate a damaged, noisy or malfunctioning is properly anchored to the correct cable anchor
winch. slot at the cable drum.
7. Do not leave a load suspended for any extended 24. Do not lift a load with a twisted, kinked or damaged
period of time. wire rope.
8. Never leave a suspended load unattended. 25. Consult wire rope manufacturer for size, type and
maintenance of wire rope.
9. Winch should be maintained and operated by
qualified personnel. 26. Maintain five wraps of wire rope on the cable drum
at all times.
10. Inspect winch, rigging, mounting bolts and hoses
before each shift. 27. In case of a power failure or breakdown leading to
an unexpected stop of the hydraulic power circuit,
11. Warm-up equipment before operating winch, stand clear of the area and the load being hoisted,
particularly at low ambient temperatures. take the necessary precautions to prevent access
12. Verify winch function by raising and lowering a full to area where the load is halted.
test load to a safe height before each shift. 28. The noise level of the winch is 90 dBA measured
13. Do not weld any part of the winch. on a distance of 1.00 meter, 1.60 meters high. The
measuring equipment used was: Realistic #42-
14. Verify gear lubrication and brake circulation supply 3019.
and return before operating winch.
29. Clean up any oil spillage immediately.
15. Be sure of equipment stability before operating
winch. 30. Wear proper clothing and personal protection
equipment such as, footwear, safety goggles and
16. Wear proper clothing to avoid entanglement in a hard hat. Read manual first.
rotating machinery.
17. Always stand clear of the load.
365 REV.051117 PAGE 1

DESCRIPTION OF THE MODEL PL5
GENERAL DESCRIPTION:
The PULLMASTER Model PL5 is a planetary hydraulic winch having equal speed in both directions.
The main components of this unit are:
✛ Hydraulic gear motor

✛ Multi disc brake with static and dynamic function
✛ Over-running clutch
✛ Primary planet reduction
✛ Final planet reduction
✛ Brake housing
✛ End housing
✛ Cable drum
FUNCTION IN FORWARD ROTATION (HOISTING):

In forward rotation, the output torque and rpm of the hydraulic motor are transmitted to the sungear
of the primary planet reduction. The output of the primary reduction is transferred to the final sungear,
which is splined to the primary planet hub. The final planet assembly does not rotate, so the rotation
is transmitted to the cable drum by the final drive planet gears. In forward rotation, or when a load is
lifted, an over-running clutch, which connects the motor drive shaft to the automatic brake assembly,
permits free rotation of the sungear, without effecting the brake. Pressure required to rotate the drum
at full speed without load may vary up to 400 psi (28 bar). When the winch rotation is stopped, the load
on the cable drum causes the over-running clutch to lock and the maximum load is held safely by the
disc brake.
FUNCTION IN REVERSE ROTATION (LOWERING):

In reverse rotation, or when the winch is pressurized for lowering a load, hydraulic pressure from the
reverse side of the hydraulic motor is channelled to the brake piston, causing the brake piston to release
the multi-disc brake against a number of brake springs. The pressure required to rotate the drum at full
speed, depending upon load, may vary 250 psi to 500 psi (17 bar to 34 bar) and without load from 500
psi to 1000 psi (34 bar to 69 bar). The over-running clutch, connecting the motor drive shaft to the brake
assembly, locks, causing the brake discs to rotate between divider plates, which are engaged into the
brake housing. If the load on the cable drum tends to effect the lowering speed, the resulting pressure
drop in the brake piston causes friction between the brake discs and the divider plates. In this way,
a completely smooth paying out speed can be achieved in a stepless operation by modulation of the
winch control handle. When the control handle is returned to neutral position, rotation stops and the
disc brake applies automatically. A hydraulic counter-balance valve or holding valve is not required for
smooth and positive operation of the automatic brake.
During the lowering operation of the winch, the friction created by the brake discs results in heat. This
heat is dissipated by the circulation of hydraulic fluid through the brake housing, supplied internally
through the hydraulic motor. This circulation flow is internally vented to the return line flow through a
check valve arrangement inside the hydraulic motor. The circulation flow is supplied only when a load
is lowered. A separate vent line connecting the PULLMASTER Model PL5 with the hydraulic reservoir
is not normally required.
(See TYPICAL HYDRAULIC CIRCUITS.)
IMPORTANT: Pressure in the brake housing must never exceed 100 psi (7 bar). Excessive brake
housing pressure will cause the safety valve located on top of the motor to leak. Brake
housing pressure can be gauged at the safety valve port.
PAGE 2 365 REV.050718

EXPLANATION OF MODEL CODING
PL 5 X - XX X - XX - XX X - XXXX
BASIC UNIT SERIES
SIZE OF UNIT
REDUCTION RATIO
Only used for non-standard reduction ratios
For “A” ratio: refer to appendix “B”
TYPE OF BRAKE
-12 Automatic brake, counterclockwise hoisting, intravent
-13 Automatic brake, external brake release, counterclockwise
hoisting, intravent
-14 Automatic brake, external brake release, clockwise hoisting,
intravent
-15 Automatic brake, clockwise hoisting, intravent
M
Denotes metallic brake plates
HYDRAULIC MOTOR
- 210 Gear motor - 33 cc displacement
(For optional motors refer to APPENDIX A)
DRUM SIZE
-1 7.38 inch drum diameter x 11.00 inch flange diameter x 6.56 inch length - STANDARD
(For optional drum sizes refer to APPENDIX A)
OPTIONS
SPECIFICATION NUMBER
Describes features not identified by preceding codes
NOTE: Clockwise and counterclockwise drum rotation is the direction of rotation for pulling or hoisting,
established by looking at the hydraulic motor.
365 REV.050718 PAGE 3

OPTIONS
CLOCKWISE ROTATION:
The drum rotation of the standard PULLMASTER Model PL5 planetary winch is counterclockwise for
hoisting, when looking at the hydraulic motor of the winch. Drum rotation for clockwise hoisting direction
is available as an option.
EXTERNAL BRAKE RELEASE:

PULLMASTER planetary winches can be supplied with an external brake release which permits
release of the automatic disc brake from an external pressure source.
DANGER
FAILURE TO PROPERLY VENT EXTERNAL BRAKE RELEASE PORT WILL
TRAP BRAKE PRESSURE AND ALLOW THE LOAD TO DROP,
CAUSING PROPERTY DAMAGE, SEVERE INJURY OR DEATH.
WINCHES SUPPLIED WITH EXTERNAL BRAKE RELEASE OPTION
MUST BE CONNECTED ACCORDING TO “TYPICAL HYDRAULIC CIRCUIT”.
CABLE DRUM SIZES:

Aside from the standard drum sizes listed in APPENDIX A, the PULLMASTER Model PL5 planetary
winch can be supplied with optional drums to accommodate large wire rope storage capacity.
DRUM GROOVING:
Cable drums for the PULLMASTER Model PL5 planetary winch can be grooved. Where this option is
a requirement, it is necessary to state the size of wire rope which is to be used with the winch.
OPTIONAL GEAR SECTION FOR THE HYDRAULIC MOTOR:

The performance of the standard PULLMASTER Model PL5 planetary winch may be changed by using
a different displacement motor.
(See APPENDIX A for performance information.)
HYDRAULIC MOTORS FOR HIGH PRESSURE HYDRAULIC SYSTEMS:

The operating pressure of the PULLMASTER Model PL5 planetary winch with standard hydraulic motor
is limited to 2100 psi (145 bar). For hydraulic systems operating with higher hydraulic pressure, the winch
can be supplied with a hydraulic piston motor which will provide for the same basic performance in terms
of line pull and line speed capacity.
(Contact the factory for this requirement.)
The PULLMASTER WINCH CORPORATION will consider other options for quantity requirements.
PAGE 4 365 REV.050718

SPECIFICATIONS
Performance specifications are based on standard hydraulic motor, gear ratio and cable drum with 7/16
inch diameter wire rope. See APPENDIX A for performance of available options.
CABLE DRUM DIMENSIONS (STANDARD DRUM):

Barrel Diameter 7.38 in 187 mm
Flange Diameter 11.00 in 279 mm
Barrel Length 6.56 in 167 mm
CABLE STORAGE CAPACITY:

Size of wire rope 1/4 in 348 ft 106 m
5/16 in 218 ft 67 m
3/8 in 157 ft 48 m
7/16 in 110 ft 34 m
1/2 in 100 ft 31 m
MAXIMUM OPERATING PRESSURE: 2100 psi 145 bar
MAXIMUM OPERATING VOLUME: 24 (US) gpm 91 l/min
MINIMUM OPERATING VOLUME: 6 (US) gpm 23 l/min
DRUM TORQUE AT MAXIMUM PRESSURE: 17,578 lb-in 1986 Nm
DRUM RPM AT MAXIMUM VOLUME: 66 rpm
LINE PULL AT MAXIMUM PRESSURE:

Bare drum 4500 lb 20.0 kN
Full drum 3328 lb 14.8 kN
LINE SPEED AT MAXIMUM VOLUME:

Bare drum 135 fpm 41 m/min
Full drum 183 fpm 56 m/min
PERMISSIBLE SYSTEM BACK PRESSURE

AT MOTOR RETURN PORT: 65 psi 4.5 bar
PERMISSIBLE PRESSURE
AT BRAKE HOUSING SAFETY VALVE: 100 psi 7 bar
LUBRICATING OIL: Volume required (-1, -2 drum): 0.3 (US) gal (1.1 litre)
Volume required (-6 drum): 0.5 (US) gal (1.9 litre)
Refer to RECOMMENDATIONS for viscosity and instructions.
365 REV.050718 PAGE 5

PERFORMANCE GRAPHS
PG-PL5-C
LINE PULL VS. OIL PRESSURE
LINE PULL - kN
0 3.3 6.7 10.0 13.3 16.7 20.0
2100 145
1800
UM UM
124
L DR DR
E
UL AR
OIL PRESSURE - bar

OIL PRESSURE - psi
F B
1500 104
1200 83
900 62
600 41
300 21
0 0
0 750 1500 2250 3000 3750 4500
LINE PULL - lb
LINE SPEED VS. OIL VOLUME
LINE SPEED - m/min

0 10 20 30 40 50 60
24 91
UM UM
20 DR DR 76
LL
OIL VOLUME - (US)gpm
E
AR FU
B
OIL VOLUME - l/min
16 61
12 45
8 30
4 15
0 0
0 33 66 99 132 165 198
LINE SPEED - fpm
Performance graphs are based on standard hydraulic motor, gear ratio and cable drum with 7/16
inch diameter rope.
PAGE 6 365 REV.050718

TYPICAL HYDRAULIC CIRCUITS
HC-PL5-S1-B
PRESSURE 800 PSI [55 BAR]

RELIEF VALVE 2.5(US)GPM [9.5 L/MIN]
REQUIRED FOR MODELS
SUPPLIED WITH EXTERNAL
BRAKE RELEASE OPTION
HYDRAULIC WINCH CONTROL

FILTER
PUMP VALVE
(MOTOR SPOOL)
4-WAY SPRING
RETURN TO
CENTER
RESERVOIR
1. TYPICAL HYDRAULIC CIRCUIT - STANDARD CONTROL VALVE

Refer to above hydraulic circuit for installations where the winch is controlled by an individual
control valve. Note that the valve must have a motor spool (both winch ports open to tank in
neutral position). A motor drain line is not required.
CONTROL VALVE STACK
WINCH CONTROL
VALVE
(MOTOR SPOOL +
POWER BEYOND)
2. TYPICAL HYDRAULIC CIRCUIT - POWER BEYOND CONTROL VALVE

Refer to above hydraulic circuit when the winch control valve is used in a circuit containing
stacked valves controlling other functions, as occurs on hydraulic cranes and loaders. The winch
control valve must have a motor spool and power beyond feature. The winch valve is shown
upstream of the stacked control valves. If the winch control valve is located downstream of the
stacked control valves, the valve stack must have the power beyond feature. A motor drain line
is not required.
365 REV.050718 PAGE 7

TYPICAL HYDRAULIC CIRCUITS CONTINUED
HC-PL5-S1-B
MOTOR DRAIN LINE

(MUST GO DIRECT
TO RESERVOIR)
CONTROL VALVE STACK
WINCH CONTROL
VALVE
(CYLINDER SPOOL)
3. TYPICAL HYDRAULIC CIRCUIT - STACKED CONTROL VALVE

Refer to above hydraulic circuit when the winch control valve is one of several stacked control
valves and has a cylinder spool (winch ports blocked in neutral position). In this configuration,
the safety valve must be replaced with a drain line plumbed directly to the reservoir. The drain
line cannot be connected to a common return line.
IMPORTANT: For proper function of the winch in any circuit, the return line back pressure measured
at the motor return port and the brake housing pressure measured at the safety valve
must not exceed pressures per SPECIFICATIONS.
PAGE 8 365 REV.050718

RECOMMENDATIONS
HYDRAULIC FLUID: HYDRAULIC PRESSURE RELIEF:
The hydraulic fluid selected for use with The hydraulic circuit for the PULLMASTER
PULLMASTER planetary winches should be a planetary winch requires a pressure relief set at the
high grade, petroleum based fluid with rust, operating pressure (see SPECIFICATIONS).
oxidation and wear resistance. Fluid cleanliness Usually, a pressure relief is part of the hydraulic
and operating viscosity are critical to winch control valve. Where this is not the case, a separate
reliability, efficiency and service life. pressure relief valve must be installed and set at
the recommended maximum pressure.
For optimum performance, the recommended
viscosity range at operating temperature is 81 - HYDRAULIC RESERVOIR:
167 SUS (16 - 36 CS). For extreme operating It is recommended that the hydraulic reservoir has
conditions of short duration, the maximum viscosity sufficient capacity to provide good heat dissipation
range of 58 - 4635 SUS (10 - 1000 CS) should not in order to prevent over-heating of the hydraulic
be exceeded. fluid.
For optimum performance, the recommended The hydraulic reservoir should be made from clean
hydraulic fluid temperature operating range is 80 and scale-free material to prevent contamination
- 150F (27 - 66C). For extreme operating conditions of the hydraulic fluid. In order to prevent air from
of short duration, the maximum temperature range being mixed with the hydraulic fluid, the reservoir
of -5 - 180F (-21 - 82C) should not be exceeded.
should have an over-flow baffle separating the
return lines from the suction line and all return lines
LUBRICATION: should enter the reservoir below the fluid level. The
The winch gear train requires oil bath lubrication. reservoir should be mounted close to and above
The winch is shipped from the factory without the hydraulic pump in a location which provides for
lubricating oil. free air circulation around the reservoir.
IMPORTANT: ADD LUBRICATING OIL UP TO

HYDRAULIC FILTER:
THE LEVEL OF THE END
Consult hydraulic component manufacturer for
HOUSING OIL FILL PORT
recommendation. Generally, 5 to 10 micron filters
BEFORE RUNNING WINCH.
are acceptable. In order to prevent accidental
stoppage of the return line flow, the filter should
Refer to INSTALLATION DIMENSIONS for
location of lubricating oil fill port. Refer to have a by-pass feature.
SPECIFICATIONS for quantity of oil required.
SAE 90 lubricating oil is recommended. Consult HYDRAULIC HOSES:
lubricating oil supplier or factory for temperature The following hydraulic hose with suitable fittings
beyond normal operating range. is recommended for the PULLMASTER Model PL5
planetary winch.
HYDRAULIC PUMP:
For maximum performance of the PULLMASTER Pressure lines: SAE 100R2-14 or better
planetary winch the hydraulic pump must supply Motor drain line
the maximum flow of hydraulic fluid at the hydraulic (when required): SAE 100R6-6 or better
pressure stated in SPECIFICATIONS.
It is recommended that larger hydraulic hose be
HYDRAULIC CONTROL VALVE: installed where drain line or pressure lines are
excessively long.
The standard control valve used for operating
PULLMASTER planetary winches must have a
four-way, spring return to neutral feature, which USE OF AN E STOP:
(FOR EUROPEAN MACHINERY DIRECTIVE
provides for open flow from the pressure ports of
APPLICATIONS)
the winch to the reservoir in neutral position of the
control (motor spool). It is important to point out The use of an E stop (emergency) is mandatory in
that good speed control, especially when lowering the controls circuit. The E stop is to be placed in the
a load, depends on the “metering” characteristics operator’s control panel. The E stop has to be
of the control valve. The better the oil flow is designed and placed in line with EN 60204 and EN
“metered”, the better will be the speed control. 418.
365 REV.050718 PAGE 9

INSTALLATION INSTRUCTIONS
DANGER
FAILURE TO FOLLOW INSTALLATION INSTRUCTIONS WILL
RESULT IN PROPERTY DAMAGE, SEVERE INJURY OR DEATH.
The initial installation or mounting of a PULLMASTER planetary winch is critically important for proper
operation and performance. If the winch is mounted to an uneven surface, the centre line of the unit
can be distorted to a point where the winch will not operate in either direction. It is therefore very
important that the following instructions are observed when a PULLMASTER planetary winch is
installed:
1) Make certain that the mounting platform is sufficiently strong in order to avoid deflection when
a load is lifted.
2) Set the winch on the mounting platform and check for surface contact on all mounting pads of
the winch.
3) If there is a space between the mounting surface and one of the mounting pads, the mounting
surface is not even and the space below the mounting pad must be shimmed. If this condition
exists, proceed as follows:
a) Install mounting bolts snug tight on the three mounting pads which are in contact with the
mounting surface. For mounting bolt size and grade, see INSTALLATION DIMENSIONS.
b) Measure the space underneath the fourth mounting pad with a feeler gauge and use shim
stock of equivalent thickness in the space between the mounting pad and the mounting
surface.
c) Only after this procedure, should the fourth mounting bolt be installed. Tighten all four
bolts as per BOLT TORQUE CHART at back of manual.
4) Fill the winch with lubricating oil. Required volume is 0.3 (US) gallon (1.1 litre). Refer to
SPECIFICATIONS for -2 and -6 drums. Refer to INSTALLATION DIMENSIONS for location of filler port.
5) Use recommended circuit components and hydraulic hoses.
6) When required, the winch motor drain line must be connected directly to the reservoir. Do not
connect to a common return line.
IMPORTANT: Excessive pressure at brake housing will damage the winch motor or oil seals. Never
plug safety valve port.
7) Before operating the winch with a load, verify that hydraulic fluid is circulating through the brake
assembly by removing the safety valve and checking flow when the winch is run in the lowering
direction. Flow should measure 1.5 gpm (6 l/min).
NOTE: The hydraulic pressure to rotate the drum at full speed in reverse direction may vary 250
psi to 500 psi (17 bar to 34 bar) depending on the load and from 500 psi to 1000 psi (34
bar to 69 bar) without load.
To rotate the drum at full speed in forward direction, pressure required may be up to 400
psi (28 bar).
PAGE 10 365 REV.050718

OPERATING INSTRUCTIONS
DANGER
FAILURE TO FOLLOW OPERATING INSTRUCTIONS COULD
After the PULLMASTER planetary winch has been installed in accordance with the INSTALLATION
INSTRUCTIONS, the wire rope can be fastened to the cable drum.
IMPORTANT: The ropes, chains, slings, etc. are not part of the winch and are not covered by this
manual. Refer to manufacturer’s handling, inspection and maintenance
recommendations to avoid potential accidents. For selection of ropes, etc. please
check following product standards: DIN 15020, prEN818-1/9, prEN 1492-1/2, prEN
1677-1/3 and other relevant product standards.
1) The cable drum of the PULLMASTER planetary winch has two cable anchor slots, one for clockwise
and one for counterclockwise hoisting. Standard rotation for hoisting is counterclockwise when
looking at the hydraulic motor of the unit. It is critical to select the cable anchor slot which will permit
winding of the wire rope on the drum in the correct direction of rotation. If the wire rope is wound
on the cable drum in the wrong direction of rotation, the winch will have no braking capacity. Each
winch is shipped from the factory with a label on the drum, indicating the correct cable anchor slot.
WIRE ROPE INSTALLATION

Counterclockwise hoisting winch shown. SI1013 - PL5
(Use cable anchor slot on opposite side
of drum for clockwise hoisting winch.)
Feed the wire rope through the cable
anchor slot. Loop rope back into slot as
shown. Insert cable anchor into slot,
small end first and long side nearest the
drum flange. Pull rope tight to wedge CABLE ANCHOR SLOT
rope in slot. CABLE ANCHOR
2) On wire rope installation, care must be taken that the wire rope is wrapped completely around the
cable anchor and properly pulled into the cable anchor slot in the cable drum. The cable drum
requires a minimum of 5 wraps of wire rope for safety.
3) The winch operation is controlled by a single control valve lever which has a forward, a reverse
and a neutral position. Speed control in either direction is obtained by modulation of the control
valve lever. Maximum line speed in either direction is obtained when the control valve lever is moved
as far as it can go. The disc brake of the winch will come on automatically when the winch control
lever is returned to neutral.
4) Always warm up equipment prior to operating winch, particularly in low ambient temperature.
Circulate hydraulic oil through the winch control valve for several minutes to warm the hydraulic
systems. To prime the winch with warm oil, operate the winch at slow speed, forward and reverse,
several times.
5) To ensure proper winch installation and function, raise and lower a full test load to a safe height
before using winch for regular operation at the start of each shift.
6) Prevent corrosion damage to winch interior. If not used regularly, run winch up and down at least
once every two weeks.
If, after a new installation, the winch does not function properly, refer to the TROUBLE SHOOTING
section of this manual.
365 REV.051117 PAGE 11

TROUBLE SHOOTING
GENERAL:
In most cases, when the hydraulic winch does not perform satisfactorily, the cause for malfunction is
found somewhere in the hydraulic circuit. Before the winch is removed from its mounting and
disassembled, all of the hydraulic circuit components should be checked for proper function.
IMPORTANT:
The hydraulic oil volume relates to the line speed or rpm of the winch.
Therefore, if the winch does not produce the specified maximum rated line speed or drum rpm, a loss
of hydraulic flow somewhere in the hydraulic circuit can be analysed. If this condition exists, install
a flow meter into the hydraulic circuit to check the volume of oil supplied to the pressure port of the
hydraulic winch motor when the winch control is completely opened. The flow meter should indicate
the maximum operating volume. If this test indicates a loss of hydraulic flow, check the hydraulic pump,
the relief valve and the control valve. If the pump is driven by V-belts, check for belt slippage.
The hydraulic pressure relates to the pulling capacity of the winch.

If the winch will not produce the specified maximum line pull, install a pressure gauge in the pressure
line leading to the hoisting port on the hydraulic winch motor. Stall the winch to prevent rotation of
the drum and then open the control valve. Check the hydraulic pressure reading of the installed
pressure gauge. If the pressure reads below the specified maximum operating pressure, look for
trouble in the hydraulic pump, the relief valve and the control valve. If the hydraulic pump is driven
by V-belts, check for belt slippage. When checking oil pressure and volume in the hydraulic circuit,
verify that the hydraulic reservoir is filled to the top level and the hydraulic pump is running at maximum
operating rpm.
Only after the hydraulic system has been checked and found to be in order, use the following indications
for probable causes of failure in the winch:
FAILURE PROBABLE CAUSE

Winch will not produce line pull at maximum a) Winch is mounted to an uneven surface.
pressure as listed in SPECIFICATIONS. (See INSTALLATION INSTRUCTIONS.)
b) Cable sheaves or block purchase operated with the
winch are not turning freely.
c) Damage or wear in the hydraulic motor.
d) The relief valve pressure may be set too low.
e) Excessive back pressure in the hydraulic system.
Winch will not produce line speed at maximum a) Winch is mounted to an uneven surface.
volume as listed in SPECIFICATIONS. (See INSTALLATION INSTRUCTIONS.)
d) Excessive back pressure in the hydraulic system.
Winch will not reverse. a) Leakage out of the brake piston prevents the disc
brake from being released against the brake springs.
This is caused by damage to the O-rings on the brake
piston or connecting tube.
b) Insufficient hydraulic pressure.
(See SPECIFICATIONS for minimum operating
pressure.)
c) Winch is mounted to an uneven surface.
(See INSTALLATION INSTRUCTIONS.)
d) Hydraulic pressure is not reaching the brake piston
due to plugged passage.
PAGE 12 365 REV.050718

TROUBLE SHOOTING CONTINUED

Brake will not hold. a) Brake plates or divider plates have been damaged by
contamination in the hydraulic fluid or lack of circulation
flow in the brake housing.
b) Brake piston is seized in the brake housing because
of contamination in the hydraulic fluid.
c) Excessive back pressure in the return line of the
hydraulic system causes the brake to release.
d) Control valve has incorrect spool which traps hydraulic
pressure in the brake piston when the control valve
handle is returned to neutral position. For proper
function of the automatic brake, both pressure ports
of the winch must be open to the reservoir in neutral
position of the control valve.
e) Wire rope is fastened to the incorrect cable anchor slot.
f) Over-running clutch is damaged or surface where over-
running clutch engages on motor drive shaft is worn or
indented.
g) Winch supplied with external brake release option is not
plumbed per TYPICAL HYDRAULIC CIRCUITS. Failure
to vent external brake release port to reservoir may trap
pressure and cause winch brake to slip.
Brake vibrates when lowering a load. a) Pump does not supply sufficient flow. Pump rpm must
be maintained at normal operating speed when a load
is lowered.
b) Brake is running too hot. This is caused by a complete
lack of, or insufficient, circulation flow.
c) Control valve for the winch operation has poor metering
characteristics.
d) Damaged brake plates or divider plates.
e) Over-running clutch is damaged or surface where over-
running clutch engages on motor drive shaft is worn or
indented.
f) Air has mixed with hydraulic oil resulting in foamy oil.
Oil leaks. a) Oil leaks from the motor flange are caused by a
damaged O-ring seal on the motor flange.
b) Oil leaks occurring between the cable drum flanges and
housings are caused by excessive pressure in the
brake housing. Excessive pressure in the brake
housing will damage the oil seal between the brake
housing and cable drum interior.
c) Oil leaks from the safety valve are caused by the
excessive pressure in the brake housing or operation
with incorrect hydraulic fluid during cold weather or
incorrect spool in the control valve.
Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Model PL5 winch.
365 REV.050718 PAGE 13

SERVICE INSTRUCTIONS
GENERAL:
Before disassembling the PULLMASTER Model PL5 planetary winch, read and understand the
following instructions.
Replace expendable parts such as O-rings and oil seals when reassembling the winch. Have a winch
seal kit (Part No. 23025) on hand before the unit is disassembled. If motor is to be serviced, have on
hand motor seal kit (Part No. 24227).
NOTE: Backup washers may be included with seal kit. Install with oil seals as per instructions. If not
present in seal kit, the oil seals supplied do not require backup washers.
Disconnect all hydraulic hoses, remove the winch from its mounting and relocate to a clean working area,
similar to one used for service work on any other hydraulic component. Special tools are not required
to service the winch. Adjustments and calibrations are not required.
All parts, as they are removed from the winch assembly, should be inspected for wear and damage.
Worn or damaged parts must be replaced. Thoroughly clean parts before reassembly. Do not use solvent
to clean the brake friction plates. During reassembly, lubricate all O-rings and oil seals with grease before
installation.
The following SERVICE INSTRUCTIONS refer to part descriptions and item numbers which appear in
the group drawings.
DISASSEMBLY
For the majority of required service or repair work, disassembly is required only on the brake housing
of the PULLMASTER Model PL5 planetary winch. There are no special tools needed for the service
or repair work and no adjustments or calibrations are necessary. Proceed with the disassembly as follows:
REMOVAL OF HYDRAULIC MOTOR ASSEMBLY:
1) Before removing hydraulic motor, refer to page 18 drawing # SI1043 and tick mark the position of
the hydraulic motor to facilitate reassembly.
2) Remove four capscrews, item 931, and lockwashers, item 933, from the motor adaptor, item 900.
Brake springs, item 752, apply pressure against inside of motor adaptor, therefore it is recommended
that capscrews are unscrewed, one turn at a time, until spring pressure has been released. The
complete motor assembly, including motor adaptor, can now be removed from brake housing
assembly.
3) Remove and discard two O-rings, item 801 and item 707. (O-ring, item 801, seals pressure transfer
hole for automatic brake release and is situated on flange of brake housing.)
DISASSEMBLY OF HYDRAULIC MOTOR ASSEMBLY:
If service or repair work requires access to interior of brake housing, hydraulic motor should not be
disassembled. If problem has been analysed to be in hydraulic motor, proceed with disassembly as follows:
1) Remove four hex capscrews, item 951, together with lockwashers, item 953, from motor assembly.
IMPORTANT: Failure to exercise care when removing motor port end cover or gear housing could
permanently damage machined surfaces of motor components. Take care not to
damage machined surfaces of motor components at disassembly.
2) Remove port end cover, item 871, from gear housing, item 860.
3) Remove gear set, item 881, item 882 and thrust blocks, item 885.
4) Remove and discard channel seals, item 887, item 888 and backup seals, item 897.
5) Carefully pry gear housing, item 860, off of motor adaptor, item 900. Dowel pins, item 865, may stay
in gear housing.
6) Discard section seals, item 869.
Section seals, channel seals and backup seals in hydraulic motor assembly are not part of winch seal
kit. Seal kit for hydraulic motor can be ordered from factory under Part No. 24227.
PAGE 14 365 REV.050718

SERVICE INSTRUCTIONS CONTINUED
DISASSEMBLY OF BRAKE HOUSING ASSEMBLY:

Disassemble brake housing assembly as follows:
1) Remove ten brake springs, item 752. Examine springs for damage and measure overall length.
Overall spring length should be 1.25 inch. Springs measuring less than 1.19 inch should be
replaced.
2) Pull brake piston, item 750, out of brake housing, item 700.
3) Remove and discard O-rings, item 751 and 753.
4) Thoroughly inspect brake piston outer diameters and brake housing inner bores for scoring caused
by hydraulic fluid contamination. Minor surface damage may be repaired by polishing with a fine
emery cloth.
5) Remove circlip, item 727, from primary sungear, item 440. Remove brake hub, item 720, sprag clutch,
item 723, and sprag clutch aligners, item 722, from primary sungear.
DANGER
DAMAGED FRICTION OR DIVIDER PLATES WILL REDUCE BRAKING CAPACITY AND ALLOW THE
LOAD TO DROP, CAUSING PROPERTY DAMAGE, SEVERE INJURY OR DEATH. SOLVENT MAY DAMAGE
THE FRICTION PLATES. DO NOT USE SOLVENT TO CLEAN THE FRICTION PLATES. PERFORM
THOROUGH INSPECTION AND IF NECESSARY, REPLACE FRICTION AND DIVIDER PLATES AS A SET.
6) Remove five friction plates, item 716, and six divider plates, item 713, and inspect for damage or
wear. Plates should be flat and smooth. Plates should not show heat discoloration. Paper material
on friction plates should be intact and grooved. If any damage is detected, replace friction and divider
plates as a set (winches may contain optional metallic friction plates).
7) Remove brake spacer, item 712.
DISASSEMBLY OF PRIMARY DRIVE:
If the primary drive requires service or repair, disassemble as follows:
1) Remove pipe plug, item 503, from cable drum, item 500, to drain lubricating oil from the winch interior.
2) Remove eight capscrews, item 555, and lockwashers, item 553. Remove two tie bars, item 556.
Stand winch upright on its end housing.
3) Remove six capscrews, item 537, and lockwashers, item 541, through access opening in brake
housing. Lift brake housing with bearing flange out of cable drum, item 500 (bearing flange may
stay in the cable drum). Remove and discard O-ring, item 539.
4) Remove circlip, item 719, from primary sungear, item 440.
5) Remove primary sungear, item 440, from brake housing, item 700.
DANGER
MINOR SURFACE DEFECTS WHERE THE OVER-RUNNING CLUTCH ENGAGES THE MOTOR DRIVE
SHAFT WILL RESULT IN BRAKE FAILURE AND ALLOW THE LOAD TO DROP, CAUSING PROPERTY
DAMAGE, SEVERE INJURY OR DEATH. THOROUGHLY INSPECT THIS AREA AND, IF NECESSARY,
REPLACE PRIMARY SUNGEAR, SPRAG CLUTCH AND BRAKE HUB ASSEMBLY AS A SET.
6) Thoroughly inspect primary sungear, item 440, and brake hub, item 720, particularly surfaces where
sprag clutch, item 723, engages.
7) If any indentation or surface damage is detected, replace brake hub, sprag clutch and primary
sungear as a set.
8) Remove two thrust washers, item 737, and thrust bearing, item 739. Inspect parts and replace if
damaged.
9) Remove and discard oil seal, item 711, and backup washer, item 710.
10) Remove primary planet hub assembly with final sungear, item 340, from cable drum.
365 REV.050718 PAGE 15

11) Inspect planet hub stopper, item 402, for damage or wear and replace if less than .09 inch thick.
12) Inspect three primary planet gears, item 420, for damage or wear. If it is necessary to remove planet
gears, remove circlip, item 411, and press planet pin, item 410, out of planet hub, item 400. Inspect
needle bearing, item 423, and two thrust washers, item 421, and replace if damaged or worn.
13) Remove final sungear, item 340, with circlip, item 341, and sungear stopper, item 344. Inspect
stopper for damage or wear. If stopper is worn more than .03 inch below face of sungear, stopper
should be replaced.
14) Inspect planet hub stopper, item 704, for damage or wear and replace if less than .09 inch thick.
15) Pull bearing flange, item 530, and ball bearing, item 533, off of brake housing.
16) Remove circlip, item 535. Push ball bearing, item 533, out of bearing flange. Inspect and replace
if damaged.
17) Remove and discard oil seal, item 531.
DISASSEMBLY OF FINAL DRIVE:
If final drive requires service or repair, disassemble as follows:
1) Remove final planet hub assembly from cable drum.
2) Inspect three final planet gears, item 320, for damage or wear. If it is necessary to remove planet
gears, remove circlip, item 311, and press planet pin, item 310, out of final planet hub, item 300.
Inspect 20 loose rollers, item 323, and two thrust washers, item 321, and replace if damaged.
Winches with optional -6 drum only:
2a) Remove coupling, item 520, from end housing spline.
3) Remove end housing, item 100, out of cable drum ball bearing, item 507.
4) Remove circlip, item 513. Push ball bearing, item 507, out of cable drum. Inspect and replace if
damaged.
5) Remove and discard oil seal, item 505.
6) Inspect cable drum gear teeth for damage or wear.
REASSEMBLY
Thoroughly clean all parts. Use only new, well-greased O-rings and oil seals. Unless otherwise specified,
torque fasteners per BOLT TORQUE CHART at back of manual.
REASSEMBLY OF FINAL DRIVE:
Reassemble final drive by reversing the disassembly procedure.
1) Press new, well-greased oil seal, item 505, into cable drum, item 500.
2) Press ball bearing, item 507, into cable drum and secure with circlip, item 513.
3) Insert end housing, item 100, into cable drum ball bearing, item 507.
Winches with optional -6 drum only:
3a) Engage coupling, item 520, onto end housing.
4) Reassemble final planet hub assembly. Use grease to temporarily hold 20 loose rollers, item 323,
in bore of planet gear, item 320. Position thrust washers, item 321, on either side of planet gear
and press planet pin, item 310, into final planet hub, item 300. Retain with circlip, item 311.
5) Insert final planet hub assembly into cable drum. Ensure that planet hub spline is fully engaged.
REASSEMBLY OF PRIMARY DRIVE:
Reassemble primary drive by reversing the disassembly procedure.
1) Press new, well-greased oil seal, item 531, into bearing flange, item 530. Press ball bearing, item
533, into bearing flange and secure with circlip, item 535.
2) Verify planet hub stopper, item 704, is installed on brake housing hub.
3) Verify sungear stopper, item 344, and circlip, item 341, are installed on final sungear, item 340.
PAGE 16 365 REV.050718

4) Install final sungear into primary planet hub, item 400.

5) Reassemble primary planet hub assembly. Press needle bearing, item 423, into planet gear, item
420. Position thrust washer, item 421, on either side of planet gear and press planet pin, item 410,
into primary planet hub, item 400. Retain with circlip, item 411.
6) Verify planet hub stopper, item 402, is installed on planet hub.
7) Insert primary planet hub assembly into cable drum. Ensure that final sungear, item 340, is fully
engaged with final planet gears, item 320.
8) Press new, well-greased oil seal, item 711, and backup washer, item 710, into brake housing bore,
item 700.
9) Install thrust bearing, item 739, (with thrust washer, item 737, on either side) against oil seal, item 711.
10) Insert primary sungear, item 440, through brake housing bore, item 700, and fasten with circlip, item 719.
11) Install new, well-greased O-ring, item 539, onto bearing flange, item 530. Insert bearing flange into
cable drum opening and fasten with six capscrews, item 537, and lockwashers, item 541. Slide brake
housing, item 700, into bearing flange, turning primary sungear, item 440, to engage primary planet
gears, item 420.
12) Use eight capscrews, item 555, and lockwashers, item 553, to secure tie bars, item 556.
13) Install pipe plug, item 503, into cable drum.
REASSEMBLY OF BRAKE HOUSING ASSEMBLY:
Reassemble brake housing assembly by reversing the disassembly procedure.
1) Install sprag clutch, item 723, into bore of brake hub, item 720, and position sprag clutch aligners,
item 722, on either side of brake hub. Carefully slide brake hub assembly onto primary sungear,
item 440. Secure with circlip, item 727.
IMPORTANT: For proper brake function, verify that brake hub rotation is correct. When viewed from
the motor end, the primary sungear of a counterclockwise hoisting winch must turn freely
clockwise and lock in the counterclockwise direction.
DANGER
INCORRECT ASSEMBLY OF THE FRICTION PLATE AND DIVIDER PLATE STACK WILL
REDUCE BRAKING CAPACITY AND ALLOW THE LOAD TO DROP, CAUSING PROPERTY
DAMAGE, SEVERE INJURY OR DEATH. REASSEMBLE PER INSTRUCTIONS.
2) Install brake spacer, item 712, into brake housing, item 700.
NOTE: For PL5 with - 213 motor: Refer to 3a)
3) Starting and finishing with a divider plate, alternately install six divider plates, item 713, and five
friction plates, item 716.
3a) Starting with two divider plates, item 713, two friction plates, item 716, repeat two divider plates,
two friction plates, one divider plate, one friction plate ending with one divider plate, item 713.
4) Install new, well-greased O-rings, items 751 and 753, into piston, item 750. Carefully install brake
piston in brake housing, item 700.
5) Install ten brake springs, item 752.
REASSEMBLY OF HYDRAULIC MOTOR:
If the hydraulic motor was disassembled, the following procedure should be followed for reassembly:
1) Clean all parts thoroughly before reassembly and apply grease liberally to all seals. Use only new
seals (seal kit Part No. 24227) for hydraulic motor.
2) Install new, well-greased rubber channel seal, item 887 and item 888, into thrust block, item 885,
so that protrusions in seal match recesses in block. Install new backup seal, item 897, over top of
channel seal, leaving flat side of backup seal flush with surface of thrust block. Insert thrust block,
item 885, into the gear housing, making sure seals are facing away from gear set.
365 REV.050718 PAGE 17

3) Install well-greased section seal, item 869, on gear housing, item 860. Install gear housing together
with seal section, onto motor adaptor, item 900, lined up on two dowel pins. Tap on tight using
a soft headed hammer.
4) Install gear set, item 881 and item 882, in gear housing. (External spline end of gear goes into bore
of motor adaptor.)
5) Insert other thrust block, complete with backup and channel seals, making sure seals are facing
away from gear set. Install a well-greased seal section, item 869, on gear housing.
6) Install port end cover, item 870, onto gear housing and lightly torque four hex capscrews, item 951,
and lockwashers, item 953, to approximately 10 ft-lb (14 Nm).
REPLACE HYDRAULIC MOTOR ASSEMBLY:
1) Install new O-ring, item 707, onto motor adaptor pilot. Use grease to temporarily hold two O-rings,
item 801, into recesses on flange of motor adaptor, item 900.
2) Position motor assembly with brake release pressure transfer holes of motor adaptor and brake
housing aligned, as per drawing # SI1043 below. Tighten four capscrews, item 931, and
lockwashers, item 933, one turn at a time to evenly compress springs.
CCW HOISTING -12,-13 CW HOISTING -14,-15 SI1043

PIPE ADAPTOR AND
SHUTTLE ARE USED
ON THIS SIDE FOR
EXTERNAL BRAKE
RELEASE
3) Plumb winch assembly to a hydraulic supply and torque motor capscrews according to following
procedure:
- Ensure that circulation supply flow is being supplied to the brake housing.
- Run the winch, with no load, in the hoisting direction at reduced speed
(approximately 30% of maximum hydraulic volume).
- With winch running, evenly tighten four capscrews, item 951, to 45 ft-lb (61 Nm).
- Test motor operation by running winch at full speed in both directions.
IMPORTANT: Before operating the winch, add lubricating oil up to the level of the end housing oil
fill port. Refer to INSTALLATION INSTRUCTIONS for location of fill port. Required
volume of oil is 0.3 (US) gallon (1.1 litre) for -1 and -2 drum, 0.5 (US) gallon (1.9 litre)
for -6 drum. To ensure proper reassembly, run the winch in both directions without load.
DANGER
LIFTING A LOAD WITH A NEWLY SERVICED WINCH WILL ENABLE AN INSTALLATION OR SERVICE
PROBLEM TO GO UNDETECTED AND ALLOW THE LOAD TO DROP, CAUSING PROPERTY
DAMAGE, SEVERE INJURY OR DEATH. TO ENSURE PROPER REINSTALLATION, REFER TO
PROCEDURES AND TESTS DESCRIBED IN “INSTALLATION” AND “OPERATING INSTRUCTIONS”.
PAGE 18 365 REV.050718

RECOMMENDED MAINTENANCE
Winch gear train lubricating oil should be changed after the initial six months or 50 hours of operation,
whichever comes first. Lubricating oil should then be changed every 12 months or 500 operating hours,
whichever comes first.
Hydraulic system fluid should be changed at least once every 12 months.
For optimum performance over an extended period of time, the following preventive maintenance service
should be done every 12 months or 500 operating hours, whichever comes first:
1) Disconnect all hydraulic hoses and remove the winch from its mounting.
2) Disassemble the winch as per instructions.
3) Discard and replace all O-rings and oil seals.
4) Clean all parts and inspect for wear and damage as per instructions. Replace worn or
damaged parts as required.
5) Reassemble the winch as per instructions.
6) Follow INSTALLATION and OPERATING INSTRUCTIONS when returning winch to its

mounting.
When ordering parts for the PULLMASTER Model PL5 planetary winch, always quote the complete
model number, serial number and specification (spec) number (if applicable) of the unit.
MODEL # ________________________
SERIAL # ________________________
SPEC # ________________________
SI1030-PL5 Spec #
O
CN
SPE
SER
. NO
Serial #
PULLMASTER WINCH CORPORATION reserves the right to change specifications and the design of
PULLMASTER planetary winches at any time without prior notice and without incurring any obligations.
365 REV.050718 PAGE 19

FOR SAFETY: A MINIMUM OF 5 WRAP OF WIRE ROPE MUST BE MAINTAINED AT ALL TIMES!
*= dimension 'L' is for models with counterclockwise hoisting. for models with clockwise hoisting, add 1.2" (30 mm) to 'L'.
PAGE 20
FILL AND DRAIN
PORT 3/8-18 NPT SAFETY VALVE
C
MOTOR PORTS
1.16-12 UN PRESSURIZE FOR
SAE O-RING CLOCKWISE
COUNTERCLOCKWISE
BOSS ROTATION
FILL AND DRAIN
PORT 1/2-14 NPT
PRESSURIZE
FOR COUNTER
CLOCKWISE OPTIONAL
ROTATION EXTERNAL
BRAKE
RELEASE PORT
7.4 1/8-27 NPT
[187] B
L*
M
2.3 4 MOUNTING HOLES

.5 2.5 .53 DIA. (13.5)
[13] [63] [57] USE 1/2 DIA.
R BOLTS GRADE 8
1.7 OR BETTER
H
[44]
S
J I
P
DRUM UNITS MOTOR DISPLACEMENT

CODE
B C E H J L* M P R S CODE CC / REV I (in.) I (mm)
INSTALLATION DIMENSIONS
11.0 6.6 11.2 7.000 13.2 7.1 5.69 12.5 7.875 10.0 in. 33 5.7 145
-1 -210
279 167 284 177.80 335 180 144 318 200.00 254 mm
12.4 6.6 12.6 7.000 13.2 7.8 6.38 13.9 11.500 13.6 in. -211 27 5.3 135
-2 314 167 319 177.80 335 197 162 352 292.10 346 mm
-212 23 5.1 129
11.0 10.0 11.2 10.435 16.6 7.1 5.69 12.5 7.875 10.0 in.
-6 279 254 284 265.04 422 180 144 318 200.00 254 mm -213 14 4.5 116
365 REV.051117
I1120
NOTE: For brake stack-up with -213 motor refer to BRAKE GROUP on PAGE 24.
365 REV.050718
ASSEMBLY DRAWING
PAGE 21
G1153 & G1283
PARTS REFERENCE - DRUM GROUP
ITEM NO. QTY. PART NO. DESCRIPTION
100 1 * END HOUSING

101 1 25032 PIPE PLUG 1/2 - 14 NPT
300 1 20367 PLANET HUB
310 3 20369 PLANET PIN
311 3 25091 CIRCLIP ROTOR CLIP SH-87
320 3 20370 PLANET GEAR
321 6 25068 THRUST WASHER TORRINGTON # TRA 1423
323 60 25270 LOOSE ROLLER 5/32 X 1.25 TOR. #E151-Q
340 1 20366 SUNGEAR
341 1 25273 CIRCLIP ANDERTON # A1000-137
344 1 20082 SUNGEAR STOPPER
400 1 *** PLANET HUB
402 1 20372 PLANET HUB STOPPER
410 3 *** PLANET PIN
420 3 *** PLANET GEAR
423 3 25063 NEEDLE BEARING TORRINGTON # B1012
500 1 * CABLE DRUM
502 1 20085 CABLE ANCHOR
503 1 25085 PIPE PLUG 3/8 - 18 NPT
505 1 25008 OIL SEAL
507 1 25007 BALL BEARING # 6014
511 1 * SET SCREW 5/16 - 18NC X 7/16
513 1 25006 CIRCLIP ROTOR CLIP HO-433
520 1 * COUPLING
530 1 20363 BEARING FLANGE
531 1 25008 OIL SEAL
533 1 25007 BALL BEARING # 6014
535 1 25006 CIRCLIP ROTOR CLIP HO-433
537 6 25171 CAPSCREW - HEX HEAD 5/16 - 18 NC X 7/8 GRADE 5
539 1 25276 O-RING -164 6 1/4" ID 3/32" CS
541 6 25025 LOCKWASHER 5/16"
553 8 25328 LOCKWASHER 7/16"
555 8 25265 CAPSCREW - HEX HEAD 7/16 - 14 NC X 1.25 GRADE 5
556 2 * TIE BAR
* These parts vary. Refer to APPENDIX B.

*** These parts vary. Refer to APPENDIX B.
PAGE 22 365 REV.050718

DRUM GROUP
DESIGN REVISION EFFECTlVE FROM SERIAL # 75036
G1153
507 311 502 321 320 323 313 503 411 421 420 423
505 530
520
531 511
410
344
533
101
310 535
100 537 Group drawings may reference more parts than are
actually present in a specific assembly. Parts that are
referenced on the drawing but are not on the PARTS
REFERENCE list should be ignored.
555 553 556 513 340 300 500 402 341 400 539 541
Refer to PAGE 21 for ASSEMBLY DRAWING and
PAGE 25 for winch seal kit.
365 REV.050718 PAGE 23

BRAKE GROUP
DESIGN REVISION EFFECTlVE FROM SERIAL # 75036
G1283
900 840
751 752 754 753 707 801
723
722 950 802 807 809
739 955
711 FRICTION PLATE STACK-UP

FOR PL5 WITH -213 MOTOR
704 865 882 872
710 871
440
737 805
719 931
720
933
712
953 951
716
897
713 700 750 832 881 860 885 869 887

727 888
Group drawings may reference more parts than are

actually present in a specific assembly. Parts that are
referenced on the drawing but are not on the PARTS
Refer to PAGE 21 for ASSEMBLY DRAWING and PAGE 25 for winch seal kit. REFERENCE list should be ignored.
PAGE 24 365 REV.050718

PARTS REFERENCE - BRAKE GROUP
440 1 *** SUNGEAR
700 1 ** BRAKE HOUSING
707 1 25015 O-RING -047 4 1/2" ID 1/16" CS
710 1 20714 BACK UP WASHER FOR OIL SEAL #25278
711 1 25278 OIL SEAL
712 1 21902 BRAKE SPACER
713 6 25024 DIVIDER PLATE
716 5 20034 FRICTION PLATE (OPTIONAL - METALLIC PLATES # 26362)
719 1 25539 CIRCLIP ROTOR CLIP SE-118
720 1 22881 BRAKE HUB
722 2 20183 SPRAG CLUTCH ALIGNER
723 1 25187 SPRAG CLUTCH
737 2 25483 THRUST WASHER INA # AS 3047
739 1 25537 THRUST BEARING INA # AXK 3047
750 1 23034 PISTON
751 1 25528 O-RING -245 4 3/8" ID 1/8" CS 90 DUROMETER
752 10 20340 BRAKE SPRING
753 1 25261 O-RING -246 4 1/2" ID 1/8" CS 90 DUROMETER
754 1 23044 ORIFICE PLUG
801 2 25792 O-RING -009 7/32" ID 1/16" CS
802 1 * SHUTTLE
805 1 25040 PIPE PLUG 1/8 - 27 NPT
807 1 * *
832 2 26785 CHECK VALVE
840 1 20870 SAFETY VALVE
860 1 ** GEAR HOUSING
865 2 26371 DOWEL PIN
869 2 26787 SECTION SEAL
871 1 26378 PORT END COVER
872 1 26379 PLUG - ORB #4
881 1 ** GEAR DRIVEN * These parts vary.
882 1 ** GEAR DRIVE Refer to BRAKE CODE CHART below.
885 4 26788 THRUST BLOCK
887 4 26789 CHANNEL SEAL ** Refer to APPENDIX B. (Motor Parts)
888 4 26790 CHANNEL SEAL *** Refer to APPENDIX B. (Reduction Ratio)
897 2 26786 BACKUP SEAL
900 1 24154 MOTOR ADAPTOR
931 4 25772 CAPSCREW
933 4 25298 LOCKWASHER 3/8" HIGH COLLAR
950 1 * MOTOR
951 4 ** CAPSCREW - HEX HEAD
953 4 26369 WASHER
955 2 25536 PLASTIC CAPLUG 1.0625" -12 THREADED
23025 WINCH SEAL KIT, CONSISTING OF ITEMS:

505, 531, 539, 707, 710, 711, 751, 753 AND 801.
24227 MOTOR SEAL KIT, CONSISTING OF ITEMS: 869, 887 AND 897.
ITEM 950, MOTOR SUB-ASSY CONSISTS OF ITEMS: 800, 802, 805,

807, 809, 832, 860, 865, 869, 871, 872, 881, 885, 887, 897, 951 AND 953.
BRAKE CODE CHART BRAKE CODE

-12 -13 -14 -15
ITEM PART DESCRIPTION
NO.
PART NUMBERS
802 SHUTTLE N/A 20849 20849 N/A
807 PIPE PLUG 1/8 - 27 NPT 25040 N/A N/A 25040
807 PIPE ADAPTOR 1/8 - 27 NPT N/A 25622 25622 N/A
809 CAPLUG 1/8 NPT N/A 25374 25374 N/A
950 MOTOR -210 (33cc) 24146 24210 24210 24146
950 MOTOR -211 (27cc) 24147 24211 24211 24147
950 MOTOR -212 (23cc) 24148 24212 24212 24148
950 MOTOR -213 (14cc) 24149 24213 24213 24149
365 REV.050718 PAGE 25

APPENDIX A
PERFORMANCE DATA
Model Number Hydraulic Requirement Drum Drum Bare Drum Full Drum
Flow Pressure Torque RPM Line Pull Line Speed Line Pull Line Speed
PL5-12-210-1 24 (US) gpm 2100 psi 17,578 lb-in 66 4500 lb 135 fpm 3328 lb 183 fpm
91 l/min 145 bar 1986 Nm 20.0 kN 41 m/min 14.8 kN 56 m/min
PL5A-12-212-1 11 (US) gpm 2400 psi 19,532 lb-in 29.5 5000 lb 60 fpm 3698 lb 82 fpm
PL5A-12-212-2 11 (US) gpm 2400 psi 19,532 lb-in 29.5 5000 lb 60 fpm 3272 lb 92 fpm
CABLE STORAGE
DRUM BARREL FLANGE LENGTH WIRE ROPE DIAMETER
CODE DIAMETER DIAMETER 1/8" 3/16" 1/4" 5/16" 3/8" 7/16" 1/2"
-2 7.38" 12.38" 6.56" 2146 ft 975 ft 510 ft 354 ft 234 ft 177 ft 130 ft
187 mm 314 mm 167 mm 654 m 297 m 155 m 108 m 71 m 54 m 40 m
-6 7.38" 11.00" 10.00" 2106 ft 1022 ft 531 ft 333 ft 239 ft 168 ft 153 ft
187 mm 279 mm 254 mm 642 m 311 m 162 m 101 m 73 m 51 m 47 m
Performance specifications are based on 7/16 inch diameter wire rope.
Performance data (line pull and line speed) for models with -6 drum is same as equivalent model with -1 drum.
PAGE 26 365 REV.050718

APPENDIX B
WINCH PARTS
100 500 511 520 556 700

DRUM
CODE END CABLE SET COUPLING TIE BRAKE
HOUSING DRUM SCREW BAR HOUSING
-1 23026 20361 - - 23042 23033
-2 23077 22299 - - 23042 23075
-6 23026 22123 25526 21745 23076 23033
MOTOR PARTS
ITEM
860 881 882 951
MOTOR
CODE GEAR GEAR GEAR CAPSCREW
HOUSING DRIVEN DRIVE HEX HEAD
-210 26793 26791 26792 26370
-211 26797 26795 26796 26794
-212 26798 26799 26800 26801
-213 26802 26803 26804 26399
REDUCTION RATIO
PART NUMBERS
400 410 420 440
PLANET PLANET PLANET

SUNGEAR
HUB PIN GEAR
STANDARD 23022 20776 23023 23028
“A” 20373 20080 20371 23078
365 REV.050718 PAGE 27

BOLT TORQUE CHART
BOLT DIAMETER TORQUE TORQUE

Inches Lb-Ft Nm
1/4 9 12
5/16 18 24
3/8 32 43
7/16 50 68
1/2 75 102
9/16 110 149
5/8 150 203
3/4 265 359
7/8 420 569
1 640 868
1 1/8 800 1085
1 1/4 1000 1356
1 3/8 1200 1627
1 1/2 1500 2034
NOTE: Unless otherwise specified, torque bolts per above chart.
PAGE 28 365 REV.050718

The Three Basic
Types of
PULLMASTER
Planetary
Winches
EQUAL SPEED IN
BOTH DIRECTIONS
PL and M Series
Seven basic models provide for line
RAPID pull capacities from 1,102 lb (500 kp)
to 50,000 lb (22,680 kp). With the
REVERSE available options PULLMASTER
H and HL Series planetary winches can be adapted
For winch operations where a for a wide range of applications
load has to be lowered at high and for special operational
speed and with complete control requirements.
the PULLMASTER planetary
winches in the 'H' series offer
reversing speeds approximately
4.5 times faster than forward
speed. Models in the series are available in line pull
capacities from 8,500 lb (3,856 kp) to 50,000 lb
(22,680 kp).
RECOVERY
R Series
The 'R' Series PULLMASTER recovery winches
are of the same design concept as PULLMASTER
hoisting winches. Freespooling is a standard fea-
ture of this model and is offered with a manually
actuated clutch or is suitable for
hydraulic remote control.
Service for PULLMASTER planetary winches can be obtained through a world wide network of
PULLMASTER distributors. For the distributor nearest to you contact the factory.
Use only authentic PULLMASTER replacement parts in the repair of a PULLMASTER Planetary winch.
Purchased items such as bearings, seals, O-rings, etc., can be supplied from the factory.
However, a cross reference list for such parts is shown in the PARTS REFERENCE of this manual.
When in doubt about proper function, installation or repair of a PULLMASTER planetary winch please
contact your nearest PULLMASTER Distributor or the factory.
PULLMASTER WINCH CORPORATION

8247 - 130TH STREET, SURREY, B.C. CANADA V3W 7X4
TELEPHONE: 604-594-4444 FAX: 604-591-7332
E-MAIL: [email protected] WEBSITE: www.pullmaster.com
PMC 365 REV.051117
PRINTED IN CANADA
INSTRUCTION AND PARTS MANUAL
MODEL HL25
PLANETARY HYDRAULIC WINCH
PML
THE LOGICAL CHOICE
PULLMASTER WINCH CORPORATION

8247-130th Street, Surrey, B.C. V3W 7X4, Canada
Telephone: 604-594-4444 Fax: 604-591-7332
Website: www.pullmaster.com
E-mail: [email protected]
READ THIS MANUAL BEFORE INSTALLING, OPERATING OR

SERVICING THIS PRODUCT. THIS MANUAL CONTAINS IMPORTANT
INFORMATION. MAKE THIS MANUAL AVAILABLE TO ALL PERSONS
RESPONSIBLE FOR THE OPERATION, INSTALLATION, SERVICING
AND MAINTENANCE OF THIS PRODUCT.
PMC 313 051117

PULLMASTER LIMITED WARRANTY
Effective 1/1/2002
SUPERSEDES ALL PRIOR WARRANTIES
Seller warrants that each article sold under this order shall at the time of shipment (i) conform to applicable
specifications, and (ii) be free from defects in material and workmanship during normal and ordinary use and
service (the “Warranty”).
Buyer’s exclusive remedy and Seller’s sole obligation under this Warranty shall be, at Seller’s option, to repair or
replace any article or part thereof which has proven to be defective, or to refund the purchase price of such article
or part thereof.
This Warranty shall expire one (1) year from the date the article is first shipped by Seller. Notice of claimed breach
of this Warranty must be given by Buyer to Seller within the applicable period. Such notice shall include an
explanation of the claimed warranty defect and proof of date of purchase of the article or part thereof for which
warranty coverage is sought. No allowances shall be made by Seller for any transportation, labor charges, parts,
“in and out” costs, adjustments or repairs, or any other work, unless such items are authorized in writing and in
advance by Seller. Nor shall Seller have any obligation to repair or replace items which by their nature are
expendable.
If an article is claimed to be defective in material or workmanship, or not to conform to the applicable specifications,
Seller will either examine the article at Seller’s site or issue shipping instructions for return to Seller. This Warranty
shall not extend to any articles or parts thereof which have been installed, used, or serviced otherwise than in
conformity with Seller’s applicable specifications, manuals, bulletins, or instructions, or which shall have been
subjected to improper installation, operation, or usage, misapplication, neglect, overloading, or employment for
other than normal and ordinary use and service.
This Warranty shall not apply to any articles or parts thereof furnished by Seller to Buyer’s specifications and/or
furnished by Buyer or acquired from others at Buyer’s request.
SELLER MAKES NO EXPRESS WARRANTIES AND NO IMPLIED WARRANTIES OF ANY KIND, OTHER THAN
THE WARRANTY EXPRESSLY SET FORTH ABOVE. SUCH WARRANTY IS EXCLUSIVE AND IS MADE AND
ACCEPTED IN LIEU OF ANY AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT
LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE.
The remedies for this Warranty shall be only those expressly set forth above, to the exclusion of any and all other
remedies of whatsoever kind. The limited remedies set forth above shall be deemed exclusive, even though they
may fail their essential purpose. No agreement varying or extending the foregoing Warranty, remedies, exclusions,
or limitations shall be effective unless in writing signed by an executive officer of Seller and Buyer. This Warranty
is non-transferable.
Under no circumstances shall Seller be liable (i) for any damage or loss to any property other than the warranted
article or part thereof, or (ii) for any special, indirect, incidental, or consequential damage or loss, even though
such expenses, damages, or losses may be foreseeable.
The foregoing limitations on Seller’s liability in the event of breach of warranty shall also be the absolute limit of
Seller’s liability in the event of Seller’s negligence in manufacture, installation, or otherwise, with regard to the
articles covered by this Warranty, and at the expiration of the Warranty period as above stated, all such liabilities
shall terminate.
WARNING
PULLMASTER planetary winches/drives are not designed for operations involving lifting or moving
personnel. The PULLMASTER WINCH CORPORATION cannot be held liable or responsible
for any accident resulting from such use of PULLMASTER planetary winches/drives.
Note: Specifications contained in this Instruction and Parts Manual are subject to change without notice.
SAFETY RECOMMENDATIONS
Definition: Caution indicates a potentially
hazardous situation which, if not avoided may
DANGER result in minor or moderate injury.
Definition: Warning indicates a potentially

FAILURE TO COMPLY WITH THE FOLLOWING SAFETY hazardous situation which, if not avoided could
RECOMMENDATIONS AND LOCAL RULES AND
REGULATIONS WILL RESULT IN PROPERTY Definition: Danger indicates a potentially
hazardous situation which, if not avoided will
DAMAGE, SEVERE INJURY OR DEATH. result in death or serious injury.
The planetary hydraulic winches are made for hoisting and lowering loads and to be operated by trained and professional
personnel. They are not designed for operations involving lifting or moving personnel. The winches are powered by hydraulic
power. The ropes / cables for hoisting operations are not supplied by PULLMASTER. The winches are always assembled in
an application, they do not function as an independent machine and it is not allowed to use them as such.
The winches are to be used within the specifications as listed in the manual under “SPECIFICATIONS”. Other use as foreseen
in the functional description of the hydraulic winch is not allowed without written permission from PULLMASTER.
1. Do not install, operate or service winch before 18. Use only recommended hydraulic oil and gear
reading and understanding manufacturer's lubricant.
instructions.
19. Keep hydraulic system clean and free from
2. The winch described herein is not designed for contamination at all times.
operations involving lifting or moving personnel.
20. Maintain winch and equipment in good operating
3. Do not lift or carry loads over people. condition. Perform scheduled maintenance regularly.
4. Do not exceed recommended operating pressure 21. Keep hands clear when winding wire rope onto
(psi) and operating volume (gpm). the winch drum.
5. Do not jerk the winch. Always smoothly 22. Do not use the wire rope as a ground for welding.
accelerate and decelerate load.
23. Rig the winch carefully. Ensure that the wire rope
6. Do not operate a damaged, noisy or is properly anchored to the correct cable anchor slot at
malfunctioning winch. the cable drum.
7. Do not leave a load suspended for any extended 24. Do not lift a load with a twisted, kinked or
period of time. damaged wire rope.
8. Never leave a suspended load unattended. 25. Consult wire rope manufacturer for size, type and
maintenance of wire rope.elen
9. Winch should be maintained and operated by
qualified personnel. 26. Maintain five wraps of wire rope on the cable
drum at all times.
10. Inspect winch, rigging, mounting bolts and
hoses before each shift. 27. In case of a power failure or breakdown leading to
an unexpected stop of the hydraulic power circuit, stand
11. Warm-up equipment before operating winch,
clear of the area and the load being hoisted, take the
particularly at low ambient temperatures.
necessary precautions to prevent access to area where
12. Verify winch function by raising and lowering a the load is halted.
full test load to a safe height before each shift.
28. The noise level of the winch is 87dBA measured
13. Do not weld any part of the winch. on a distance of 1.00 meter, 1.60 meters high. The
14. Verify gear lubrication and brake circulation measuring equipment used was: Realistic #42-3019.
supply and return before operating winch. 29. Clean up any oil spillage immediately.
15. Be sure of equipment stability before operating 30. Wear proper clothing and personal protection
winch. equipment such as, footwear, safety goggles and a hard
16. Wear proper clothing to avoid entanglement in hat. Read manual first.
rotating machinery.
17. Always stand clear of the load.
313 REV.051117 PAGE 1

DESCRIPTION OF THE MODEL HL25
GENERAL DESCRIPTION:
The PULLMASTER Model HL25 is a planetary, hydraulic winch with two forward speeds and one reverse speed.
At low forward or hoisting speed this unit has a line pull capacity of 25,000 lb on the first layer of wire. In the "rapid
forward" mode the line pull capacity is reduced by a ratio of 4.67 and the line speed increases by the same ratio.
The change from low speed to rapid forward speed is actuated hydraulically and can be made while the drum
is rotating. The main components of this unit are:
✧ Hydraulic motor
✧ Multi-disc brake with static and dynamic function
✧ High speed clutch
✧ Primary planet reduction
✧ Final planet reduction
✧ Brake housing
✧ Final drive housing
✧ Cable drum
FUNCTION IN FORWARD ROTATION:

LOW FORWARD SPEED
During low forward speed the output torque and rpm of the hydraulic motor is transmitted by the motor drive shaft
to the primary sungear of the primary drive. The output torque and rpm of the primary drive is transmitted to the
final drive by the final sungear, which is splined to the primary planet hub. The output torque and rpm of the final
drive is transmitted to the cable drum by a spline, attaching the final planet hub to the cable drum.
The motor drive shaft is splined to a clutch hub which connects to a set of friction and divider plates. During low
speed operation, a pressure plate, which is "spring applied" and "pressure released", permits free rotation of the
friction plates.
The motor drive shaft is also attached to a connecting shaft by a sprag clutch which permits free rotation of the
motor drive shaft while the connecting shaft is stationary. The connecting shaft is held stationary by another sprag
clutch to a brake hub. During low forward speed operation, the automatic brake remains applied, hence, the brake
hub, the connecting shaft and the internal gear do not rotate.
RAPID FORWARD SPEED

When rapid forward speed is actuated, hydraulic pressure is channelled from the motor to the center bore of the
motor drive shaft to the clutch piston. The hydraulic pressure causes the clutch to engage against the clutch
springs. The clutch hub is splined to the motor drive shaft and the drive gear is splined to the connecting shaft,
the internal gear of the primary drive will rotate with the motor drive shaft. Thus, the planetary drive is eliminated.
The elimination of the primary drive results in a forward or hoisting line speed 4.67 times faster than low forward
speed. The line pull capacity during "rapid forward" operation must be decreased by a ratio of 4.67. When the
pressure is removed from the clutch, the clutch is disengaged by the clutch springs and the unit reverts to low
forward speed. Since the sprag clutch, which connects the connecting shaft to the brake hub, permits free
rotation, the automatic brake of the winch is not affected during rapid forward speed.
NOTE: The change over from low forward speed to rapid forward speed can be made while the drum is
rotating, providing the load on the wire rope does not exceed 5357 lb (23.8 kN) on the first layer
of wire rope. If this load is exceeded, winch will stall.
PAGE 2 313 REV.980301

DESCRIPTION OF THE MODEL HL25
CONTINUED
FUNCTION IN REVERSE ROTATION:
RAPID REVERSE
When the hydraulic motor is pressurized for rapid reverse, the rotation of the motor drive shaft causes the sprag
clutch to lock, resulting in a solid assembly between the motor drive shaft and the connecting shaft. Rotation of
the connecting shaft causes the sprag clutch between the connecting shaft and the brake hub to lock making
a solid assembly between these two components. Hydraulic pressure is automatically transmitted to the brake
piston, forcing the brake piston to release brake against a series of brake springs. The friction plates, which are
engaged in the brake hub, can now rotate between the divider plates. Since both sprag clutches are locked, the
friction plates, brake hub, connecting shaft, internal gear and primary sungear turn at the same revolution as the
motor drive shaft. Thus, the primary drive is eliminated, resulting in a reversing speed 4.67 times faster than low
forward speed.
If a load on the cable drum tends to affect the reversing speed, the resulting pressure drop in the brake piston
causes friction between the friction plates and the divider plates. Thus, a completely smooth reversing speed can
be controlled in a stepless operation by modulation of the winch control handle. When the control is returned to
neutral position, rotation stops and the disc brake applies automatically. The pressure in the brake piston is vented
to the reservoir by the motor spool of the winch control valve.
During reverse operation of the winch, or when a load is being lowered, the friction created by the brake disc
results in temperature. On the standard Model HL25 this temperature is dissipated by a circulation flow of
hydraulic fluid, supplied from an external source (see HYDRAULIC CIRCUIT). For efficient cooling of the
automatic brake, the external circulation flow should be adjusted to 7 (US) gpm (26 l/min). This circulation flow
must be returned directly to the reservoir with a permissible back pressure of 30 psi (2 bar) (see HYDRAULIC
CIRCUIT).
IMPORTANT: Under no circumstances must the back pressure in the brake housing be permitted to exceed
30 psi (2 bar). Excessive pressure in the brake housing will damage the oil seals separating the
brake housing from the drum interior. Damage to this seal will cause the cable drum to fill up with
hydraulic fluid. In order to prevent potential damage to the drum seals and the end cover of the
winch, when the cable drum fills up with hydraulic fluid, a breather relief (see PARTS
REFERENCE, item 130) is installed on the end cover. The breather relief bleeds to atmosphere
and serves as a warning signal that the oil seal between the brake housing and drum has been
damaged.
313 REV.970901 PAGE 3

EXPLANATION OF MODEL CODING
HL 25 X - XX - XX - XX X - X XXXX
BASIC UNIT SERIES
HL = Rapid forward and reverse
SIZE OF UNIT
REDUCTION RATIO
Only used for non standard reduction ratios
TYPE OF BRAKE
-7 Automatic brake, clockwise drum rotation, external circulation flow
-8 Automatic brake, external brake release, clockwise drum rotation,

external circulation flow
-9 Automatic brake, external brake release, counterclockwise drum

rotation, external circulation flow
-10 Automatic brake, counterclockwise drum rotation, external

circulation flow
HYDRAULIC MOTOR
-86 Standard hydraulic gear motor - WM76 (12.3 in3 displacement)
-129 Standard hydraulic piston motor - VOLVO 110 cc (6.7 in3 displacement)
(For other motor options contact factory)
DRUM SIZE
-1 10 inch drum diameter X 17 inch flange diameter X 11 inch length - STANDARD
(For other drum sizes refer to APPENDIX A)
OPTIONS
-F Hydraulically actuated freespooling
DESIGN REVISION
SPECIFICATION NUMBER
Describes features not identified by preceding codes
NOTE: Clockwise and counterclockwise drum rotation is the direction of rotation for pulling or hoisting,
established by looking at the hydraulic motor.
PAGE 4 313 REV.970901

OPTIONS
COUNTERCLOCKWISE ROTATION:
The drum rotation of the standard PULLMASTER Model HL25 planetary winch is clockwise for hoisting when
looking at the hydraulic motor of the winch. Drum rotation for counterclockwise hoisting direction is available as
an option.
EXTERNAL BRAKE RELEASE:

PULLMASTER planetary winches can be supplied with an external brake release which permits release of the
automatic disc brake from an external pressure source.
DANGER
FAILURE TO PROPERLY VENT EXTERNAL BRAKE RELEASE
PORT WILL TRAP BRAKE PRESSURE AND ALLOW THE
LOAD TO DROP, CAUSING PROPERTY DAMAGE, SEVERE
INJURY OR DEATH. WINCHES SUPPLIED WITH EXTERNAL
RELEASE OPTION MUST BE CONNECTED ACCORDING
TO TYPICAL HYDRAULIC CIRCUIT.
CABLE DRUM SIZES:

Aside from the standard drum sizes listed in APPENDIX A, the PULLMASTER Model HL25 planetary winch can
be supplied with optional drums to accommodate large wire rope storage capacity.
DRUM GROOVING:
Cable drums for the PULLMASTER Model HL25 planetary winch can be grooved. Where this option is a
requirement, it is necessary to state the size of wire rope which is to be used with the winch.
OPTIONAL GEAR SECTION FOR THE HYDRAULIC MOTOR:

The performance of the standard PULLMASTER Model HL25 planetary winch may be changed by using a
different displacement motor. (Contact the factory for performance information.)
HYDRAULIC MOTORS FOR HIGH PRESSURE HYDRAULIC SYSTEMS:

The operating pressure of the PULLMASTER Model HL25 planetary winch is limited to 2500 psi (172 bar). For
hydraulic systems operating with a higher range of hydraulic pressure, the winch can be supplied with a hydraulic
piston motor, which will provide for the same basic performance in terms of line pull and line speed capacity.
(Contact the factory for this requirement.)
FREESPOOLING:
This option permits wire rope being pulled off the cable drum by an operator. Freespooling should not be
confused with free fall. The freespool clutch cannot be disengaged or re-engaged with a load on the wire rope
or while the cable drum is turning.
The PULLMASTER WINCH CORPORATION will consider other options for quantity requirements.
313 REV.970901 PAGE 5

SPECIFICATIONS
Performance specifications are based on standard hydraulic motor, gear ratio and cable drum with 7/8 inch
diameter wire rope. For other cable drums refer to APPENDIX A. For other reductions or motors, refer to
supplement inside back cover. Performance specifications for winches supplied with optional motors are
provided in attached supplement.
CABLE DRUM DIMENSIONS (STANDARD DRUM):

Barrel diameter 10.00 in 254 mm
Flange diameter 17.00 in 432 mm
Barrel length 11.00 in 279 mm
CABLE STORAGE CAPACITY:

(Size of wire rope) 7/16 in 612 ft 186 m
1/2 in 413 ft 126 m
9/16 in 383 ft 117 m
5/8 in 297 ft 90 m
3/4 in 210 ft 64 m
7/8 in 140 ft 43 m
1 in 91 ft 28 m
-86 Gear Motor -129 Piston Motor
MAXIMUM OPERATING PRESSURE: 2500 psi (172 bar) 3800 psi (262 bar)
MAXIMUM OPERATING VOLUME: 115 (US) gpm (435 l/min) 61 (US)gpm (231 l/min)
MINIMUM OPERATING VOLUME: 30 (US) gpm (114 l/min) 14 (US) gpm (53 l/min)
DRUM TORQUE AT MAXIMUM PRESSURE: 135,937 lb-in 15,359 Nm
DRUM RPM AT MAXIMUM VOLUME: Hoisting 49 rpm

Lowering & High Speed Hoisting 229 rpm
LINE PULL AT MAXIMUM PRESSURE IN LOW FORWARD MODE:

Bare drum 25,000 lb 111.2 kN
Full drum 16,860 lb 75.0 kN
ALLOWABLE LINE PULL IN RAPID FORWARD OR RAPID REVERSE MODE:

Bare drum 5,357 lb 23.8 kN
Full drum 3,613 lb 16.1 kN
LINE SPEED AT MAXIMUM VOLUME IN LOW FORWARD MODE:

LINE SPEED AT MAXIMUM VOLUME IN RAPID FORWARD OR RAPID REVERSE MODE:

PERMISSIBLE SYSTEM BACK PRESSURE AT MOTOR RETURN PORT: 65 psi 4.5 bar
PERMISSIBLE PRESSURE AT CIRCULATION SUPPLY PORT: 30 psi 2 bar
LUBRICATING OIL: Refer to RECOMMENDATIONS for viscosity and instructions.

Refer to APPENDIX A for oil volume required.
PAGE 6 313 REV.010201

RECOMMENDATIONS
HYDRAULIC FLUID: HYDRAULIC PRESSURE RELIEF:
The hydraulic fluid selected for use with PULLMASTER The hydraulic circuit for the PULLMASTER planetary
planetary winches should be a high grade, petroleum winch requires a pressure relief set at the operating
based fluid, with rust, oxidation and wear resistance. pressure (see SPECIFICATIONS). Usually, a pressure
Fluid cleanliness and operating viscosity are critical to relief is part of the hydraulic control valve. Where this is
winch reliability, efficiency and service life. not the case, a separate pressure relief valve must be
installed and set at the recommended maximum pressure.
For optimum performance, the recommended viscosity
range at operating temperature is 81 - 167 SUS (16 - 36 HYDRAULIC RESERVOIR:
CS). For extreme operating conditions of short duration, It is recommended that the hydraulic reservoir has
the maximum viscosity range of 58 - 4635 SUS (10 - sufficient capacity to provide good heat dissipation in
1000 CS) should not be exceeded. order to prevent over-heating of the hydraulic fluid. The
hydraulic reservoir should be made from clean and
For optimum performance, the winch recommended scale-free material to prevent contamination of the
hydraulic fluid temperature operating range is 80 - hydraulic fluid. In order to prevent air from being mixed
150F (27 - 66 C). For extreme operating conditions of with the hydraulic fluid, the reservoir should have an
short duration, the maximum temperature range of -5 over-flow baffle separating the return lines from the
- 180F (-21 - 82 C) should not be exceeded. suction line and all return lines should enter the reservoir
below the fluid level. The reservoir should be mounted
LUBRICATION: close to and above the hydraulic pump in a location
The winch gear train requires oil bath lubrication. The which provides for free air circulation around the reservoir.
winch is shipped from the factory without lubricating oil.
HYDRAULIC HOSES:
IMPORTANT: ADD LUBRICATING OIL BEFORE The following hydraulic hoses are recommended for
RUNNING WINCH. maximum efficiency of the PULLMASTER Model HL25
planetary winch:
Refer to INSTALLATION DIMENSIONS for location of
lubricating oil fill port. Refer to APPENDIX A for quantity Pressure lines: Equivalent to SAE 100R12-32
Circulation return line: Equivalent to SAE 100R4-16
of oil required. For normal operating temperature use
Circulation supply line: Equivalent to SAE 100R6-6
SAE 90 lubricating oil. For temperatures beyond normal High speed shifting line: Equivalent to SAE 100R1-4
operating range, consult lubricating oil supplier or
factory. It is recommended that a larger size of hydraulic hose
is installed where the pressure lines or the circulation
HYDRAULIC PUMP: lines are excessively long.
For maximum performance of the PULLMASTER
planetary winch, the hydraulic pump must supply the HYDRAULIC FILTER:
maximum flow of hydraulic fluid at the hydraulic pressure Hydraulic filter recommendations for the hydraulic circuit
stated in SPECIFICATIONS. of the PULLMASTER planetary winch, based on a
return line filter, are given as follows:
HYDRAULIC CONTROL VALVE: Average Atmosphere: 10 microns
The standard control valve used for operation of the Dusty Atmosphere: 5 microns
PULLMASTER planetary winch must have a four-way, In order to prevent accidental stoppage of the return
spring return to neutral feature, which provides for line flow, the oil filter should have a by-pass feature.
open flow from the pressure ports of the winch to the
reservoir in neutral position of the control (motor spool).
It is important to point out that good speed control,
USE OF AN E STOP:
(FOR EUROPEAN MACHINERY DIRECTIVE APPLICATIONS)
especially when lowering a load, depends on the
"metering" The use of an E stop (emergency) is mandatory in the
controls circuit. The E stop is to be placed in the
operator's control panel. The E stop must be designed
and placed in line with EN 60204 and EN 418.
313 REV.021028 PAGE 7

PERFORMANCE GRAPHS
FOR STANDARD GEAR MOTOR
PG-HL25-86-A
LINE PULL - kN
0 22 44 67 89 111
2500 UM 172
UM
DR
L DR
2000 138
OIL PRESSURE - bar

OIL PRESSURE - psi
RE
UM
FUL
BA
DR
L L UM
FU E DR
1500 AR 103
B
1000 69
500 34
0 0
0 5000 10000 15000 20000 25000
LINE PULL - lb
HOISTING
LINE SPEED VS. OIL VOLUME HIGH SPEED HOISTING
AND LOWERING
LINE SPEED - m/min
0 30 61 91 122 152 183 213 244 274 294
115 435
100 378
M
M
RUM
U
DR
DR
RE RU
M
ED
LL
BA LD
OIL VOLUME - l/min
80 L 302
FU
FU
BAR
60 227
40 151
20 76
0 0
0 100 200 300 400 500 600 700 800 900 965
LINE SPEED - fpm
Performance graphs are based on standard hydraulic motor, gear ratio and cable drum with
7/8 inch diameter wire rope.
PAGE 8 313 REV.970901

PERFORMANCE GRAPHS
FOR STANDARD PISTON MOTOR
PG-HL25-129-A
LINE PULL - kN
0 22 44 67 89 111
3800 262
M
UM
RU
L DR
3040 209
ED
OIL PRESSURE - bar

OIL PRESSURE - psi
BAR
FUL
UM
DR M
L RU
FUL ED
2280 R 157
BA
1520 105
760 52
0 0
0 5000 10000 15000 20000 25000
LINE PULL - lb
HOISTING
LINE SPEED VS. OIL VOLUME HIGH SPEED HOISTING

AND LOWERING
LINE SPEED - m/min
0 30 61 91 122 152 183 213 244 274 294
61 231
M
50 UM 189
U
UM
DR
DR
E DR
OIL VOLUME - l/min

RE UM
LL
BA DR
LL
FU
FU
BAR
40 151
30 113
20 76
10 38
0 0
0 100 200 300 400 500 600 700 800 900 965
LINE SPEED - fpm
Performance graphs are based on standard hydraulic motor, gear ratio and cable drum with
7/8 inch diameter wire rope.
313 REV.970901 PAGE 9

TYPICAL HYDRAULIC CIRCUIT
GEAR MOTOR
HC-HL25-D
PRESSURE REDUCING
VALVE - FACTORY
PRESET 250 PSI
[17 BAR]
FAST FORWARD
CONTROL VALVE
400 PSI [28 BAR]

PRESSURE REQUIRED
FOR MODELS SUPPLIED
WITH FREESPOOL OPTION
800 PSI [55 BAR]
2(US)GPM [8 L/MIN]
REQUIRED FOR MODELS
CIRCULATION RETURN LINE
BRAKE RELEASE OPTION
(MUST GO DIRECT
TO RESERVOIR)
CIRCULATION SUPPLY
LINE 7 (US) GPM
[26 L/MIN]
CONTROL VALVE
(MOTOR SPOOL)
4-WAY SPRING
RETURN TO CENTER
PRESSURE
RELIEF VALVE
FILTER
HYDRAULIC
PUMP
RESERVOIR
PAGE 10 313 REV.010201

TYPICAL HYDRAULIC CIRCUIT
PISTON MOTOR
HC-HL25-129-C
PRESSURE REDUCING
VALVE - FACTORY
PRESET 250 PSI
[17 bar]
FAST FORWARD
CONTROL VALVE
3.5 TO 4(US) gpm

[13 TO 15 l/min]
400 PSI [28 BAR]

PRESSURE REQUIRED
FOR MODELS SUPPLIED
WITH FREESPOOL OPTION 7 (US) gpm 800 PSI [55 BAR]
2(US)GPM [8 L/MIN]
26 l/min REQUIRED FOR MODELS
CIRCULATION RETURN LINE BRAKE RELEASE OPTION
(MUST GO DIRECT
TO TO
TO RESERVOIR) FORWARD REVERSE
PORT PORT
CIRCULATION
SUPPLY LINE
CONTROL VALVE
(MOTOR SPOOL)
4-WAY SPRING
RETURN TO CENTER
PRESSURE
RELIEF VALVE
FILTER
HYDRAULIC
PUMP
RESERVOIR
313 REV.010201 PAGE 11

INSTALLATION INSTRUCTIONS
DANGER
FAILURE TO FOLLOW INSTALLATION INSTRUCTIONS WILL
The initial installation or mounting of a PULLMASTER planetary winch is critically important for proper operation
and performance. If the winch is mounted to an uneven surface, the centre line of the unit can be distorted to a
point where the winch will not operate in either direction. It is therefore very important that the following
instructions are observed when a PULLMASTER planetary winch is installed:
1) Make certain that the mounting platform is sufficiently strong in order to avoid deflection when a load is lifted.
2) Set the winch on the mounting platform and check for surface contact on all mounting pads of the winch.
3) If there is a space between the mounting surface and one of the mounting pads, the mounting surface is not
even and the space below the mounting pad must be shimmed. If this condition exists, proceed as follows:
a) Install mounting bolts snug tight on the three mounting pads which are in contact with the mounting
surface. (For mounting bolt size and grade see INSTALLATION DIMENSIONS.)
b) Measure the space underneath the fourth mounting pad with a feeler gauge and use shim stock of
equivalent thickness in the space between the mounting pad and the mounting surface.
c) Only after this procedure should the fourth mounting bolt be installed. Tighten all four bolts per BOLT
TORQUE CHART.
4) Fill the winch with lubricating oil. (See APPENDIX A for oil volume required.)
5) Use recommended circuit components and hydraulic hoses.
6) The circulation return line of the winch should be plumbed in such a manner that the brake housing remains
full of oil at all times. Connect the return line directly to reservoir. Do not connect to a common return line.
7) Before operating the winch with a load, verify adequate circulation flow through the circulation return line as
stated in TYPICAL HYDRAULIC CIRCUIT. Verify that pressure measured at the circulation supply port does
not exceed the permissible pressure stated in SPECIFICATIONS. Ensure there is no back pressure at
pressure reducing valve tank port.
8) Verify that breather relief, item 130, is above oil level on end cover, item 120. Rotate end cover if breather
relief is below oil level.
IMPORTANT: Do not replace breather relief with a pipe plug. The breather relief does not prevent oil seal
failure but serves as an indicator or warning that the oil seals between brake housing and the
cable drum interior have failed and must be replaced immediately. If these oil seals are
changed, additional failure of the drum seal and potential damage to the end cover is
prevented.
9) Ensure brake housing and clutch housing are full of oil at all times.
PAGE 12 313 REV.970901

OPERATING INSTRUCTIONS
DANGER
FAILURE TO FOLLOW OPERATING INSTRUCTIONS WILL
After the PULLMASTER planetary winch has been installed in accordance with the INSTALLATION
INSTRUCTIONS, the wire rope can be fastened to the cable drum.
IMPORTANT: The ropes, chains, slings, etc. are not part of the winch and are not covered by this manual.
Refer to manufacturer’s handling, inspection and maintenance recommendations to avoid
potential accidents. For selection of ropes, etc. please check following product standards:
DIN 15020, prEN818-1/9, prEN 1492-1/2, prEN 1677-1/3 and other relevant product standards.
1) The cable drum of the PULLMASTER planetary winch has two cable anchor slots, one for clockwise and one
for counterclockwise hoisting. Standard rotation for hoisting is clockwise when looking at the hydraulic motor
of the unit. It is critical to select the cable anchor slot which will permit winding of the wire rope on the drum
in the correct direction of rotation. If the wire rope is wound on the cable drum in the wrong direction of rotation,
the winch will have no braking capacity. Each winch is shipped from the factory with a label on the drum
indicating the correct cable anchor slot. SI1013 - HL25
WIRE ROPE INSTALLATION CABLE ANCHOR
Clockwise hoisting winch shown. CABLE ANCHOR SLOT
(Use cable anchor slot on opposite side of
drum for counterclockwise hoisting winch.)
Feed the wire rope through the cable

anchor slot. Loop rope back into slot
as shown. Insert cable anchor into
slot, small end first and long side
nearest the drum flange. Pull rope
tight to wedge rope in slot.
2) On wire rope installation, care must be taken that the wire rope is wrapped completely around the cable
anchor and properly pulled into the cable anchor slot in the cable drum. The cable drum requires 5 wraps
of wire rope for safety.
3) The winch operation is controlled by a single control valve lever which has a forward, a reverse and a neutral
position. Speed control in either direction is obtained by modulation of the control valve lever. Maximum line
speed in either direction is obtained when the control valve lever is moved as far as it can go. The disc brake
of the winch will come on automatically when the winch control lever is returned to neutral.
4) Always warm up equipment prior to operating winch, particularly in low ambient temperature. Circulate
hydraulic oil through the winch control valve for several minutes to warm the hydraulic system. To prime the
winch with warm oil, operate the winch at slow speed, forward and reverse, several times.
5) Prevent corrosion damage to winch interior. If not used regularly, run winch up and down at least once every
two weeks.
6) To ensure proper winch installation and function, raise and lower a full test load to a safe height before using
winch for regular operation at the start of each shift.
If, after a new installation, the winch does not function properly, refer to the TROUBLESHOOTING section
of this manual.
313 REV.051117 PAGE 13

TROUBLE SHOOTING
GENERAL:
In most cases, when the hydraulic winch does not perform satisfactorily, the cause of malfunction is found
somewhere in the hydraulic circuit. Before the winch is removed from its mounting and disassembled, all
hydraulic circuit components should be checked for proper function. Make certain hydraulic reservoir is filled to
top level. If the pump is drive by v-belts, check for belt slippage.
IMPORTANT:
The hydraulic operating volume relates to the line speed or rpm of the winch.
Therefore, if the winch does not produce the specified maximum rated line speed or drum rpm, install a flow
meter into the hydraulic circuit to check the volume supplied to the pressure port of the hydraulic winch motor
when the winch control is completely opened. The flow meter should indicate the maximum operating volume.
If this test indicates a loss of hydraulic flow, check the hydraulic pump, the relief valve and the control valve.
The hydraulic operating pressure relates to the line pull or lifting capacity of the winch.
If the winch will not lift the specified maximum line pull, install a pressure gauge into the pressure line leading
to the hoisting port on the hydraulic winch motor. Stall the winch to prevent rotation of the drum and then open
the control valve. Check the hydraulic pressure reading of the installed pressure gauge. If the pressure reads
below the specified maximum operating pressure, look for trouble in the hydraulic pump, the relief valve and
the control valve.
Only if the hydraulic system has been checked and found to be in order, use the following indications for
probable causes of failure in the winch:

Winch will not produce line pull at maximum a) Winch is mounted to an uneven surface.
pressure as listed in SPECIFICATIONS. (See INSTALLATION INSTRUCTIONS.)
d) Excessive back pressure in the hydraulic system.
e) Relief valve may be set too low. (See SPECIFICATIONS
for maximum operating pressure.)
f) Winch is in high speed mode.
Winch will not produce line speed at maximum a) Winch is mounted to an uneven surface.
volume as listed in SPECIFICATIONS. (See INSTALLATION INSTRUCTIONS.)
c) Damage or wear in the hydraulic motor
d) Excessive back pressure in the hydraulic circuit.
Winch will not reverse. a) Leakage out of the brake piston prevents the brake
from being released against the brake springs. This is
caused by damaged O-ring seals on the brake piston.
b) The O-ring seals, on the brake release channel between
the motor adaptor, clutch housing or brake housing is
damaged. If this failure occurs there will be leakage either
from the motor adaptor, clutch housing or brake housing.
c) Insufficient hydraulic pressure. (See SPECIFICATIONS
for minimum operating pressure.)
d) Winch is mounted to an uneven surface.
(See INSTALLATION INSTRUCTIONS.)
e) Hydraulic pressure is not reaching the brake piston
(plugged brake release passage in the brake housing).
PAGE 14 313 REV.970317

TROUBLE SHOOTING CONTINUED
Clutch will not engage (will not shift into rapid a) Loss of clutch release pressure. Check pressure
forward speed). reducing valve and O-rings.
b) Seized clutch piston caused by contamination in oil supply.
c) Incorrect hydraulic connections. Refer to TYPICAL
HYDRAULIC CIRCUITS.
Brake will not hold. a) Brake plates or divider plates have been damaged by
contamination in the hydraulic fluid, or lack of circulation
flow in the brake housing.
b) Brake piston is seized in the brake housing because of
contamination in the hydraulic fluid.
c) Excessive back pressure in the return line causes the
brake to release.
d) Control valve has incorrect spool, which traps hydraulic
pressure in the brake piston when the control valve handle
is returned to neutral position. For proper function of the
automatic brake, both pressure ports of the winch must be
open to the reservoir in neutral position of the control valve.
e) Wire rope is fastened to the incorrect cable anchor slot.
f) Sprag clutch is damaged or surfaces where sprag
clutch engages on motor drive shaft or brake hub are
worn or indented.
g) Winch supplied with external brake release option is
not plumbed per HYDRAULIC CIRCUIT. Failure to
vent external brake release port to reservoir may trap
pressure and cause winch brake to slip.
Brake vibrates when lowering a load. a) Pump is too slow. Pump rpm must be maintained at
normal operating speed when a load is lowered.
b) Brake is running too hot. This is caused by a complete
lack of, or insufficient circulation flow. To check the
circulation, observe the flow of oil from the circulation
return line of the winch. (See TYPICAL HYDRAULIC
CIRCUIT when the winch is reversed.)
c) Control valve has poor metering characteristics.
d) Damaged brake plates or divider plates.
e) The sprag clutch, which connects the motor shaft with
the brake assembly, is damaged.
f) Air mixed with hydraulic oil (foamy oil).
Oil leaks. a) Oil leaks from the hydraulic motor flange and the motor
adaptor are caused by damaged O-ring seals.
b) Oil leaks occurring between the cable drum flanges and
housings are caused by excessive pressure in the brake
housing. Excessive pressure will damage the oil seal which
separates the brake housing from the cable drum interior.
c) If the breather relief on the end cover leaks, the seal
between the drum interior and the brake housing is
damaged and must be replaced. This condition is
caused by excessive pressure in the brake housing of
the winch, operation with the incorrect hydraulic fluid
during cold weather, or a restriction in the circulation
return line leading back to reservoir.
Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Model HL25 winch.
313 REV.970317 PAGE 15

SERVICE INSTRUCTIONS
GENERAL:
Before attempting disassembly of the PULLMASTER Model HL25 planetary winch, the following instructions for
disassembly and reassembly should be read and understood:
It is suggested that all expendable parts, such as O-rings and oil seals, are not reused on reassembly. Because
the following service instructions cover the HL25 planetary winch with either a gear motor or a piston motor, verify
the proper seal kits are on hand before disassembly. For models with a gear motor, use seal kit (Part No. 23120)
and, providing the hydraulic motor has to be serviced, seal kit (Part No. 23117). Two new roller bearings, item
875, may also be required (Part No. 25352). For models with a piston motor, use seal kit (Part No. 23140).
NOTE: Backup washers may be included with seal kit. Install with oil seals as per instructions. If not present
in seal kit, the oil seals supplied do not require backup washers.
A clean working area is of prime importance, similar to conditions used for service work on any other hydraulic
component.
All parts, as they are removed from the winch assembly, should be inspected for wear and damage. Worn or
damaged parts must be replaced. Thoroughly clean parts before reassembly. Do not use solvent to clean the
brake or clutch friction plates.
During reassembly, lubricate all O-rings and oil seals with grease before installation.
In the following service instructions, reference to parts is made by numbers and shown on the applicable group
drawings. The service instructions cover assembly and disassembly of Model HL25 with either hydraulic gear
or piston motors. Refer to appropriate instructions and group drawing for each motor. The remaining instructions
apply to all Model HL25s.
DISASSEMBLY
For the majority of required service or repair work, disassembly is required only in the brake housing or clutch
housing of the PULLMASTER Model HL25 planetary winch. There are no special tools needed for the service
or repair work and no adjustments or calibrations are necessary. Proceed with the disassembly as follows:
DISASSEMBLY OF HYDRAULIC GEAR MOTOR ASSEMBLY:

If the analysed service or repair work requires access to the interior of the brake housing or clutch housing, the
hydraulic gear motor should not be disassembled. In this case, the hydraulic motor should be removed together
with the motor adaptor as a complete assembly. If a problem has been analysed to be in the hydraulic motor,
proceed with the disassembly as follows:
1) Remove two socket head capscrews, item 849, and lockwashers, item 847, from transfer tube housing, item
846. Remove transfer tube housing from end cover, item 870. Remove and discard O-ring, item 112. If
pressure reducing valve, item 841, is faulty, replace at this time.
2) Press slotted spring pins, item 848, partially out of transfer tube housing, item 846, to release tube locator,
item 848. Remove and discard O-ring, item 113.
3) Remove transfer tube assembly, item 844, from center of motor drive gear, which is part of gear set, item
881. Remove and discard O-ring, item 879.
4) Remove eight hex capscrews, item 951, together with lockwashers, item 953, from motor assembly.
IMPORTANT: Failure to exercise care when removing motor port end cover or gear housing could
permanently damage machined surfaces of these motor components. Take care not
to damage machined surfaces of motor components at disassembly.
5) Remove (pry loose if necessary) port end cover, item 870, together with bearings, item 875, and ring seal,
item 877. Thrust plate, item 885, and dowel pins, item 865, may stay in gear housing.
PAGE 16 313 REV.970901

6) If thrust plate comes off with end cover, carefully pry it off of bearings, item 875, and discard teflon seals,
item 887.
7) Remove gear set, item 881, which consists of two gears which are a matched set.
8) Carefully pry gear housing, item 861, off of motor adaptor, item 800. Thrust plate, item 885, and dowel pins,
item 865, may stay in gear housing.
9) If thrust plate stays on motor adaptor, carefully pry it off of bearings, item 875, and discard teflon seals, item 887.
10) Discard gasket seals, item 869. It is also advisable to replace ring seals, item 877, at this time. Bearings, item
875, have to be removed to allow access to ring seals.
Teflon seals, gasket seals and ring seals in the hydraulic motor assembly are not part of winch seal kit. Seal kit
for hydraulic motor can be ordered from factory under Part No. 23117. All parts of the hydraulic motor, with
exception of motor adaptor, item 800, and port end cover, item 870, are standard parts of the hydraulic motor,
having a 3 inch gear section. All of these parts can be ordered from PULLMASTER or Authorized Distributors/
Dealers in Canada, the United States and in most overseas areas.
REMOVAL OF HYDRAULIC GEAR MOTOR ASSEMBLY:

If disassembly of the hydraulic gear motor is not necessary, proceed as follows:
1) Remove transfer tube assembly, item 844, as instructed in step 1 - 3 under DISASSEMBLY OF HYDRAULIC
GEAR MOTOR ASSEMBLY.
2) Remove nine hex head capscrews, item 931, with lockwashers, item 541, and remove motor adaptor, item
800, from clutch housing, item 650.
3) Remove and discard three O-rings, item 801, from flange of motor adaptor.
REMOVAL OF HYDRAULIC PISTON MOTOR:

If fitted with a piston motor, proceed as follows:
1) Remove brake tube assembly, item 852, from motor and motor adaptor, item 800.
2) Remove four hex head capscrews, item 815, and lockwashers, item 817, from motor, item 850. Pull motor
out of motor adaptor, item 800, and discard O-ring, item 819.
3) Remove nine hex head capscrews, item 931, with lockwashers, item 933. Remove motor adaptor, item 800,
and discard three O-rings, item 801.
4) Unscrew six socket head capscrews, item 687, with lockwashers, item 685, and remove bearing carrier, item
664, from motor adaptor. Discard, O-ring, item 667. Remove two seal rings, item 666.
5) Remove clutch connector, item 668, from bearing carrier, item 664, and check that oil passages are clear.
6) Inspect ball bearing, item 665, for damage. If replacement is required, press out of bearing carrier, item 664.
7) Inspect needle bearing, item 669, in motor adaptor. If damaged, press out of motor adaptor and replace.
DISASSEMBLY OF CLUTCH ASSEMBLY:

1) Remove three socket head capscrews, item 682, and lockwashers, item 683, from clutch housing, item 650.
Since brake springs, item 752, apply pressure against inside of clutch housing, it is recommended that these
three capscrews are unscrewed, one turn at a time, until spring pressure has been released. Remove and
discard O-ring, item 707, and O-ring, item 651. Remove and discard three O-rings, item 763.
2) Pull motor drive shaft, item 730, and complete clutch assembly, from brake housing.
3) Disassemble clutch assembly by removing circlip, item 671, from clutch hub, item 670. Remove clutch plate,
item 654, external retaining ring, item 658, eight friction plates, item 673, and seven divider plates, item 675.
313 REV.010201 PAGE 17

Clamp clutch hub, item 670, to pressure plate, item 652, and remove circlip, item 679. Remove clutch hub, three
clutch springs, item 676, pressure plate, item 652, and gland, item 656, from motor drive shaft. Remove and
discard O-rings, item 653, 657 and 735.
Models with piston motors only: Discard two O-rings, item 689.
4) The surface of motor drive shaft which engages sprag clutch, item 672, should be inspected for wear or
indentations. If motor drive shaft shows any surface damage, it should be replaced.
5) Inspect three clutch springs for damage and measure overall length. Overall spring length should be 1.25
inch. If any spring measures less than 1.19 inch, all three springs should be replaced as a set.
6) Inspect eight friction plates, item 673, for damage or excessive wear. Plates should be flat and smooth. Plates
should not show heat discoloration. Paper material on friction plates should be intact and grooved. If any
damage is detected, replace friction plates and divider plates as a set.
7) Remove circlip, item 661, and slide drive gear, item 660, off of connecting shaft, item 600.
DISASSEMBLY OF BRAKE HOUSING ASSEMBLY:

1) Remove 18 brake springs, item 752, from brake piston, item 750. Thoroughly examine springs for damage
and measure overall length. Overall spring length should be 2.27 inch. If any spring measures less than 2.21
inch, replace all springs as a set.
2) Pull brake piston, item 750, out of brake housing using two 5/8-11NC bolts screwed into two puller holes in
piston and discard O-rings, item 751 and 753.
3) Thoroughly examine inner bores of brake housing and outer diameters of brake piston for scoring caused by
hydraulic fluid contamination. Minor surface damage may be repaired by polishing with a fine emery cloth.
DANGER
DAMAGED FRICTION OR DIVIDER PLATES WILL REDUCE BRAKING
CAPACITY AND ALLOW THE LOAD TO DROP, CAUSING PROPERTY
DAMAGE, SEVERE INJURY OR DEATH. SOLVENT MAY DAMAGE THE
FRICTION PLATES. DO NOT USE SOLVENT TO CLEAN THE FRICTION
PLATES. PERFORM THOROUGH INSPECTION AND, IF NECESSARY,
REPLACE FRICTION AND DIVIDER PLATES AS A SET.
4) Remove five friction plates, item 715, together with six divider plates, item 713, and inspect for damage or
wear. Plates should be flat and smooth. Plates should not show heat discoloration. Paper material on friction
plates should be intact and grooved. If any damage is detected, replace friction and divider plates as a set.
5) Remove brake spacer, item 712.
DISASSEMBLY OF FINAL DRIVE:

1) Remove drain plug, item 121, from end cover, item 120, and drain lubricating oil from final drive assembly
and the cable drum interior. (To drain all oil out of cable drum interior, winch should be tipped to an angle and
filler plug, item 503, removed.)
2) Remove internal retaining ring, item 124, and pull end cover, item 120, out of final drive housing, item 100.
3) Discard O-ring, item 123, and inspect planet hub stopper, item 126, and sungear stopper, item 122, for
excessive wear. Replace planet hub stopper if less than .30 inch and sungear stopper if less than .21 inch thick.
4) Remove final planet hub assembly from final housing, item 100.
PAGE 18 313 REV.970901

5) Inspect three final planet gears, item 320, for damage or wear. If necessary to remove final planet gears,
remove circlip, item 311, and press planet pin, item 310, out of planet hub, item 300. Inspect loose rollers,
item 323, and two thrust washers, item 321, and replace if damaged.
DISASSEMBLY OF PRIMARY DRIVE AND CABLE DRUM ASSEMBLY:

For ease of working on remainder of unit, set winch upright on final drive housing.
1) Remove the two winch base halves, item 550 and 552, by removing the 28 hex capscrews, item 551, and
lockwashers, item 553.
2) Remove access plug, item 734, using a 1/2-13NC bolt (motor adaptor bolt, item 821, is suitable), from inside
brake housing and discard O-ring, item 735.
3) Remove six hex capscrews, item 537, with lockwashers, item 541, from bearing flange, item 530, by rotating
brake housing until access hole is over top.
4) Lift brake housing, together with the bearing flange and primary planet hub assembly, out of cable drum, item
500, and discard O-ring, item 539.
5) Remove retaining ring, item 401, and remove primary planet hub assembly from inside internal gear, item 430.
6) Inspect three primary planet gears, item 420, for damage or wear. If necessary to remove primary planet
gears, remove circlip, item 411, and press planet pin, item 410, out of planet hub, item 400. Inspect loose
rollers, item 423, and two thrust washers, item 421, and replace if damaged.
7) Remove primary sungear, item 440, from center of connecting shaft, item 600.
8) Remove circlip, item 431, and internal gear, item 430, from connecting shaft spline.
9) Remove and inspect two thrust washers, item 433, and thrust bearing, item 435. Replace if cracked or
otherwise damaged.
10) Connecting shaft, item 600, can now be pulled out of brake housing. Remove and inspect two thrust washers,
item 615, and thrust bearing, item 617. Replace if cracked or otherwise damaged.
11) Remove sprag clutch aligner, item 677, and sprag clutch, item 672, from connecting shaft, item 600.
12) Remove needle bearing, item 603, inspect and replace if damaged.
13) Remove and discard oil seal, item 607, and if present, backup washer, item 606, from inside of connecting shaft.
14) Remove sprag clutch aligner, item 722, from outside of connecting shaft. Remove brake hub, item 720, sprag
clutch, item 723, and sprag clutch aligner, item 724. Thoroughly inspect surfaces where sprag clutches ride
on and in connecting shaft. If damaged or indented, connecting shaft must be replaced.
DANGER
MINOR SURFACE DEFECTS WHERE THE SPRAG CLUTCH ENGAGES THE
CONNECTING SHAFT AND BRAKE HUB, WILL RESULT IN BRAKE
FAILURE AND ALLOW THE LOAD TO DROP, CAUSING PROPERTY
DAMAGE, SEVERE INJURY OR DEATH. THOROUGHLY INSPECT
THESE AREAS AND, IF NECESSARY, REPLACE BRAKE HUB,
SPRAG CLUTCH AND CONNECTING SHAFT AS A SET.
313 REV.970901 PAGE 19

15) Remove and discard oil seal, item 711, and if present, backup washer, item 710, from bore of brake housing.
Inspect two needle bearings, item 605, and replace if necessary.
16) To separate bearing flange, item 530, and brake housing, item 700, use a standard bearing puller or insert
two heel bars in slot between bearing flange and brake housing and pry brake housing out of ball bearing,
item 533.
17) Remove internal retaining ring, item 534, to remove ball bearing, item 533. Remove and discard oil seal, item 531.
REASSEMBLY
Thoroughly clean all parts. Use only new, well-greased O-rings and oil seals. Unless otherwise specified, torque
fasteners per BOLT TORQUE CHART at back of manual.
REASSEMBLY OF FINAL DRIVE:

Reassemble final drive end of winch as follows:
1) Press new, well-greased oil seal, item 105, into final housing, item 100.
2) Press ball bearing, item 103, into final housing and secure with retaining ring, item 104.
3) Press cable drum, item 500, into ball bearing, item 103, and secure with circlip, item 513.
4) Reassemble final planet hub assembly. Use grease to temporarily hold 24 loose rollers, item 323, in bore
of planet gear, item 320. Position thrust washers, item 321, on either side of planet gear and press planet
pin, item 310, into final planet hub, item 300. Retain with circlip, item 311.
5) Insert final planet hub assembly into final housing, item 100. Ensure that final planet hub spline is fully
engaged with cable drum, item 500.
6) Install new, well-greased O-ring, item 123, into end cover, item 120. Verify that planet hub stopper, item 126,
and sungear stopper, item 122, are installed into end cover.
7) Gently insert end cover into final housing, item 100, and fasten with retaining ring, item 124.
REASSEMBLY OF PRIMARY DRIVE:

Turn winch over, resting on end cover with cable drum opening facing up. Reassemble primary drive as follows:
1) Press new, well-greased oil seal, item 531, into bearing flange, item 530. Press ball bearing, item 533, into
bearing flange and secure with retaining ring, item 534.
2) Press bearing flange assembly onto brake housing, item 700, and install new, well-greased O-ring, item 539.
3) Install new, well-greased oil seal, item 607, with backup washer (if included in seal kit), item 606, into
connecting shaft, item 600.
4) Press needle bearing, item 603, into connecting shaft, item 600.
5) If removed, replace two needle bearings, item 605, by pressing into brake housing, item 700. Install new, well-
greased oil seal, item 711, with backup washer (if included in seal kit), item 710, into brake housing.
6) Slide sprag clutch aligner, item 724, onto connecting shaft, item 600, followed by sprag clutch, item 723, and
sprag clutch aligner, item 722. Twist connecting shaft assembly through center of brake hub, item 720, as
shown in BRAKE GROUP drawing.
IMPORTANT: For proper brake function, verify that sprag clutch is installed correctly. When viewed from
motor end, connecting shaft of clockwise hoisting winch must run freely clockwise and lock
in counterclockwise direction.
PAGE 20 313 REV.970317

7) Place thrust bearing, item 617 (held between two thrust washers, item 615), onto sprag clutch aligner, and
against brake hub, item 720.
8) Install connecting shaft, item 600, with brake hub assembly, into bore of brake housing, item 700, and through
oil seal, item 711. Place thrust bearing, item 435 (held between two thrust washers, item 433), onto internal
gear, item 430. Install internal gear onto spline of connecting shaft, item 600, and fasten with circlip, item 431.
9) Reassemble primary planet hub assembly. Use grease to temporarily hold 20 loose rollers, item 423, in bore of
planet gear, item 420. Verify placement of sungear stopper, item 444. Position thrust washers, item 421, on either
side of planet gear and press planet pin, item 410, into final planet hub, item 400. Retain with circlip, item 411.
10) Insert primary sungear, item 440, between three planet gears and insert sungear shaft into connecting shaft,
engaging planet gears with internal gear. Fasten with retaining ring, item 401.
11) Insert final sungear, item 340, into cable drum and engage three planet gears, item 320.
12) Lower brake housing assembly onto cable drum, while engaging spline of final sungear with primary planet
hub, item 400. Line up mounting holes of bearing flange, item 530, with those in cable drum.
13) Rotate brake housing to line up access holes and fasten bearing flange, using six capscrews, item 537, and
lockwashers, item 541.
14) Install new, well-greased O-ring, item 735, into access plug, item 734. Install access plug into access hole
inside brake housing.
15) Attach base halves, item 500 and 552, using 28 capscrews, item 551, and lockwashers, item 553.
REASSEMBLY OF BRAKE HOUSING ASSEMBLY:

Reassemble brake housing assembly as follows:
1) Install brake spacer, item 712, into brake housing.
DANGER
INCORRECT ASSEMBLY OF THE FRICTION PLATE AND DIVIDER PLATE
STACK WILL REDUCE BRAKING CAPACITY AND ALLOW THE LOAD
TO DROP, CAUSING PROPERTY DAMAGE, SEVERE INJURY OR
DEATH. REASSEMBLE PER INSTRUCTIONS.
2) Starting and finishing with a divider plate, alternately install seven divider plates, item 713, and six friction
plates, item 715.
3) Liberally grease O-ring, item 751, and O-ring, item 753, and install on brake piston, item 750.
4) Slide brake piston into brake housing with holes for brake springs facing out of brake housing assembly.
5) Install 18 brake springs, item 752, in brake piston. (Brake piston has 20 holes and two empty holes should
be opposite each other.)
6) Liberally grease three new O-rings, item 763, and install into recesses on clutch housing, item 650. Install
new, well-greased O-ring, item 707, on flange of clutch housing.
7) Using three socket head capscrews, item 682, and high collar lockwashers, item 683, fasten clutch housing,
item 650, to brake housing, item 700. Ensure brake release passage way is to right side below center and
capscrews are at 2 o'clock, 6 o'clock and 10 o'clock positions. Tighten one turn at a time to compress brake
springs, item 752.
8) Install sprag clutch, item 672, and sprag clutch aligner, item 677, into bore of connecting shaft, item 600.
313 REV.970901 PAGE 21

REASSEMBLY OF CLUTCH ASSEMBLY:
Reassemble clutch assembly as follows:
1) Install drive gear, item 660, onto connecting shaft, item 600, and fasten with circlip, item 661.
2) Install new, well-greased O-ring, item 735, into motor drive shaft, item 730.
3) Install new, well-greased O-ring, item 657, into gland, item 656, and install gland onto motor drive shaft.
4) Install new, well-greased O-ring, item 653, into pressure plate, item 652, and install pressure plate onto motor
drive shaft and gland.
5) Install three clutch springs, item 676, into holes in clutch piston, item 670, and install clutch piston onto motor
drive shaft, item 730. While holding clutch springs compressed, install circlip, item 679, which fastens clutch
hub onto motor drive shaft.
6) Starting and finishing with a friction plate, alternately install eight friction plates, item 673, and seven divider
plates, item 675, onto clutch hub, item 670. Install external retaining ring, item 658, into clutch hub. Install
clutch plate, item 654, and fasten with circlip, item 671.
TESTING PROCEDURE: Before clutch assembly is installed into winch, it should be tested for proper
operation. Apply pressure to motor drive shaft and verify friction and divider
plates close tight. Release pressure and verify that plates are loose and run free.
7) Verify circlip, item 727, is on motor drive shaft. Insert end of motor drive shaft into sprag clutch aligner, item
677. Twist motor drive shaft to allow each divider plate to engage with drive gear, item 660.
IMPORTANT: For proper drive function, verify that sprag clutch, item 672, is installed correctly. When
viewed from motor end, motor drive shaft of a clockwise hoisting winch must turn freely
clockwise and lock in counterclockwise direction.
RE-INSTALLATION OF HYDRAULIC PISTON MOTOR:

For models with hydraulic piston motors, proceed as follows:
1) Install two new, well-greased O-rings, item 689, into exposed grooves of motor drive shaft, item 730. Verify
pipe plug, item 663, is installed tightly into end of motor drive shaft.
2) If removed, press ball bearing, item 665, into bearing carrier, item 664.
3) Install clutch connector, item 668, into ball bearing, item 665. Tap tight with a soft-headed hammer if
necessary.
4) Install two seal rings, item 666, onto clutch connector. Notched sides must face each other. Install new, well-
greased O-ring, item 667, into bearing carrier, item 664, and install assembly onto motor adaptor, item 800.
Fasten with six socket head capscrews, item 687, and lockwashers, item 685.
5) Liberally grease three new O-rings, item 801, and install into recesses on motor adaptor, item 800. Install
new, well-greased O-ring, item 707, onto flange of motor adaptor.
6) Install motor adaptor assembly onto clutch housing, item 650. Engage clutch connector, item 666, with clutch
hub, item 670, and fasten with nine hex head capscrews, item 931, and lockwashers, item 541.
7) Install new, well-greased O-ring, item 819, onto hydraulic piston motor, item 850, and install motor into motor
adaptor, item 800. Fasten with four hex head capscrews, item 815, and lockwashers, item 817.
8) Install brake tube assembly, item 852.
PAGE 22 313 REV.970901

REPLACEMENT OF HYDRAULIC GEAR MOTOR ASSEMBLY:
1) Liberally grease three new O-rings, item 801, and install into recesses on motor adaptor, item 800. Install
new, well-greased O-ring, item 707, on flange of motor adaptor.
2) Slide hydraulic motor assembly on splined end of motor drive shaft, item 730, and line up pressure transfer
holes of clutch housing and motor adaptor. Tighten nine capscrews, item 931, and lockwashers, item 541.
REASSEMBLY OF HYDRAULIC GEAR MOTOR:

If the hydraulic gear motor was disassembled, the following procedure should be followed for reassembly:
1) Clean all parts thoroughly before reassembly and apply grease liberally to all seals. Use only new seals (seal
kit Part No. 23117) for hydraulic motor.
2) Install two new teflon seals, item 887, on each thrust plate, item 885. Press one of thrust plates, together with
two teflon seals, onto bearings, item 875, installed in motor adaptor, item 800.
3) Install new, well-greased gasket seal, item 869, on each side of gear housing, item 861. Slide gear housing together
with gasket seals, onto motor adaptor, lined up on two dowel pins. Tap on tight using soft headed hammer.
4) Install gear set, item 881, in gear housing. (Longer gear with internal spline goes into top position.)
5) Press other thrust plate, complete with two new teflon seals, onto bearings installed in port end cover.
6) Install port end cover, item 870, together with two bearings, item 875, and new ring seal, item 877, onto gear
housing, lined up on two dowel pins, item 865. Tap on tight using soft headed hammer. Install and lightly torque
eight hex capscrews, item 951, and lockwashers, item 953, to approximately 50 ft-lb (70 Nm).
7) Plumb winch assembly to a hydraulic supply and torque motor capscrews according to the following procedure:
- Ensure that circulation supply flow is being supplied to the brake housing.
- Run the winch , with no load, in the hoisting direction at reduced speed
(approximately 30% of maximum hydraulic volume).
- With winch running, evenly tighten eight capscrews, item 951, to 200 ft-lb (270 Nm).
- Test motor operation by running winch at full speed in both directions.
IMPORTANT: Before operating the winch, add lubricating oil up to the level of the end cover oil fill port.
(Refer to INSTALLATION INSTRUCTIONS for location of fill port. Refer to APPENDIX A
for oil volume required.)
To ensure proper reassembly, run the winch in both directions without load.
8) Install new, well-greased O-ring, item 879, into transfer tube assembly, item 844. Install transfer tube
assembly through port end cover, item 870, and engage motor drive shaft, item 730.
9) Install new, well-greased O-ring, item 113, into tube locator, item 848, and install tube locator into transfer tube
housing, item 846. Press two slotted spring pins, item 859, which stop tube locator from spinning, into place.
10) Install new, well-greased O-ring, item 112, onto transfer tube housing, item 846. Install transfer tube housing,
with pressure reducing valve, item 841, attached, onto port end cover, item 870. Fasten with two socket head
capscrews, item 849, and high collar lockwashers, item 847.
DANGER
LIFTING A LOAD WITH A NEWLY SERVICED WINCH WILL ENABLE AN
INSTALLATION OR SERVICE PROBLEM TO GO UNDETECTED AND ALLOW THE
LOAD TO DROP CAUSING PROPERTY DAMAGE, SEVERE INJURY OR DEATH. TO
ENSURE PROPER REINSTALLATION, REFER TO PROCEDURES AND TESTS
DESCRIBED IN “INSTALLATION” AND “OPERATING INSTRUCTIONS”.
313 REV.970901 PAGE 23

RECOMMENDED MAINTENANCE
Winch gear train lubricating oil should be changed after the initial six months or 50 hours of operation, whichever
comes first. Lubricating oil should then be changed every 12 months or 500 operating hours, whichever
comes first.
Hydraulic system fluid should be changed at least once every 12 months.
For optimum performance over an extended period of time, the following preventive maintenance service should
be done every 12 months or 500 operating hours (whichever comes first):
1) Disconnect all hydraulic hoses and remove the winch from its mounting.
2) Disassemble the winch as per instructions.
3) Discard and replace all O-rings and oil seals.
4) Clean all parts and inspect for wear and damage as per instructions. Replace worn or damaged
parts as required.
5) Reassemble the winch as per instructions.
6) Follow INSTALLATION and OPERATING INSTRUCTIONS when returning winch to its mounting.
When ordering parts for the PULLMASTER Model HL25 planetary winch, always quote the complete model and
serial number of the unit.
MODEL NO. _______________
SERIAL NO. _______________
PULLMASTER WINCH CORPORATION reserves the right to change specifications and the design of
PULLMASTER planetary winches at any time without prior notice and without incurring any obligations.
PAGE 24 313 REV.980301

ASSEMBLY DRAWING
PISTON MOTOR
G1000-A & G1003-B & G1010-E
313 REV.010201 PAGE 25

PARTS REFERENCE - FINAL DRIVE
100 1 20399 FINAL HOUSING
103 1 25332 BALL BEARING # 6024
104 1 20460 BEARING RETAINER
105 1 25148 OIL SEAL
120 1 21816 END COVER
121 2 25237 PIPE PLUG 3/4 - 14 NPT
123 1 25340 O-RING -281 15" ID 1/8" CS
124 1 20416 RETAINING RING
130 1 20677 BREATHER RELIEF ASSEMBLY
321 6 25167 THRUST WASHER TORRINGTON # TRB 2840
323 72 25297 LOOSE ROLLER TORRINGTON # G613 - Q
340 1 * SUNGEAR
500 1 * CABLE DRUM
502 1 20423 CABLE ANCHOR
503 1 25032 PIPE PLUG 1/2 - 14 NPT
550 1 * BASE
551 28 25346 CAPSCREW - HEXHEAD 5/8 - 11NC X 1.75 GRADE 5
552 1 * BASE
553 28 25359 LOCKWASHER 5/8"
23120 WINCH SEAL KIT FOR MODELS WITH GEAR MOTORS,

CONSISTS OF ITEMS:
105, 123, 531, 539, 607, 651, 653, 657, 659, 707, 711,
735, 751, 753, 763, 801, 837, 839, 845 AND 879
23140 WINCH SEAL KIT FOR MODELS WITH PISTON MOTORS,

CONSISTS OF ITEMS:
105, 123, 531, 539, 607, 651, 653, 657, 659, 667, 689,
707, 711, 735, 751, 753, 763, 801, 819 AND 845
* These parts vary according to drum code. Refer to APPENDIX B.
Refer to PAGE 25 for ASSEMBLY DRAWING - PISTON MOTOR and

PAGE 38 for ASSEMBLY DRAWING - GEAR MOTOR.
PAGE 26 313 REV.970901

FINAL DRIVE GROUP
G1000-A
130 320 124 323 321 313 104 103 105 502 503 500 343
311
310
126
340
122
513
120
300
121
123
100
553 551 550 552
Groups drawings may reference more parts than are actually present in a specific assembly. Parts that are
referenced on the drawing but are not on the PARTS REFERENCE list should be ignored.
313 REV.970317 PAGE 27

PARTS REFERENCE - BRAKE GROUP
411 3 25004 CIRCLIP ROTOR CLIP C-87
423 60 25270 LOOSE ROLLER 5/32 X 1.25 TORRINGTON # E151 - Q
430 1 20411 INTERNAL GEAR
433 2 25363 THRUST WASHER TORRINGTON #TRA 6881
435 1 25362 THRUST BEARING TORRINGTON #NTA 6881
440 1 21036 SUNGEAR
530 1 20402 BEARING FLANGE
531 1 25148 OIL SEAL
533 1 25333 BALL BEARING #6026
534 1 20461 BEARING RETAINER
537 6 25081 CAPSCREW - HEX HEAD 1/2 - 13NC X 1.50 GRADE 5
539 1 25109 O-RING - 269 8-3/4 ID 1/8" CS
541 6 25014 LOCKWASHER 1/2"
600 1 21088 CONNECTING SHAFT
603 1 25361 NEEDLE BEARING TORRINGTON #B-3012
605 2 25366 NEEDLE BEARING TORRINGTON #NBH 4812
607 1 26009 OIL SEAL
615 2 25296 THRUST WASHER TORRINGTON #TRB 6074
617 1 25690 THRUST BEARING TORRINGTON #NTA 6074
650 1 21090 CLUTCH HOUSING
651 1 25339 O-RING -278 12" ID 1/8" CS
660 1 21135 DRIVE GEAR
672 1 25303 SPRAG CLUTCH BORG WARNER # 140373 "B"
682 3 21140 CAPSCREW - SOC HEAD 1/2 - 13NC X 4-1/4 LONG GRADE 8
683 3 25161 LOCKWASHER 1/2" HI COLLAR
700 1 20390 BRAKE HOUSING
703 1 25347 PLASTIC CAPLUG 1 NPT THREADED
707 1 25339 O-RING -278 12" ID 1/8" CS
711 1 25933 OIL SEAL
712 1 21125 BRAKE SPACER
715 6 25304 FRICTION PLATE
720 1 21087 BRAKE HUB
723 1 25663 SPRAG CLUTCH
734 1 20422 ACCESS PLUG
735 1 25344 O-RING - 123 1-3/16" ID 3/32" CS
750 1 20397 PISTON
751 1 25343 O-RING -90 DURO -451 11" ID 1/4" CS
752 18 20413 BRAKE SPRING
753 1 25342 O-RING -90 DURO -452 11-1/2" ID 1/4" CS
763 3 25127 O-RING -90 DURO -013 7/16" ID 1/16" CS
Refer to PAGE 26 for winch seal kit and PAGE 25 for ASSEMBLY DRAWING - PISTON MOTOR
or PAGE 38 for ASSEMBLY DRAWING - GEAR MOTOR.
PAGE 28 313 REV.010201

BRAKE GROUP
G1003-B
401 423 413 435 534 605 711 617 606 715 600 751 750 753 763
421 707
411 650
410 752
420 661
400 677
444 672
440 660
431 651
433 682
430 683
710 603
531 724
533 752
539 530 541 537 734 735 700 712 615 722 723 703 713 607 720
Group drawings may reference more parts than are actually present in a specific assembly. Parts that are
313 REV.970317 PAGE 29

PARTS REFERENCE - GEAR MOTOR GROUP
112 1 25694 O-RING -022 1" ID 1/16" CS
113 1 25695 O-RING -015 9/16" ID 1/16" CS
541 9 21139 CAPSCREW - HEX HEAD 1/2 - 13NC X 4-3/4 LONG GRADE 5
652 1 21134 PRESSURE PLATE
653 1 25588 O-RING -126 1-3/8" ID 3/32" CS
654 1 21136 CLUTCH PLATE
656 1 21137 GLAND
657 1 25703 O-RING -153 3-1/2" ID 3/32" CS
670 1 21133 CLUTCH HUB
676 3 20340 CLUTCH SPRING
679 1 25710 CIRCLIP ROTOR CLIP SHR-125
730 1 21131 MOTOR DRIVE SHAFT
731 1 25288 CIRCLIP ROTOR CLIP C-112
735 1 25344 O-RING -123 1-3/16" ID 3/32" CS
801 3 25127 O-RING -90 DURO -013 7/16" ID 1/16" CS
802 1 * *
805 2 25040 PIPE PLUG 1/8
807 1 * *
809 1 * *
813 2 25993 PIPE PLUG 1/4 NPT SOCKET HEAD 'LEVL-SEAL' UNBRAKO
827 3 26276 PLASTIC CAPLUG 3/8 NPT
841 1 25714 PRESSURE REDUCING VALVE
843 1 25715 PIPE ADAPTOR #6 SAE X 1/4 NPT AIRWAY 6401-6-4
844 1 21113 TRANSFER TUBE ASSY (INCLUDES ITEM 867)
845 1 25716 O-RING -906 SAE ORB #06
846 1 21114 TRANSFER TUBE HOUSING
847 2 25298 LOCKWASHER 3/8" HIGH COLLAR
848 1 21115 TUBE LOCATOR
849 2 25772 CAPSCREW - SOCKET HEAD 3/8 - 16NC X 1.00 GRADE 5
859 2 25717 SLOTTED SPRING PIN 1/16" DIA X 1/4 LONG
861 1 25350 GEAR HOUSING
865 4 25356 DOWEL PIN
867 1 25608 LOOSE ROLLER 2.5 MM DIA X 15.8 MM
869 2 25348 GASKET SEAL
870 1 21117 PORT END COVER
875 4 25352 ROLLER BEARING
877 2 25646 RING SEAL
879 1 25018 O-RING -010 1/4" ID 1/16" CS
881 1 25645 GEAR SET
885 2 25644 THRUST PLATE
887 4 25647 TEFLON SEAL
899 2 25993 PIPE PLUG 1/4 NPT SOCKET HEAD "LEVL-SEAL" UNBRAKO
927 1 25031 PIPE PLUG 1/4 NPT
933 9 25014 LOCKWASHER 1/2"
950** 1 * SUB - ASSY MOTOR
951 8 25357 CAPSCREW - HEX HEAD 5/8 X 6.75 GRADE 5
953 8 25325 WASHER
955 2 25559 PLASTIC CAPLUG 2.0" DAEMAR T-21
23117 MOTOR SEAL KIT FOR GEAR MOTOR, CONTAINS ITEMS: 869, 877 AND 887.
LK;
* These part numbers and descriptions vary according to brake code.
Refer to APPENDIX C.
LK;
** ITEM 950 MOTOR SUB-ASSY, CONSISTS OF ITEMS:
800, 802, 803, 804, 805, 807, 809, 846, 848, 849, 859, 861, 865,
869, 870, 875, 877, 881, 885, 887, 899, 929, 951, 953 AND 955.
Refer to PAGE 26 for winch seal kit and PAGE 38 for ASSEMBLY DRAWING.
PAGE 30 313 REV.980301

GEAR MOTOR GROUP
G1007-B
927
950
951
827
953
541
955
931
846
843
849
827
847
845
113
841
848
112
859
899
875
870
869
877
844
865
867
887
879
861
809
881
807
885
801
800
813
802
805
731
671
673
676
653
735
730
727
656
657
670
652
679
675
658
654
313 REV.970901 PAGE 31

PARTS REFERENCE - PISTON MOTOR GROUP
541 9 25014 LOCKWASHER 1/2"
652 1 21635 PRESSURE PLATE
653 1 25588 O-RING -126 1-3/8" ID 3/32" CS
654 1 21136 CLUTCH PLATE
656 1 21137 GLAND
657 1 25703 O-RING -153 3-1/2" ID 3/32" CS
664 1 21568 BEARING CARRIER
665 1 25810 BALL BEARING 065 X 100 X 18 # 6013
666 2 21634 SEAL RING
667 1 25858 O-RING -237 3-3/8 ID 1/8 CS
668 1 21623 CLUTCH CONNECTOR
669 1 25856 NEEDLE BEARING TORRINGTON # NB4012
670 1 21549 CLUTCH HUB
676 3 20340 CLUTCH SPRING
679 1 25710 CIRCLIP ROTOR CLIP SHR-125
685 6 25161 LOCKWASHER 1/2" HI COLLAR
687 6 25424 CAPSCREW - SOCKET HEAD 1/2 - 13NC X 1.50 GRADE 5
689 2 25694 O-RING -022 1" ID 1/16" CS
730 1 21570 MOTOR DRIVE SHAFT
735 1 25344 O-RING -123 1-3/16" ID 3/32" CS
801 3 25127 O-RING -90 DURO -013 7/16" ID 1/16" CS
803 1 25370 PIPE PLUG 1/16 NPT
805 2 25040 PIPE PLUG 1/8
807 1 25040 PIPE PLUG 1/8
815 4 25564 CAPSCREW - HEX HEAD 3/4 - 10NC X 2.00 GRADE 5
817 4 25299 LOCKWASHER 3/4"
819 1 25061 O-RING -163 6" ID 3/32" CS
826 1 25491 PIPE NIPPLE 1/4 NPT AIRWAY 5405-4-4
827 3 26276 PLASTIC CAPLUG 3/8 NPT
828 1 26048 PIPE COUPLING 1/4 NPT AIRWAY 5000-4-4
841 1 25714 PRESSURE REDUCING VALVE
843 1 25715 PIPE ADAPTOR #6 SAE X 1/4 NPT AIRWAY 6401-6-4
845 1 25716 O-RING -906 SAE ORB #06
850 1 23223 MOTOR -129 VOLVO F12-110
852 1 22715 TUBE ASSEMBLY 1/4" OD 1/8 NPT X 1/8 NPT -90L
931 9 21139 CAPSCREW - HEX HEAD 1/2 - 13NC X 4-3/4 LONG
939 1 25040 PIPE PLUG 1/8 NPT
Refer to PAGE 26 for winch seal kit and PAGE 25 for ASSEMBLY DRAWING.
PAGE 32 313 REV.980301

PISTON MOTOR GROUP
G1010-E
939
BRAKE TUBE IS SHOWN FOR
931
OPPOSITE MOTOR PORT.
CW HOISTING. FOR CCW
HOISTING, CONNECT TO
827
541
850
805
815
841
NOTE:
817
827
805
819
852
845
853
843
802
828
807
669
809
826
801
800
685
667
687
666
671
668
658
664
803
675
652
676
653
735
727
730
656
657
670
679
689
673
654
665
313 REV.970901 PAGE 33

PAGE 34
FOR SAFETY: A MINIMUM OF 5 WRAPS OF
BREATHER RELIEF VALVE WIRE ROPE MUST BE MAINTAINED PRESSURIZE FOR P
AT ALL TIMES ! CLOCKWISE
FILLER PORT
3/4-14 NPT ROTATION PRESSURIZE FOR
C D
FILLER PORT CLOCKWISE COUNTER-CLOCKWISE
1/2-14 NPT ROTATION
(LOCATED EITHER
IN CABLE ANCHOR SAE 4-BOLT FLANGE GAGE PORTS OPTIONAL
POCKET OR ON SEE MOTOR CHART 1/4-18 NPT EXTERNAL BRAKE
BARREL) FOR PORT SIZE RELEASE PORT
1/8-27 NPT
B DIA
E L
A DIA
M
N
GEAR MOTOR
FREE SPOOL HIGH SPEED CLUTCH

1.25
PORT [31.8] 4 MOUNTING HOLES 1 9/32 DIA [32.5] PORT 9/16"-18 UNF
1/4-18 NPT USE 1-1/4" MOUNTING BOLT SAE O-RING
GRADE 5 OR BETTERS CIRCULATION SUPPLY DRAIN PORT
CIRCULATION
DRAIN PORT 1.3 RETURN PORT PORT 3/8-18 NPT 9/16"-18 UNF
3/4-14 NPT H c/c SAE O-RING
[32] 1-11 1/2 NPT
R c/c
6.8
G I S
[173]
J
STANDARD CABLE ANCHOR IS
[STANDARD MODELS]
SUITABLE FOR 7/16" - 7/8"
K DIA WIRE ROPE ON 10" DIA

[FREE SPOOL MODELS] DRUM BARREL
313 REV.051117
I1006-1-D
GEAR MOTOR
I1006-2 & I1006-3-A
Dimensions in inches
(Dimensions in millimeters)
DRUM
A B C D E F G H J K M N P R S
-1 10.0 17.0 11.0 11.8 19.9 19.9 21.0 18.500 31.8 34.2 11.38 8.9 20.8 17.750 20.8
(254) (432) (279) (300) (505) (505) (533) (469.90) (808) (869) (289) (225) (527) (450.85) (527)
-2 10.0 24.0 11.0 11.8 24.4 20.9 21.0 18.500 31.8 34.2 12.38 10.0 25.9 22.875 25.9
(254) (610) (279) (300) (619) (530) (533) (469.90) (808) (869) (314) (254) (657) (581.03) (657)
-3 10.0 24.0 17.0 11.8 24.4 20.9 27.0 24.500 37.8 40.2 12.38 10.0 25.9 22.875 25.9
(254) (610) (432) (300) (619) (530) (686) (622.30) (961) (1021) (314) (254) (657) (581.03) (657)
-4 10.0 24.0 22.0 11.8 24.4 20.9 32.0 29.500 42.8 45.2 12.38 10.0 25.9 22.875 25.9
(254) (610) (559) (308) (619) (530) (813) (749.30) (1088) (1148) (314) (254) (657) (581.03) (657)
HYDRAULIC GEAR MOTORS
COMMERCIAL WM76 SERIES COMMERCIAL M365 SERIES
MOTOR GEAR MOTOR PORT SIZE I L MOTOR GEAR MOTOR PORT SIZE I L
CODE WIDTH SAE 4-BOLT FLANGE CODE WIDTH SAE 4-BOLT FLANGE
CODE 61 CODE 61
- 86 3.00 8.9 2.7 - 42 2.50 9.3 2.5

(76.2) (225) (68) (63.5) (236) (64)
2.0
- 87 2.75 8.6 2.7 - 101 2.25 1.5 9.0 2.5
(69.9) (219) (68) (57.2) (229) (64)
- 88 2.50 8.4 2.7 - 102 2.00 8.8 2.5

(63.5) (212) (68) (50.8) (223) (64)
- 89 2.25 1.5 8.1 2.7

(57.2) (206) (68)
- 90 2.00 7.9 2.7

(50.8) (200) (68)
- 91 1.75 7.6 2.7

(44.5) (193) (68)
- 92 1.50 1.25 7.4 2.7

(38.1) (187) (68)
- 93 1.25 7.1 2.7

(31.8) (181) (68)
- 94 1.00 1.00 6.9 2.7

(25.4) (174) (68)
313 REV.970317 PAGE 35

PAGE 36
FOR SAFETY: A MINIMUM OF 3 TO 4 WRAPS OF
WIRE ROPE MUST BE MAINTAINED HIGH-SPEED CLUTCH
CIRCULATION SUPPLY
AT ALL TIMES ! PRESSURE AND DRAIN
PORT 3/8-18 NPT
PORTS 9/16-18 UNF
BREATHER RELIEF VALVE SAE 0-RING
P
C D MOTOR CASE DRAIN

FILLER PORT
(SEE MOTOR CHART FOR DRAIN
3/4-14 NPT FILLER PORT
PORT SIZE) PLUMB UPPERMOST
1/2-14 NPT
DRAIN PORT DIRECT TO TANK. CLOCKWISE
(LOCATED EITHER
IN CABLE ANCHOR
DRAIN LINE MUST ENTER
OPTIONAL
POCKET OR ON RESERVOIR BELOW MINIMUM
EXTERNAL BRAKE
BARREL) FLUID LEVEL. FILL MOTOR
RELEASE PORT
CASE BEFORE START-UP.
1/8-27 NPT
B DIA
L
E A DIA
F T
M
PISTON MOTOR
SAE 4-BOLT FLANGE

SEE MOTOR CHART
1.25 FOR PORT SIZE
[31.8] 4 MOUNTING HOLES 1-9/32 DIA [32.5]
PRESSURIZE FOR
USE 1-1/4" MOUNTING BOLTS CLOCKWISE ROTATION
FREE SPOOL GRADE 5 OR BETTER
PORT PRESSURIZE FOR
1/4-18 NPT COUNTERCLOCKWISE
1.3 CIRCULATION
H c/c ROTATION
[32] RETURN PORT
1-11 1/2 NPT R c/c
DRAIN PORT
6.8
3/4-14 NPT G I S
[173]
J STANDARD CABLE ANCHOR IS

[STANDARD MODELS] SUITABLE FOR 7/16" - 7/8"

DIA WIRE ROPE
K
[FREE SPOOL MODELS]
I1007-1-E
313 REV.010201
PISTON MOTOR
I1007-2-E & I1007-3-E
DRUM
CODE A B C D E F G H J K M N P R S
-1 10.0 17.0 11.0 11.8 19.9 19.9 21.0 18.500 31.8 34.2 11.38 8.9 20.8 17.750 20.8
(254) (432) (279) (300) (505) (505) (533) (469.90) (808) (869) (289) (225) (527) (450.85) (527)
-2 10.0 24.0 11.0 11.8 24.4 20.9 21.0 18.500 31.8 34.2 12.38 10.0 25.9 22.875 25.9
(254) (610) (279) (300) (619) (530) (533) (469.90) (808) (869) (314) (254) (657) (581.03) (657)
-3 10.0 24.0 17.0 11.8 24.4 20.9 27.0 24.500 37.8 40.2 12.38 10.0 25.9 22.875 25.9
(254) (610) (432) (300) (619) (530) ( 686) (622.30) (961) (1021) (314) (254) (657) (581.03) (657)
-4 10.0 24.0 22.0 11.8 24.4 20.9 32.0 29.500 42.8 45.2 12.38 10.0 25.9 22.875 25.9
(254) (610) (559) (308) (619) (530) (813) (749.30) (1088) (1148) (314) (254) (657) (581.03) (657)
HYDRAULIC PISTON MOTOR
VOLVO F SERIES
MOTOR MODEL MOTOR PORT SIZE SCREW DRAIN I L T*

CODE NO. SAE 4-BOLT FLANGE THREAD PORT
-68 F11 11/2" M16 x 2 3

/4" 15.6 4.6 7.8
150 CODE 62 BSP (396) (118) (197)
* -129 F12 11/4" 1

/2"-13 11/16"-12 12.0 3.3 6.7
110 CODE 62 SAE ORB (305) (85) (170)
-130 F11 11/4" M14 x 2 3

/4" 12.9 3.7 6.5
78 CODE 62 BSP (327) (95) (165)
7 7
-166 F12 1" /16"-14 /8"-14 11.1 3.1 6.3
80 CODE 62 SAE ORB (282) (78) (160)
* INCLUDES SANDWICH GAGE BLOCK
* PRIOR TO SERIAL # 52015: -129 Motor was Model F11-110 with 11/4" 4 bolt flange ports with
M14 x 2 screw threads. Drain ports were 3/4" BSP.
313 REV.010201 PAGE 37

ASSEMBLY DRAWING
GEAR MOTOR
G1000-A & G1003-B & G1007-B
PAGE 38 313 REV.010201

APPENDIX A
LOW SPEED HOISTING HIGH SPEED HOISTING & LOWERING
LINE PULL LINE SPEED MAXIMUM LINE SPEED

AT MAXIMUM AT MAXIMUM ALLOWABLE AT MAXIMUM LUBRICATING
CABLE DRUM SIZES WIRE ROPE STORAGE PRESSURE* VOLUME* VOLUME*
OIL
LINE PULL* VOLUME
DRUM INCHES FEET REQUIRED
CODE (MILLIMETERS) (METERS)
POUNDS FEET/MINUTE POUNDS FEET/MINUTE U.S.
GALLON
(KILONEWTONS) (METERS/MINUTE) (KILONEWTONS) (METERS/MINUTE) (LITERS)
BARREL FLANGE LENGTH 3/4 inch 7/8 inch 1 inch BARE FULL BARE FULL BARE FULL BARE FULL
DRUM DRUM DRUM DRUM DRUM DRUM DRUM DRUM
-1 10.0 17.0 11.0 210 140 91 25000 16860 140 207 5357 3613 651 965 2.3
(254) (432) (279) (64) (43) (28) (111.2) (75.0) (43) (63) (23.8) (16.1) (198) (294) (8.7)
-2 10.0 24.0 11.0 515 398 264 25000 11757 140 297 5357 2519 651 1384 2.3
(254) (610) (279) (157) (121) (80) (111.2) (52.3) (43) (90) (23.8) (11.2) (198) (422) (8.7)
-3 10.0 24.0 17.0 796 615 408 25000 11757 140 297 5357 2519 651 1384 3.0
(254) (610) (432) (243) (187) (124) (111.2) (52.3) (43) (90) (23.8) (11.2) (198) (422) (11.3)
-4 10.0 24.0 22.0 1031 796 528 25000 11757 140 297 5357 2519 651 1384 3.6
(254) (610) (559) (314) (243) (161) (111.2) (52.3) (43) (90) (23.8) (11.2) (198) (422) (13.6)
* Performance specifications are based on standard hydraulic motor with 7/8 inch diameter rope.
313 REV.010201 PAGE 39

APPENDIX B
ITEM 340 500 550 / 552
FINAL CABLE
DRUM CODE BASE
SUNGEAR DRUM
-1 20409 20395 20671
-2 20409 20396 20444
-3 20408 20393 20443
-4 20407 20391 20403
PAGE 40 313 REV.970317

APPENDIX C
BRAKE CODE
-7 -8 -9 - 10
ITEM PART
NO. DESCRIPTION
PART NUMBERS
802 SHUTTLE N/A 20849 20849 N/A
1/8-27 NPT
807 PIPE PLUG 25040 N/A N/A 25040
1/8-27 NPT
807 PIPE N/A 25622 25622 N/A
ADAPTOR
1/8 NPT
809 CAPLUG N/A 26276 26276 N/A
MOTOR
950 SUB-ASSY 22054 22055 22056 22057
313 REV.970901 PAGE 41

BOLT TORQUE CHART
BOLT DIAMETER TORQUE TORQUE

Inches lb-ft Nm
1/4 9 12
5/16 18 24
3/8 32 43
7/16 50 68
1/2 75 102
9/16 110 149
5/8 150 203
3/4 265 359
7/8 420 569
1 640 868
1 1/8 800 1085
1 1/4 1000 1356
1 3/8 1200 1627
1 1/2 1500 2034
NOTE: Unless otherwise specified, torque bolts per above chart.
PAGE 42 313 REV.970317

Monobloc and Sectional Directional Control Valves
motion and progress
200 − P − 991210 − E − 03 / 10.04 1/220

HDS30
11 Sectional directional control valves HDS30
Contents
11.1 General specifications 197
11.2 Dimensional data 198
11.3 Performances curves 199
11.4 Inlet covers 201
11.5 End covers 202
11.6 Sectional bodies 203
11.7 Spool charts 204
11.8 Hydraulic circuits 204
11.9 Spool actions 205
11.10 Lever styles 206
11.11 Anti−shock and anti−cavitation valves 208
11.12 Hydraulic−Pneumatic controls ON−OFF 209
11.13 Pneumatic controls 209
11.14 Hydraulic Proportional control 210
11.15 Electro−Hydraulic controls 211
11.16 Solenoids for pilot electrovalves EHI−EHE 213
200 − P − 991210 − E − 03 / 10.04 196/220

HDS30
11.1 General specifications
Technical specification 11.1.2 Material specification:
l/min 120 Body: High strength cast−iron.

Max flow rate
U.S.G.P.M. 31 Spool: Hardened steel − Chrome plated.
Seals: Buna N".
Max continuous operating bar 250
pressure supply port P PSI 3600
Max intermittent peak pres- bar 320 11.1.3 Standard features:
sure Work port A/B PSI 4600
1) Internal load holding check valves (prevent reverse
bar 30 flow through valve when shifting)
Max back pressure
PSI 430 2) Parallel circuit.
°C −10 to +80 3) Balanced interchangeable spools (provides
Oil temperature minimum leakage, smooth operation)
°F 14 to 180
4) Wide selection inlets, work ports, and outlets
Oil viscosity mm2/s 16 to 75 threaded ports.
5) Negative overlapping of the spool.
Oil filtration m p30
Spool leakage at 100 bar (1450 PSI), Temp. 50° C 11.1.4 Optional features available:
(120° F), viscosity 27 mm2/s:
1) Open or closed centre circuit, 3 or 4 way
cm3/min 18 operations, 3 or 4 position (float position), full
Maximum
Cu. In./min 1.281 open centre (motor spool) and other spool
cm3/min 12 options.
Average 2) Carry over.
Cu. In./min 0.854
3) Series connection and priority pressure.
Lower values on demand (to be agreed with our Sales Dept..) 4) Complete lever assembly.
Number of spools 1 to 10 11.1.5 Symbols:
Adjustable direct acting relief valve (tam- P: inlet port

RV T: outlet port
per−proof seal available on request)
A/B: work ports
H.P.C.O.: carry−over
Load hold check valve in each section LC
RV: relief valve
Cartridge anti−shock, anti−cavitation and P1T1: side inlet and outlet
OA−UC−C 3.1.0.2: spool position
service relief valve
P: pressure line
11.1.1 Weight T : exhaust line
E: centre line (by pass).
Version kg lb X: remote control port for RV
Inlet with RV 3.65 8.04

1 spool section 4.12 9.08
End cover standard 2.40 5.29
200 − P − 991210 − E − 03 / 10.04 197/220

HDS30
11.2 Dimensional data
T1
H.P.C.O.
25+5 Nm
P1 A
T P
B
X 1/4" BSP
M10X1.5
Pos.3
Pos.1
Pos.2
RV
(see 11.10)
PRESS PRESS
B B
Pos.2: STROKE − 7 mm. − .28" Pos.2: STROKE − 7.5 mm. − .30"

0 0
Pos.1: STROKE − 7 mm. − .28" Pos.1: STROKE − 7.5 mm. − .30"
Pos.3: STROKE − 12 mm. − .47"
PRESS PRESS
Float A A
Dimensional data shown in mm and inches Ex.: 80 = mm

3.15" = inches
N. of sections 1 2 3 4 5 6 7 8 9 10
144 188 232 276 320 364 408 452 496 540
A
D ension
n
5.67" 7.40" 9.13" 10.86" 12.60" 14.33" 16.06" 17.80" 19.53" 21.26"
Dimen
168 212 256 300 344 388 432 476 520 564
B
6.62" 8.34" 10.08" 11.81" 13.54" 15.28" 17.01" 18.74" 20.47" 22.21"
200 − P − 991210 − E − 03 / 10.04 198/220

HDS30
11.3 Performance curves

11.3.1 Parallel circuit
Oil: Shell Tellus T37

Temperature: 50° C (120° F)
Viscosity: 27 mm2/s
P⇒T P⇒A/B
Pressure drop
Pressure drop
bar PSI bar PSI

U.S.G.P.M. U.S.G.P.M.
l/min l/min
Flow rate
Flow rate
A/B⇒T Metering
Standard Spools P → A/B T 50 bar
A/B → T 50 bar
Pressure drop
Flow rate
A/B → T 150 bar
P → A/B T 150 bar

U.S.G.M.
bar PSI
l/min
U.S.G.P.M. inches
l/min mm
Flow rate Stroke
200 − P − 991210 − E − 03 / 10.04 199/220

HDS30
11.3.2 Series circuit
Oil: Shell Tellus T37

Temperature: 50° C (120° F)
Viscosity: 27 mm2/s
P⇒T A1 ⇒ A2
Spool x
Pressure drop
Pressure drop
bar PSI bar PSI

U.S.G.P.M. U.S.G.P.M.
l/min l/min
Flow rate Flow rate
11.3.3 Transient hydraulic characteristics

Relief Valve RV
Relief valve oscillagram (Q= 31 U.S.G.P.M.)

(Q= 120 l/min.)
Peak
Setting
Pressure setting
PSI Opening Time

bar
U.S.G.P.M.
l/min
Flow rate
200 − P − 991210 − E − 03 / 10.04 200/220

HDS30
11.4 Inlet covers
11.4.1 Right and left standard inlet cover
Port relief valve settings
Pressure set range Setting

Type
bar (PSI) bar (PSI)
30 − 320 150
15
RV (420 − 4600) (2100)
T T
Right inlet cover with P and RV for parallel circuit Left inlet cover with P and RV for series circuit
∅D Type/Code ∅D Type/Code
P P
1" BSP T02* T10*
E T T E 1" BSP
std 200.9316.5001.0 200.9316.5002.0
T T04* T T12*
SAE 16 SAE 16
200.9316.9001.0 200.9316.9002.0
11.4.2 System RV remote control: vent type
P X Code
S ∅D Type/Code
1" BSP T25*

std (right) 200.9316.5010.0
1" BSP T24*

RV 200.9316.5009.0
T T (left)
11.4.3 System RV remote control: electrical type
WE... Normally closed Normally open

P
Code Code
EC EA
RV
T T
Solenoid series mini 12 V. D.C. 24 V. DC. Type/Code

Power consumption (W) 30 20.64 ∅D Without WE... With WEA With WEC
Intensity of current (A) 2.5 0.86 valve valve valve
Resistance (Ω) 4.8 28 1" BSP T22* T26* T26*
ED (%) 60 100 std (right) 200.9316.5007.0 200.9316.5017.0 200.9316.5011.0
Voltage (V. D.C. ±10 %) 24 110 1" BSP T23* T27* T27*
Solenoid code 200.5412.10017 200.5412.20016 (left) 200.9316.5008.0 200.9316.5030.0 200.9316.5012.0
* Group code with RV set at standard pressure (150 bar / 2100 PSI)
200 − P − 991210 − E − 03 / 10.04 201/220

HDS30
11.5 End covers
T
∅D
Plug H.P.C.O.
Carry−over
3/8" DIN 906
T E T
11.5.1 Left outlet cover with T for parallel circuit

(Standard)
∅D Type Code
P
1" BSP std P02 200.9306.5001.0
T E SAE 16 P04 200.9306.9001.0
Ø D Standard 1” BSP
11.5.2 Left outlet cover with T and carry−over H.P.C.O.

H.P.C.O. ∅D Type Code
P 1" BSP std P06 200.9306.5002.0
T E SAE 16 P08 200.9306.9002.0
11.5.3 Right outlet cover with T

(standard on series circuit)
∅D Type Code
P 1" BSP std P10 200.6306.5003.0
E T SAE 16 P12 200.6306.9003.0
11.5.4 Right outlet cover with T and carry−over H.P.C.O.

H.P.C.O. ∅D Type Code
P 1" BSP std P14 200.9306.5004.0
E T SAE16 P16 200.9306.9004.0
200 − P − 991210 − E − 03 / 10.04 202/220

HDS30
11.6 Sectional bodies
11.6.1 Standard circuit: parallel
Type/Code
∅D Section with
Standard valve
UC − OA − C
(UC − OA − C) ∅D
3/4" BSP K02 K06
A B 200.9417.4001.0 200.9417.4011.0
K04 K08
SAE 12
200.9417.9002.0 200.9417.9003.0
cyl. A
cyl. B
T E T
T E P
11.6.2 Optional circuit: series and tandem
Type/Code
∅D Section with
Standard valve
(UC − OA − C) UC − OA − C
∅D
K47 K51
3/4" BSP 200.9417.4003.0 200.9417.4010.0
A B
K49 K53
SAE 12 200.9417.9004.0 200.9417.9005.0
P
cyl. A
cyl. B
T E T
T E
Note: Body code consist of machined casting, seals and hold check valve only. Not to be used for complete valve order.
200 − P − 991210 − E − 03 / 10.04 203/220

HDS30
11.7 Spool charts
Spool scheme Spool features Type 3 way − 3 position

A: blocked S
4 way − 3 position E: open by pass
A/B: blocked A
4 way − 3 position
E: open by pass
A/B: blocked X
4 way − 3 position series connection
A/B: blocked B 4 way − 3 position
E: closed A/B: to tank in neutral XC
4 way − 3 position series connection
A/B to tank in neutral C
E: open by pass 4 way − 4 position
Z
4th float position
4 way − 3 position
A: blocked D 4 way − 3 position
B: to tank in neutral LSA
A/B: blocked
3 way − 3 position Load Sensing **
B: blocked G
4 way − 3 position LSC
E: open by pass
A/B: to tank in neutral
B: blocked L
A: to tank in neutral 3 way − 3 position LSG
B: blocked
with regenerative spool R**
in 2nd pos. 3 way − 3 position LSS
A: blocked
**: special body required Load Sensing **
11.8 Hydraulic circuits
11.8.1 Standard parallel circuit 11.8.3 Optional tandem circuit
P02 K02 − G K02 − C K02 − A T02 T10 K02 − A K47 − A K47 − A P10
P P
T E P P E T
B A B A B T T B A B A B A
11.8.2 Optional series circuit 11.8.4 Combined parallel/series circuit
T10 K02 − X K47 − X K47 − A P10 T10 K02 − X K7 − A K02 − A P10

P P
P E T T
P E
T B A B A B A T B A B A B A
200 − P − 991210 − E − 03 / 10.04 204/220

TESTO ITC KORINNA 28mm Allargato
MONOBLOCK
DIRECTIONAL CONTROL VALVE
SD18
Features
Simple, compact and heavy duty designed monoblock from 1 to 6 sections for open and closed centre hydraulic systems.
H Fitted with a direct or pilot operated main pressure relief valve.
H Parallel circuit.
H Optional carry--over port.
H Diemeter 25 mm -- 0.98 in interchangeable spools.
H A wide variety of service port valves.
H Available manual, pneumatic, electro--pneumatic, hydraulic and electro--hydraulic spool control kits.
Additional information
This catalogue shows the product in the most standard configurations.
Please contact Customer Service Dpt. for more detailed information or
special request.
WARNING!
All specifications of this catalogue refer to the standard product at this date.
Walvoil, oriented to a continuous improvement, reserves the right to
discontinue, modify or revise the specifications, without notice.
WALVOIL IS NOT RESPONSIBLE FOR ANY DAMAGE CAUSED BY AN 5th edition October 2001:
INCORRECT USE OF THE PRODUCT. This edition supercedes all prior documents.
2 DAT006E
SD18
Contents
Contents
Working conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dimensional data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Performance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ordering codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inlet relief options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Spool options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
“A” side spool positioners . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
“B” side options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Proportional hydraulic spool control . . . . . . . . . . . . . . . . . . 24
Port rellief options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Outlet port conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Installation and maintenance . . . . . . . . . . . . . . . . . . . . . . . . 29
DAT006E 3
SD18
Working conditions
This catalogue shows technical specifications and diagrams measured with mineral oil of 46 mm2/s -- 46 cSt viscosity at 40°C tempera-
ture.
Nominal flow rating 160 l/min

Operating pressure (maximum) 250 bar 3620 psi
Max. back pressure on outlet port T 25 bar 360 psi
Dp=100 bar -- 1450 psi
Internal leakage A(B)®T 4 cm3/min 0.24 in 3/min
fluid and valve at 40°C
Hydraulic fluid Mineral oil
Fluid temperature with NBR seals from --20° to 80°C
with FPM (VITON) seals from --20° to 100°C
Viscosity operating range from 15 to 75 mm2/s from 15 to 75 cSt
min. 12 mm2/s 12 cSt
max. 400 mm2/s 400 cSt
Max level of contamination 19/16 -- ISO 4406
Ambient temperature from --40° to 60°C
NOTE -- For different conditions please contact Customer Service.
4 DAT006E
SD18
Dimensional data
92
8.2 3.62
E 4 0.32 70
0.16 2.76
15 F 35
0.59 1.38
Æ 0.41
10.5
0.69
17.5
P
2.05
52
182
7.16
5.98
152
3.07
320
12.6
78
T
97.5
3.84
30.5
1.20
1.77 0.59
45 15
Posit.1
3.03
77
Posit.0
M12
Posit.2
29 60
32 53 53 46 1.14 2.36
1.26 2.09 2.09 1.81 Posit.3
124
4.88
WALVOIL Production batch :

106200034
P0000001
WALVOIL
P0000001 P00 = production year (2000)

106200034 00001 = progressive number
Valve code
E F Weight E F Weight
TYPE TYPE
mm in mm in kg lb mm in mm in kg lb
SD18/1--P 159 6.26 129 5.08 13.2 29.1 SD18/4--P 318 12.5 288 11.3 28.8 63.5
SD18/2--P 212 8.35 182 7.17 18.6 41 SD18/5--P 371 14.6 341 13.4 34.1 75.2
SD18/3--P 265 10.4 235 9.25 23.5 51.8 SD18/6--P 424 16.7 394 15.5 39.4 86.9
Standard threads
BSP UN--UNF
PORT
(ISO 228/1) (ISO 11926--1)
Inlet P and carry--over C G 3/4 1 5/16--12 UN--2B (SAE 16)

A and B ports G 3/4 1 1/16--12 UN--2B (SAE 12)
Outlet T G1 1 5/16--12 UN--2B (SAE 16)
PILOT PORTS
Hydraulic G 1/4 9/16--18 UNF--2B (SAE 6)
Pneumatic NPTF 1/8--27 NPTF 1/8--27
DAT006E 5
SD18
Hydraulic circuit
A side spool positioner
Load check valve

Allen wrench 8 ”A” port line
24 Nm / 17.7 lbft ”B” port line
A
T
B P Tank line
Open centre plug

Pressure line Allen wrench 12
42 Nm / 31 lbft
Free line
Spool
Lever box
Pressure relief valve
Standard configuration Upper inlet and outlet ports configuration

P
T
A1 B1 A2 B2 A1 B1 A2 B2
120 120
1750 1750
Ex.: SD18/2--P(KG3--120)/18L/18L/AET Ex.: SD18/2--P(KG3--120)/18L/18L/AET--PSA
6 DAT006E
SD18
Performance data (pressure drop vs. flow)
Open centre
From side inlet to side outlet.
40
(bar) 540
(psi)
30
A1 A2 A3 A4 A5 A6
6 sections
Pressure drop
360
T
P 20 4 sections
B1 B2 B3 B4 B5 B6 2 sections
180
10
0
0 50 100 150 200
Flow (l/min)
Inlet to work port

From side inlet to A port (spool in position 1) or B port (spool in position 2).
40
(bar) 540
(psi)
30
A1 A2 A3 A4 A5 A6
Pressure drop
360
T
P 20 P®A6(B6)
B1 B2 B3 B4 B5 B6
P®A1(B1) 180
10
0
0 50 100 150 200
Flow (l/min)
Work port to outlet

From A port (spool in position 2) or B port (spool in position 1) to side outlet.
40
(bar) 540
(psi)
30
A1 A2 A3 A4 A5 A6
Pressure drop
360
T A1(B1)®T
P 20
B1 B2 B3 B4 B5 B6 A6(B6)®T
180
10
0
0 50 100 150 200
Flow (l/min)
NOTE -- Measured with spool type 1.
DAT006E 7
SD18
Ordering codes
Pressure relief valve setting in bar 1st section following section
Ex.: SD18/ 2 -- P (KG3 - 120) / 1 8 L / 1C 8IM . P3(G3 - 120) / AET - PSA *
1. 2. 3. 4. 5. 6. 7. 8. 9.
Port relief valve setting in bar
4.
1. Body kits *
TYPE CODE DESCRIPTION 8--11--15-- 6. 7.
Without service port valves prearrangement 16--19--20
1-- P 5KC1713000 1 section J 8IM P
2-- P 5KC1723000 2 sections
5-- P 5KC1783000 5 sections 9B--10B--11B
Include body, seals, rings and load check valve.
2. Inlet relief options page 10 PSL

TYPE CODE DESCRIPTION 8P
VMD20/1 direct pressure relief valve type K (standard) I 9.
(KG2-- 80) 5KIT120112 Range 25 to 80 bar / 360 to 1150 psi
standard setting 80 bar / 1150 psi
standard setting 120 bar / 1750 psi 8EP3
VMP20/1 pilot operated pressure relief valve type X
(XG-- 120) X007211120 Range 63 to 250 bar / 900 to 3600 psi
Standard setting is referred to 10 l/min flow.
SV 3XTAP535410 Relief valve blanking plug

8EI3 PSA
1.
3. Spools page 12 9.
TYPE CODE CIRCUIT DESCRIPTION
1 3CU1610130 Double acting, 3 positions, with A and B
closed in neutral position
2 3CU1625130 Double acting, 3 positions, with A and B open
to tank in neutral position
3 3CU1631130 Single acting on A, 3 positions, B plugged F 13
requires G3/4 plug (see part I)
4 3CU1635130 Single acting on B, 3 positions, A plugged
requires G3/4 plug (see part I)
J Spools for 8IM hydraulic control
1C 3CU1610400 As type 1
2C 3CU1625400 As type 2
3C 3CU1631400 As type 3 4. “A” side spool positioners page 16
Special spools: need special body kit
TYPE CODE DESCRIPTION
F5 3CU1641130 Double acting, 4 positions, with A and B
8 5V08120000 With spring return in neutral position
to tank in 4th position (float); for type 13 spool
9B 5V09120000 With detent in position 1 and spring return
positioner
neutral position
8F 3CU1661100 Double acting, 3 positions, with regenerative
10B 5V09120000 With detent in position 2 and spring return
in position 2
neutral position
11B 5V11220000 With detent in positions 1 and 2, spring return
neutral position
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . to be continued on next page
NOTE (*) -- Items are referred to BSP thread.
8 DAT006E
SD18
Ordering codes
4. “A” side spool positioners page 16

11 5V11120000 With detent in positions 1, 0 and 2
15 5V15120000 With detent in positions 1 and 0
16 5V16120000 With detent in positions 2 and 0
19 5V19120000 With spring return in position 0 from 1
20 5V19120000 With spring return in position 0 from 2
9. 8. 6. 8P 5V08120701 ON/OFF pneumatic kit
8EP3 5V08120735 12 VDC ON/OFF electro--pneumatic kit
PSA AET J 8IM 5V08120736 24 VDC ON/OFF electro--pneumatic kit
8EI3 5V08120350 12 VDC ON/OFF electro--hydraulic kit
5V08120351 24 VDC ON/OFF electro--hydraulic kit
Special positioner
F 13 5V13020000 With detent in position 3 and spring return
neutral position, for spool type 5
AE
5. “B” side spool control kits page 23
L 5LEV120000 Standard lever
SLP 5COP120000 Without lever, with dust--proof plate
SLC 5COP220000 Without lever, with cap
AEK
6. Hydraulic spool control kit * page 24
II
Need special body kit
J 8IM 5IDR220000 Proportional hydraulic operated with spring
return in position 0, requires spools type C
3.
7. Port relief options * page 26
1--2--3--4 TYPE CODE DESCRIPTION
Kit with anti--shock: need special body kit
Range from 80 to 200 bar / 1150 to 2900 psi
5. P1(G3-- 100) 606001000 Mounted on port A
J 1C--2C--3C P2(G3-- 100) 606001000 Mounted on port B
P3(G3-- 100) 606001100 Mounted on ports A and B
L Standard setting is 100 bar - 1450 psi to 10 l/min flow.
F 5
8. Outlet port conversion * page 28
AET 3XTAP640250 Open centre plug
8F AE 3XGIU541600 G3/4 carry--over sleeve
SLP AEK 3XTAP540560 Closed centre plug
9. Inlet and outlet selection * page 6

PSL 3XTAP732200 Nr.1 G3/4 plug for side inlet
SLC 3XTAP740210 Nr.1 G1 plug for side outlet
PSA 3XTAP732200 Nr.1 G3/4 plug for upper inlet
K(G2--G3--G4) X(G3) SV
3XTAP740210 Nr.1 G1 plug for upper outlet
I Ports plug *
2.
G3/4 3XTAP732200 For single acting (spools type 3 and 4)
II Optional handlever
NOTE J F -- Spools and positioners with the TYPE CODE DESCRIPTION
same symbol must be assembled together. AL01/M12x250 170013025 For L lever box L= 250 mm / 9.84 in
DAT006E 9
SD18
Inlet relief options
Direct pressure relief valve
VMD20 ( K G 3 - 120 )
Pressure setting in bar (standard 120 / 1750 psi)
Spring type (2, 3, 4).

Adjustment type (G, H)
Adjustment type
G: with screw H: valve set and locked

Wrench 32 -- 42 Nm / 31 lbft
Wrench 16 -- 24 Nm / 17.7 lbft
Allen wrench 5
67 max.
2.64
Performance data
Spring nr. 2 (green band) Spring nr. 3 (blue band) Spring nr. 4 (red band)
400 400 400

(bar) (psi) (bar) (psi) (bar) (psi)
300 4500 300 4500 300 4500
Pressure
Pressure
Pressure
200 3000 200 3000 200 3000
100 1500 100 1500 100 1500
0 0 0
0 50 100 150 200 0 50 100 150 200 0 50 100 150 200
Flow (l/min) Flow (l/min) Flow (l/min)
Response time
(% DP)
105%
95%
Pressure
90%
1750 psi
120 bar
10%
Time (”)
0.12”
RESPONSE TIME
10 DAT006E
SD18
Inlet relief options
Pilot operated pressure relief valve
VMP20 ( X G - 120 )
Pressure setting in bar (standard 120 / 1750 psi)
Adjustment type (G, H)
Adjustment type
Wrench 36 -- 42 Nm / 31 lbft Cap on request: code 3COP117260
Wrench 13 -- 24 Nm / 17.7 lbft
Allen wrench 6
78 max. 88
3.07 3.46
Performance data
Range setting
Response time
300 (% DP)
(bar) 4000
(psi) 105%
200 3000
Pressure
95%
Pressure
90%
1750 psi
2000
120 bar
100
1000
10%
0
0 50 100 150 200 0.32” Time (”)
Flow (l/min) RESPONSE TIME
SV: relief valve blanking plug
Allen wrench 8
42 Nm / 31 lbft
DAT006E 11
SD18
Spool options
Type 1
A B 1 0 2
A B
+ 10 mm
" stroke =
+ 0.39 in
P LC P T
T T
P®A B®T
57
20 2.24
0.79 A B 45 1 0 2
1.77
A B
P LC P T
T T
259
10.2
P--A--B--T closed, with flow through line (LC) open
A B 1 0 2
A B
-- 10 mm
A stroke =
- 0.39 in
P LC P T
T T
P® B A®T
Performance data
Spool metering P®A(B) Spool metering A(B)®T

0.1 0.2 0.3 (in) 0.1 0.2 0.3 (in)
200 200
(l/min ) (l/min )
160 160
120 120 J F
Flow
Flow
J Y
80 80
F Y Q = 160l/min
40 40
F P(on ports) = 63bar/900psi
Y P(on ports) = 100bar/1450psi
0 0
0 2 4 6 8 10 J P(on ports) = 250bar/3600psi 0 2 4 6 8 10
Stroke (mm) Stroke (mm)
12 DAT006E
SD18
Spool options
Type 2
A B 1 0 2
A B
P LC P T
T T
Type 3
Port B plugged
A
1 0 2
A
P LC P T
T T
Type 4
Port A plugged
B
1 0 2
B
P LC P T
T T
DAT006E 13
SD18
Spool options
Type 5
This spool needs special body with extra machinering and must be used only with spool positioner type 13 (see page 19).
A B 1 0 2 3
A B
+ 7 mm
" stroke =
+ 0.28 in
T P T LC P T
P®A B®T
57
74 2.24
2.91 A B 45 1 0 2 3
1.77
A B
T P T LC P T
P--A--B--T closed, flow through line (LC) open
313
12.32
A B 1 0 2 3
A B
T P T LC -- 8 mm P T
stroke =
- 0.32 in
P® B A®T
A B 1 0 2 3
A B
AA
-- 16 mm
T P T LC stroke = P T
- 0.63 in
A(B) ® T (float)
Performance data
Spool metering P®A(B) Spool metering A(B)®T

0.1 0.2 0.3 (in) 0.1 0.2 0.3 (in)
200 200
(l/min ) (l/min )
160 160
120 120
Flow
Flow
J J F
80 80
F Y Q = 160l/min Y
40 40
0 0
0 2 4 6 8 10 J P(on ports) = 250bar/3600psi 0 2 4 6 8 10
Stroke (mm) Stroke (mm)
14 DAT006E
SD18
Spool options
Type 8F
This spool needs special body with extra machinering.
A B 1 0 2
A B
+ 10 mm
" stroke =
+ 0.39 in
P LC P T
T T
P®A+B (regenerative)
A B 1 0 2
A B
P LC P T
T T
P--A--B--T closed, with flow through line (LC) open
A B 1 0 2
A B
-- 10 mm
A stroke =
- 0.39 in
P LC P T
T T
P®B A®T
Performance data
Spool metering P®B Spool pressure drop A®B

0.1 0.2 0.3 (in)
200 50
(l/min ) (bar) (psi)
160 40 600
Pressure drop
120 30
400
Flow
J
80 20
F Y Q = 160l/min 200
40 10
0 0
0 2 4 6 8 10 J P(on ports) = 250bar/3600psi 0 40 80 120 160
Stroke (mm) Flow (l/min)
DAT006E 15
SD18
”A” side spool positioners
With spring return

8 kit
Supplied with standard spring type D (see force--stroke diagram); available with lighter spring type B (8MB code: 5V08220000) or
type C (8MC code: 5V08120010).
In order to correctly apply these kits please contact Customer Service, there could be some usage limitation.
Force--stroke diagram
1 0 2 - 0.3 - 0.2 - 0.1 0.1 0.2 0.3 (in)
Allen wrench 5 450 100
(N)
9.8 Nm / 7.2 lbft D (lbf)
300
C 50
Allen wrench 8 150
B
Force
24 Nm / 17.7 lbft
0 0
B
--150
C - 50
--300
D
--450 - 100
61 --10 --8 --6 --4 --2 0 2 4 6 8 10
2.40 Stroke (mm)
19 kit
1 0
Allen wrench 5
0.1 0.2 0.3 (in)
9.8 Nm / 7.2 lbft
450 100
(N)
Allen wrench 8 300 (lbf)
24 Nm / 17.7 lbft 50
150
Force
0 0
--150
- 50
--300
--450 - 100
61 0 2 4 6 8 10
2.40 Stroke (mm)
20 kit
0 2
Allen wrench 5 - 0.3 - 0.2 - 0.1 (in)
9.8 Nm / 7.2 lbft 450 100
(N)
Allen wrench 8 300 (lbf)
24 Nm / 17.7 lbft 50
150
Force
0 0
--150
- 50
--300
--450 - 100
61 --10 --8 --6 --4 --2 0
2.40 Stroke (mm)
16 DAT006E
SD18
“A” side spool positioners
With detent
9B kit
1 0 2
- 0.3 - 0.2 - 0.1 0.1 0.2 0.3 (in)
9.8 Nm / 7.2 lbft (N)
From position 0 to 1 (lbf)
300
Special wrench 50
150
24 Nm / 17.7 lbft From position 2 to 0
Force
0 0
--150 From position 1 to 0
- 50
--300
From position 0 to 2 :
--450 - 100
--10 --8 --6 --4 --2
0 2 4 6 8 10
Stroke (mm)
97
3.82 Locking--unlocking area
: Unlocking force:400 N / 90 lbf ±10%
10B kit
1 0 2
- 0.3 - 0.2 - 0.1 0.1 0.2 0.3 (in)
9.8 Nm / 7.2 lbft (N) : From position 0 to 1 (lbf)
300
Special wrench 50
150
Force
0 0
- 50
--300
From position 0 to 2
--450 - 100
--10 --8 --6 --4 --2
0 2 4 6 8 10
Stroke (mm)
97
11B kit
1 0 2
- 0.3 - 0.2 - 0.1 0.1 0.2 0.3 (in)
9.8 Nm / 7.2 lbft (N) : From position 0 to 1 (lbf)
300
Special wrench 50
150
Force
0 0
- 50
--300
From position 0 to 2 :
--450 - 100
--10 --8 --6 --4 --2
0 2 4 6 8 10
Stroke (mm)
97
DAT006E 17
SD18
11 kit
1 0 2
- 0.3 - 0.2 - 0.1 0.1 0.2 0.3 (in)
(N) : :
9.8 Nm / 7.2 lbft 300 (lbf)
From position 2 to 0 From position 0 to 1 50
Allen wrench 8 150
Force
24 Nm / 17.7 lbft
0 0
--150
From position 0 to 2 From position 1 to 0 - 50
--300
: :
--450 - 100
--10 --8 --6 --4 0 --2 2 4 6 8 10
Stroke (mm)
61
: Unlocking force: 420 N / 94.4 lbf ±10%
15 kit
1 0
0.1 0.2 0.3 (in)
(N) :
9.8 Nm / 7.2 lbft 300 (lbf)
From position 0 to 1 50
Allen wrench 8 150
Force
24 Nm / 17.7 lbft
0 0
--150
From position 1 to 0 - 50
--300
:
--450 - 100
0 2 4 6 8 10
Stroke (mm)
61
16 kit
0 2
- 0.3 - 0.2 - 0.1 (in)
(N) :
9.8 Nm / 7.2 lbft 300 (lbf)
Allen wrench 8 150
Force
24 Nm / 17.7 lbft
0 0
--150
From position 0 to 2 - 50
--300
:
--450 - 100
--10 --8 --6 --4 --2 0
Stroke (mm)
61
18 DAT006E
SD18
For spool type 5

13 kit
1 0 2 3
Allen wrench 5
9.8 Nm / 7.2 lbft - 0.6 - 0.5 - 0.4 - 0.3 - 0.2 - 0.1 0 0.1 0.2 0.3 (in)
800 (lbf)
Special wrench (N) 150
24 Nm / 17.7 lbft : From position 2 to 0 From position 0 to 1 100
400
Force
0 0
- 50
- 100
F - 150
--800
97 --16 --14 --12 --10 --8 --6 --4 --2 0 2 4 6 8 10
3.82 Stroke (mm)
Locking--unlocking area
: Unlocking force:330 N / 74.2 lbf ±10%
F Locking force:710 N / 160 lbf ±10%
DAT006E 19
SD18
8P kit
1 0 2
Wrench 9
V1 V2
24 Nm / 17.7 lbft
Wrench 17 66
2.60
42 Nm / 31 lbft
NPT 1/8”
NPT 1/8”
Operating features
Pilot pressure . . . . . . . . . . . . . . . . . . . : 6 bar (max.10)
1.38
: 87 psi (max.145)
35
164.5
6.48 Allen wrench 5
169 9.8 Nm / 7.2 lbft
6.65
Allen wrench 5
9.8 Nm / 7.2 lbft
8EP3 kit
Scheme
V1 V2
Wrench 14
9.8 Nm / 7.2 lbft
PG9 51 82
2.01 3.23
1 0 2
Connector C01
code: 2X1001020
(include in control kit)
Scheme ISO 1219
0.24
6
Æ
1 0 2
155.5
6.12
3.31
V1 V2
84
Operating features
Pilot pressure . . . . . . . . . . . . . . . . . . . : 6 bar (max.10)
: 87 psi (max.145)
154
6.06 Allen wrench 5 Solenoid operating features
179 9.8 Nm / 7.2 lbft Nominal voltage . . . . . . . . . . . . . . . . . : 12 VDC / 24 VDC
7.05 Power rating . . . . . . . . . . . . . . . . . . . . : 8 W
Special wrench Duty cycle . . . . . . . . . . . . . . . . . . . . . . : 100%
Wrench 9
24 Nm / 17.7 lbft
Allen wrench 5 Wrench 13
9.8 Nm / 7.2 lbft 24 Nm / 17.7 lbft Pneumatic solenoid valve ordering code (with connector)
CODE DESCRIPTION
2X4001012 12VDC solenoid valve
2X4001024 24VDc solenoid valve
20 DAT006E
SD18
8EI3 kit
ON--OFF electro--hydraulic spool control kit with external pilot and drain.
Allen wrench 4
42 79
6.6 Nm / 4.9 lbft 1.65 3.11 Connection ISO4400
(for connector see Scheme
page 22) 1
L
Solenoid valve V
Wrench 24 -- 9.8 Nm / 7.2 lbft
Coil
Wrench 17
24 Nm / 17.7 lbft
Wrench 9
1 0 2
7.01
178
L
V Scheme ISO 1219
1 0 2
V L
136
5.35 Allen wrench 5
159
Operating features
9.8 Nm / 7.2 lbft Pilot pressure . . . . . . . . . . . . . . . . . . . : min.10 bar-- 145 psi
6.26
Allen wrench 5 Wrench 13
: max.50 bar - 725 psi
9.8 Nm / 7.2 lbft 24 Nm / 17.7 lbft
Max.back pressure on outlet L . . . . . : 4 bar -- 58 psi
Valve and solenoids ordering codes Solenoid operating features
CODE DESCRIPTION Nominal voltage . . . . . . . . . . . . . . . . . : 12 VDC / 24 VDC
2S0EJ08002013 3 ways solenoid valve Power required . . . . . . . . . . . . . . . . . . : 21 W
2X4350012 12VDC coil Duty cycle . . . . . . . . . . . . . . . . . . . . . . : 100%
2X4350024 24VDC coil
Collector kit for external pilot and drain

A1 B1 A2 B2
Allen wrench 6
24 Nm / 17.7 lbft V
V L
20 bar
T
290 psi
Collector P
P T
P 120
1750
T
Ordering codes (BSP thread)
KE1S0 5KE1S00030 kit for 1 section
KE2S0 5KE2S00630 kit for 2 sections
Ex: SD18/2--P(KG3--120)/18EI3L/18EI3L/KE2S0--24VDC KE6S0 5KE6S00630 kit for 6 sections
DAT006E 21
SD18
8EI3 kit
Collector kit with pilot and drain lines
The kit consists of a collector with VRP pressure reducing valve and relative pipes.
Allen wrench 6 Wrench 20 VRP

24 Nm / 17.7 lbft 24 Nm / 17.7 lbft A1 B1 A2 B2
Collector
VRP code Wrench 17

2S100808VAL21
6.85
174
Inlet line Drain T
Wrench 41 P
Wrench 41 42 Nm / 31 lbft
42 Nm / 31 lbft
T VRC
120
1750
VRC back pressure valve

(not included in kit)
VRP valve operating features
Outlet pressure . . . . . . . . . . . . . . . . . . : 20 bar / 290 psi
Max.flow . . . . . . . . . . . . . . . . . . . . . . . : 8 l/min / 2.11 US gpm
Ex: SD18/2--P(KG3--125)/18EI3L/18EI3L/VRC Filtering . . . . . . . . . . . . . . . . . . . . . . . . : 80 m
--KE2R3--24VDC
Ordering codes (BSP thread) VRC valve : code XGIU541602

TYPE CODE DESCRIPTION Valve assembled on flow through passage provides pilot
KE1R3 5KE1R30630 kit for 1 section
pressure to the actuator.
KE2R3 5KE2R30630 kit for 2 sections
KE4R3 5KE4R30630 kit for 4 sections T
KE6R3 5KE6R30630 kit for 6 sections Wrench 41
42 Nm / 31 lbft
C02 connector code: 2X1001010 P
Connector according to ISO4400
33
13.5
0.53
1.3
Pressure drop P®T
60 (psi)
2 1 (bar) 800
1.97
50
Pressure drop
40 600
PG09 400
20
200
Operating features
Nominal voltage . . . . . . . . . . . : 250 VAC / 300 VDC
0
Weather protection . . . . . . . . . :IP65 0 50 100 150 200
Flow (l/min)
22 DAT006E
SD18
”B” side options
L lever box
Alluminium with protection boot lever pivot box; it can be rotated 180° (L180 configuration)
1 0 2
Vertical handlever
assembly Horizontal
handlever assembly
Allen wrench 5 M12

9.8 Nm / 7.2 lbft L180 configuration
3.50
89
74.5
2.93
1.14
29
1.38
35
45
39.5
1.56
1.77
2.13
77
54
3.03
SLP dust proof plate

Mechanical control with dust proof plate.
Spool dimension 1 0 2
32
0.51
1.26
13
Æ0.98
25
14.5
0.57
Æ 0.87
22
12
0.47
Æ 12 +0.0009
45 0.47
1.77
SLC cap
Protection cap usable with pneumatic spool and electro--hydraulic control kit.
1 0 2
Allen wrench 5 Allen wrench 8
9.8 Nm / 7.2 lbft 0.8 Nm / 0.03 lbft
100
3.94
DAT006E 23
SD18
Hydraulic spool control
8IM kit (for single acting and double acting spools)
1 0 2
VA VB
Special valve body kit
(standard body)
99 Wrench 21
3.90 24 Nm / 17.7 lbft G 1/4
VA VB
2.36
60
118.5 Allen wrench 5

4.67 9.8 Nm / 7.2 lbft
Allen wrench 6
Special spool: type 1C, 2C or 3C 24 Nm / 17.7 lbft
Wrench 19
Pressure--stroke diagram
Max. pilot pressure 50 bar / 725 psi
Port B Port A
2 0 1
- 0.3 - 0.2 - 0.1 0 0.1 0.2 0.3 (in)
40 (psi)
(bar)
500
30 400
Pilot pressure
20 300
200
10
100
Overlap area
0 Metering area
--10 --8 --6 --4 --2 0 2 4 6 8 10
Stroke (mm)
24 DAT006E
SD18
Hydraulic spool control
Connection example
Hydraulic pilot control valve

series SV01
Pressure curve 070

0.04 0.1 0.2 (in) 0.3 0.33
30 (psi)
(bar) 400
22.4 325
Pilot pressure
20 300
200
10
5.8 100
84
0
0 1 3 6 8.5 9
Stroke (mm)
1 4 T P 3 2
VA1 VA2 VA1 VB1 VA2 VB2
A1 B1 A2 B2
A1 A2
P T
T
P
T P
B1 B2
120
1750
VB1 VB2
Ex: SD18/2--P(KG3--125)/1C8IM/1C8IM/AET+
SV01--S/01W--001Ax4
DAT006E 25
SD18
Port relief options
Complete kit with cast iron block and anti--shock valves
Example of mounting on directional valve

170
6.69
90
3.54
70
52 2.76
2.05 35 18.5
1.38 0.73
P1 configuration P3 configuration
0.83
21
1.18
0.45
11.5
30
26.5
1.04
P
69.5
2.74
3.15
7.16
3.15
182
80
80
108.5
T
4.27
68.5
2.7
Wrench 4
12.7 Nm / 9.4 lbft 45
1.77
SD18 special body kit
85 53 59 124
3.35 2.09 2.32 4.88
Example of SD18 valve with extra machining

When port valves are flanged on the first or the last section of the body, top inlet and outlet are not available.
49 42 42 38
1.93 1.65 1.65 1.5
11 90
0.43 3.54
1.6
22.5
0.89
P
1.65
42
M6
T
87.5
3.44
12
0.47
17
Surface with 0.67
extra machining
26 DAT006E
SD18
Port relief options
Circuit
P 1 ( G 3 - 120 ) P1 P2 P3
A B A B A B
Setting value in bar standard 100 -- 1450 psi).
Spring type (3).
Adjustment type (G, H).
1 mounted on A port.
2 mounted on B port.
3 mounted on A and B ports.
P1 configuration P2 configuration
Example of pressure on port A and port B to tank Example of pressure on port B and port A to tank
A B A B
Adjustment type
Performance data
Spring # 3 (blue band)

Response time
300 (% DP)
(bar) 4000
(psi) 105%
200 3000
95%
Pressure
Pressure
90%
1450 psi
100 bar
2000
100
1000
10%
0
Time (”)
0 40 80 120 160 0.2”
Flow (l/min) RESPONSE TIME
DAT006E 27
SD18
Outlet port conversion
AET: (standard)
See page 6
AE: with carry--over
A1 B1 A2 B2
T T
Carry--over sleeve P
Wrench 41 -- 42 Nm / 31 lbft
C
G3/4
C 120
1750
Ex: SD18/2--P(KG3--120)/18L/18L/AE
8.2
0.32
AEK: closed centre
A1 B1 A2 B2
T T
Closed centre plug

Allen wrench 12 -- 42 Nm / 31 lbft
120
1750
Ex: SD18/2--P(KG3--120)/18L/18L/AEK
4.2
0.17
28 DAT006E
SD18
Installation and maintenance
The SD18 valve is assembled and tested as per the technical specification of this catalogue.
Before the final installation on your equipment, follow the below recommendations:
-- the valve can be assembled in any position, in order to prevent body deformation and spool sticking mount the product on a flat
surface;
-- in order to prevent the possibility of water entering the lever box and spool control kit, do not use high pressure wash down
directly on the valve;
-- prior to painting, ensure plastic port plugs are tightly in place.
A2
A1 B2
T
B1
C
Carry--over configuration
Fitting tightening torque - Nm / lbft

THREADS TYPE P and C ports A and B ports T port
BSP (ISO 228/1) G 3/4 G 3/4 G1
With O--Ring seal 90 / 66.4 90 / 66.4 100 / 73.7
With copper washer 90 / 66.4 90 / 66.4 90 / 66.4
With steel and rubber washer 70 / 51.6 70 / 51.6 100 / 73.7
UN--UNF (ISO 11926--1) 1 5/16--12 UN--2B (SAE 16) 1 1/16--12 UN--2B (SAE 12) 1 5/16--12 UN--2B (SAE 16)
With O--Ring seal 150 / 110.6 95 / 70.1 150 / 110.6
NOTE -- These torque are recommended. Assembly tightening torque depends on many factors, including lubrication, coating and
surface finish. The manufacturer shall be consulted.
DAT006E 29
SD18
Installation and maintenance
O--Ring seal 24.99x3.53 Chamfer

code: 4GUA125035
Holding O--Ring
bushing
Positioner kit
Load check valve
Body
Lever
pivot box
Main relief valve Spool

Normally spools are interchange-
able. Verify the smoothness dur-
ing the assembly
NOTE -- All articulated parts inside cap, lever box and mechanical joystick are lubricated with synthetic base grease grade NLGI2
Malfunction Cause Remedy

External leakage pivot box lever or Worn spool seal due to mechanical Locate the leakage and replace the seal.
control kit side. actuation or high back pressure. Check back pressure level.
Excessive internal leakage on A and B Increase clearance between spools and Replace the directional control valve and
ports. body due to high wear check the oil contamination level.
Dropping load during transition while Remove the load check valve and clean
High leakage on the load check valve.
raising the seat.
Inability to build pressure on A and B Pressure relief valve blocked open. Remove and clean or replace the valve.
ports. Low pump pressure and flow. Check the pump and circuit.
30 DAT006E
SD18
DAT006E 31
WALVOIL S.P.A.
42100 REGGIO EMILIA · ITALY · VIA ADIGE, 13/D
TEL. +39.0522.932411 · FAX +39.0522.300984
E--MAIL: [email protected] · HTTP: //WWW.WALVOIL.COM
SALES DEPARTMENT
TEL. +39.0522.932555 · FAX +39.0522.932455
D1409808I
DAT006E
DISTRIBUTORI COMPONIBILI TIPO HC-D25
DIMENSIONI
Portata nominale 380 l/min Sigla asta leva standard : ZA- M14 - 350
(da ordinare separatamente)
Pressione max. 350 bar
Corsa cursore 12 + 12 mm
N° sezioni di lavoro 1 2 3 4 5 6 7 8 9 10 11 12
X 225 299 373 447 521 595 669 743 817 891 965 1039
Quote variabili Y 249 323 397 471 545 619 693 767 841 915 989 1063
(mm)
Z 276 350 424 498 572 646 720 794 868 942 1016 1090
Massa (Kg) 41,3 56,8 72,3 87,8 103,4 119 134,4 150 165,5 181 196,5 212
Coppia di
serraggio tiranti Nm 110
40 .00
hc DC-α0398
P (bar)
CURVE CARATTERISTICHE
Curve perdite di carico fra P → T
Q (l/min)
P (bar)
Curve perdite di carico

P→A/P→B
Q (l/min)
P (bar)
Curve perdite di carico

A→T/B→T
Q (l/min)
Curve valvola di massima pilotata

campi taratura (bar)
P (bar)
0 - 350
Q (l/min)
DC-α.0297
hc 41 .00
CURVE CARATTERISTICHE
P (bar)
Curva valvola
anticavitazione generale
Q (l/min)
Curve valvola antiurto

campi taratura
P (bar)
pressione di passaggio (bar)

0 - 70
71 - 120
121 - 150
151 - 300
301 - 350
Q (l/min)
Curve valvola combinata

campi taratura
P (bar)
pressione di passaggio (bar)

50 - 130
131 - 220
221 - 350
Q (l/min)
P (bar)
Curva valvola anticavitazione

al servizio
Q (l/min)
Corsa (mm)
Curva comando idraulico
P (bar)
42 .00
hc DC-α0297
CIRCUITI
CIRCUITO PARALLELO
CIRCUITO PARALLELO - SERIE
DC-α.0398
hc 43 .00
Directional Control Valves
Technical Information
CDS 60 and 100
CDS 100
CDS 60
Specifications Maximum flow (CDS 100) 100 l/min [26.4 US gal/min]

Maximum flow (CDS 60) 60 l/min [15.8 US gal/min]
Work pressure 210 bar [3050 psi]
Maximum pressure 250 bar [3625 psi]
Maximum pressure (outlet section) 40 bar [580 psi]
Temperature range -40º to 80º C [-40 to 176º F]
Recommended fluid type Mineral based hydraulic oil
Recommended viscosity 26-55 mm²/sec (cSt) [123-255 SUS]
Minimum fluid cleanliness (per ISO 4406) 19/16
520L0564 • Revision B • February 2006 31

CDS 60 and 100
Typical performance Pressure vs. flow curves for main relief valve
250
[3625]
Based on oil temperature
of 45°–50°C [113°–122° F]. 200
Viscosity 32 mm²/sec [2900]
Pressure - bar [psi]
(cSt) [151 SUS]. CDS 150

[2176]
spool leakage (standard)
at 70 bar [1015 psi], 100
50°C [122°F], ISO VG46: [1450]
10 cm³/min [0.61 in³/min] 50
[725]
0
0 10 20 30 40 50 60 70 80 90 100
[2.6] [5.3] [7.9] [10] [13] [16] [19] [21] [24] [26]
Flow - l/min [US gal/min]
Pressure drop (P-T) CDS 60 Pressure drop (P-T) CDS 100

12 sections
16 12 sections 16
[232] [232] 11 sections
11 sections
10 sections
14 10 sections 14
[203] [203]
9 sections
9 sections
8 sections
12 8 sections 12
[174] [174]
7 sections
7 sections 6 sections
10 10
[145] [145] 5 sections

6 sections
8 5 sections 8 4 sections
[116] [116]
4 sections
6 6 3 sections
[87] 3 sections [87]
2 sections
4 4 2 sections
[58] 1 sections [58]
1 sections
2 2
[29] [29]
0 0
0 10 20 30 40 50 60 0 10 20 30 40 50 60 70 80 90 100
[2.6] [5.3] [7.9] [10] [13] [16] [2.6] [5.3] [7.9] [10] [13] [16] [19] [21] [24] [26]
Flow - l/min [US gal/min] Flow - l/min [US gal/min]
32 520L0564 • Revision B • February 2006

CDS 60 and 100
Inlet covers order code (example)

Inlet covers order E60 A C 2 140/40*
code
Models
Code Description
E100 CDS100
P100 CDS100 with priority flow control (contact Sauer-Danfoss)
E60 CDS60
P60 CDS60 with priority flow control (contact Sauer-Danfoss)
Port locations
Code Description
A Top port
B Side port, top port plugged
C Top port, with side gauge port (1/4-in NPT)
D Top inlet and outlet ports (use H, I, J on outlet)
Main relief valves

Code Description
A No valve, with plastic plug
B No valve, with special plug
C Valve, with direct valve and external adjustment
D Valve, with direct valve and internal adjustment
Port types
Code 1 2 3 4 5 6 7 8 9 X
SAE - ORB BSP - Parallel Metric - ISO 6149
Special porting, specify

Threads #8 #10 #12
3/8 -19 1/2 -14 3/4 -14 M18x1.5 M22x1.5 M27x2
3/4 -16UNF 7/8 -14UNF 1 1/16-12UNF
Inlet
Model outlet
     
CDS100 Section      
Inlet
Model outlet
     
CDS60 Section      
 available
Note: At this time, North America only stocks SAE-Oring boss.
* Default relief setting if not specified

CDS 60 and 100
Inlet covers order code (example)

Inlet porting and E60 A C 2 140/40*
relief valve options
Port location
D Top inlet and outlet (use with H,I,J, and L outlet covers)
A Top inlet
C Top inlet, gauge port side (1/4 in NPT)
E100 inlet cover
B Side inlet (top plugged) Relief valve

B
h1 in
P T
11
[0.43]
C
h 1 in h 7/8 h 7/16
67
[2.64]
max
D
h1 in
E60 inlet cover
47
[1.85]
E Ref. 10782 or
504069
(consult factory for
dimensional drawing)
P101 798
mm [in]
CDS 60 and 100
Mid-Inlet flow dividers/combiners order code (example)

Mid-inlet flow I60 1 2 2 140/40*
dividers and
combiners order Models
code Code Description
I60 CDS 60 mid-inlet
I100 CDS100 mid-inlet
Mid-inlet type
Code Description
1 Flow divider
2 Flow combiner
Port types
Note: At this time, North Code 1 2 3
America only stocks SAE- SAE - ORB
Oring boss. Threads #8 #10 #12
3/4 -16UNF 7/8 -14UNF 1 1/16-12UNF
Model
Mid-inlet  
CDS100
Model
Mid-inlet  
CDS60
 available
Main relief valves

Code Description
1 Plug
2 CDS 60 relief
3 CDS 100 relief

CDS 60 and 100
Mid-inlet flow Min-inlet flow combiner

dividers and Inlet
combiners (Second pump)
Relief valve A B
A B
Outlet
Bypass
Bypass outlet
Pressure Inlet bypass
Outlet P106 328E
Pressure
Min-inlet flow divider
Outlet Inlet
(First pump) (Second pump)
A B Relief valve
Relief
valve Plug
A B
Outlet
Bypass
Bypass outlet
Pressure Inlet bypass
Outlet P106 329E
Pressure

CDS 60 and 100
Outlet covers order code (example)

Outlet covers order S60 A 2
code
Models
Code Description
S100 CDS 100
S60 CDS 60
Ports
Code Description
A Top outlet
B Side outlet, top plugged
C Side outlet for power beyond (top to tank)
D Top outlet (with closed bypass)
E Top outlet (for electrical control)
F Top outlet (for electrical control, with power beyond)
G Side outlet (for electrical control, top plugged)
H Top plugged
I Top plugged, use with power beyond
J Top plugged for electrical control
L Top plugged for electrical control, use with power beyond
Port types
Code 1 2 3 4 5 6 7 8 9 X

Threads #8 #10 #12
3/8 -19 1/2 -14 3/4 -14 M18x1.5 M22x1.5 M27x2
3/4 -16UNF 7/8 -14UNF 1 1/16-12UNF
Inlet
Model outlet
     
CDS100 Section      
Inlet
Model outlet
     
 available
Note: At this time, North America only stocks SAE-Oring boss.

CDS 60 and 100
Outlet covers order code (example)

Outlet porting and S60 A 2
plug options
C T
Bypass PB
S100 outlet cover Pressure
Outlet
H Top plugged
A Top outlet (side plugged) I T
Bypass PB
Pressure
Outlet 30
[1.18]
D*
T
Bypass
Pressure
Outlet
25
[0.98]
B Side outlet (top plugged) E T
Bypass
Pressure
Outlet
J T
Bypass
Pressure
30
Outlet
[1.18]
F T
Bypass PB
Pressure
Outlet
S60 outlet cover

L T
Bypass PB
Pressure CDS 60 30.5
Outlet [1.20]
CDS 100 32
[1.25]
G T
Bypass PB
Pressure
Outlet
CDS 60 30.5
[1.20]
CDS 100 32
[1.25]
P101 799E
*Typically used for high pressure standby.
mm [in]

CDS 60 and 100
Work section order code (example)

Work section order code A100 1 A E 2 A 1 A B A100 140/40*
Model
A100 CDS 100 body for supporting valves
B100 CDS 100 normal body (no valves) See cabling and
A60 CDS 60 body for supporting valves electrical options,
B60 CDS 60 normal body (no valves) page 47.
Circuit types, page 42
1 Parallel (no priority)
2 Tandem (priority)
3 Series (no priority)
Spool types, page 43 (also see Spool compatibility, next page)
A 4-way, closed center
B 4-way, open center
C 4-way, closed center, port A plugged
D 4-way, closed center, port B plugged
E 3-way, closed center, port A plugged
F 3-way, closed center, port B plugged
J 4-way, open center, port A plugged
H 4-way, open center, port B plugged
I Float-spool in (use centering option J )
J Float-spool out (use centering option J)
L 4-way, closed center (metering spool)
M 4-way, open center (metering spool)
N 4-way, closed center, port A plugged (metering spool)
P 4-way, closed center, port B plugged (metering spool)
Q 3-way, closed center, port A plugged (metering spool)
R 3-way, closed center, port B plugged (metering spool)
S 4-way, open center, port A plugged (metering spool)
T 4-way, open center, port B plugged (metering spool)
Spool actuation, pages 44–46
A No extension (spool actuation side and centering options omitted)
B Female spool end
C Male spool end
D With support (no lever)
E With lever
F Pneumatic (use centering option A)
G Cable with lever
H Cable with joystick (use A for the adjacent body)
I With mechanical joystick (use A for the adjacent body)
J Electrical
L Hydraulic
M With mechanical joystick (use A for the adjacent body)
N Enclosed lever — E (CDS 60 only)
P Enclosed mechanical joystick — I (CDS 60 only)
Q Enclosed mechanical joystick — M (CDS 60 only)
Spool actuation mounting side, page 47
1 Actuator mounted on A port side (or solenoid side A)
2 Actuator mounted on B port side (or solenoid side B)
3 Electrical A and B (use L centering type)

CDS 60 and 100

Work section order code (continued) A100 1 A E 2 A 1 A B A100 140/40*
Spool centering and detents, page 48-49

A Spring centered
B 3 position detent
C Spring centered, detent in A
D Spring centered, detent in B
E Spring centered, detent in A and B
F Spring centered, hydraulic kickout
G Spring centered, adjustable stroke
H Spring centered, female extension
I Spring centered, male extension
J Spring centered, detent in float: use for floatation spool
L Spring centered, use for electrical command
M By spring offset
N 2-position detent, spool in
O 2-position detent, spool out
P With switch, activates spool in
Q With switch, activates spool in and out
R With switch, activates two motors
Port types
Code 1 2 3 4 5 6 7 8 9 X

Threads #8 #10 #12
3/8 -19 1/2 -14 3/4 -14 M18x1.5 M22x1.5 M27x2
3/4 -16UNF 7/8 -14UNF 1 1/16-12UNF
Inlet
Model outlet
     
CDS100 Section      
Inlet
Model outlet
     
 available
Note: at this time, North America only stocks SAE O-ring boss.
Auxiliary valves, page 50-51

A Plug Work port side A
B Direct relief with external adjustment (except electrical actuation)
C Direct relief with internal adjustment Work port side B
D Pilot retaining
E Flow control valve (electrical actuators mounted upside down)
F Anti-cavitation
Direct relief with anti-cavitation and external adjustment
G
(except electrical actuation)
H Plastic plug
I Direct relief with anti-cavitation and internal adjustment (electrical only)
J Plug, for 3-way spools
K Plug, for valves D and E
L Plastic plug, for flow control valve
M Plastic plug, for PO checks
For valves B, C, G, and I, specify pressure and flow
Example: B(140/40) Pressure 140 bar flow 40 l/min
CDS 60 and 100
Work section order Spool compatibility

code (continued) Spool types
Model
A, C, D B, G, H E F I J
A60/100 with pilot retaining  
A60/100 with pilot retaining and hydraulic unlock  
A60/100 with pilot retaining and electrical spool control  
A60/100 with flow control  
A60/100 with flow control and hydraulic unlock  
A60/100 with out pilot retaining      
A60/100 with out pilot retaining with hydraulic unlock      
A60/100 with out pilot retaining and electrical spool control      
B60/100      
B60/100 with hydraulic unlock      
B60/100 with electrical spool control      
 Parallel and tandem

 Series

CDS 60 and 100

Circuit types A100 1 A E 2 A 1 A B A100 140/40*
1 Parallel circuit (no priority)

P A B A B T
Bypass
P101 696
Pressure
Inlet Work sections Outlet

When two or more sections operate simultaneously, flow favors the lowest pressure.
2 Tandem circuit (priority)

P A B A B T
Bypass
P101 697
Pressure
When two or more sections operate simultaneously, only the section closest to the inlet receives flow.
3 Series circuit (no priority)

T P A B A B T
Bypass
P101 698
Inlet and Outlet Work Sections Outlet

When two or more sections operate simultaneously, the section closest to the inlet receives flow. Return
flow feeds the sections downstream.

CDS 60 and 100

Spool types A100 1 A E 2 A 1 A B A100 140/40*
Standard central body Bypass core
Ref. Description Symbol
A 4-way closed center A B
L 4-way closed center

metering spool P T
B 4-way open center

A B
P101 743
Pressure core
M 4-way open center
Tank (x2) metering spool P T
C 4-way closed center

port A plugged A B
Pump load check
standard on all bodies
N 4-way closed center
port A plugged P T
metering spool
D 4-way closed center

A B
port B plugged
P 4-way closed center

port B plugged P T
metering spool
E 3-way closed center

A B
port A plugged
Q 3-way closed center

port A plugged
metering spool P T
Central body for use with auxiliary valves
F 3-way closed center
A B
port B plugged
R 3-way closed center

port B plugged
metering spool P T
G 4-way open center

A B
port A plugged
S 4-way open center

port A plugged
metering spool P T
H 4-way open center

A B
port B plugged
T 4-way open center

port B plugged
metering spool P T
I Float spool in (inner

A B
inverter)
Pump load check
P T
J Float spool out (outer

A B
inverter)
P T
CDS 60 and 100

Actuation options A100 1 A E 2 A 1 A B A100 140/40*
30 CDS 60
A Without spool end B Female spool end (clevis) [1.18]
34
[1.34] CDS 100
8
[0.31] CDS 100 6.4
CDS 60
6.5 [0.25]
CDS 60
[0.26] 8.4
CDS 100
[0.33]
M8 x 1.25
M10 x 1.5
F
ø8
[0.31]
66
D With support CDS 60 [2.60]
70
CDS 100 [2.76]
C Male spool end (tang)

M10 x 1.5
30
[1.18] CDS 60
34
[1.34] CDS 100
8.3
[0.33]
M
F Pneumatic
ø8 50
[0.31] [1.97]
1/8" NPT (2x)
E With lever
113
[4.45]
15º
15º
213
[8.39]
Minimum air pressure CDS 60: 5 bar [73 psi]
Maximum air pressure: 12 bar [174 psi]
56
CDS 60 [2.20]
L Hydraulic 60
CDS 100 [2.36]
7/16 in UNF
SAE # 4 (2x)
Minimum pressure CDS 60: 8 bar [116 psi]

mm [in] * Default relief setting if not specified
Maximum pressure: 100 bar [1450 psi]
CDS 60 and 100

Actuation options (continued) A100 1 A E 2 A 1 A B A100 140/40*
G Cable with lever** H Cable with joystick** N, P, Q Consult factory for drawings
E* D* C* B* A*
26 ø6
[1.02] [0.24]
280
[11.02]
7
[0.28]
7 30º 30º
[0.28] 50 395
[1.97] 25° 25°
[15.55]
157
[6.18]
48
[1.89]
Switches have 3 Amp capacity
70
40 Ø [2.76]
118.5
[1.57] [4.66]
50
[1.97] 97
[3.82]
P101 779
I/M Mechanical joystick 2 I

1 1
307
[12.09] 2
15º
2 M
1
2
15º
83
J Electrical** [3.27]
117
[4.61]
(Ref.) (Ref.) DIN 43650
Flying leads
**See cabling and electrical
options, page 47.
12VCC 12VCC
90
[3.54]
1.5m 24VCC 24VCC
96
[3.78]
Standard sections cannot be
[5 ft]
(Ref.) (Ref.) converted to electrical due to
internal pilot.
Manual override
Minimum pilot pressure to
actuate: 35 bar [500 psi]
P101781a
mm [in]
CDS 60 and 100

Actuation options (continued) A100 1 A E 2 A 1 A B A100 140/40*
N Enclosed lever P/Q Enclosed mechanical joystick

100 [3.94]
P106 326
For dimensions, see I/M Mechanical

joystick option, previous page.
P106 325

CDS 60 and 100

Cabling and electrical A100 1 A E 2 A 1 A B A100 140/40*
options for actuator
types G, H, and J
G: Flexible cable and lock options for spool control lever

A B C
Lever lock options Without lock Lock in A and/or B Lock in central position
Standard cables 100 - 125 - 150 - 175 - 200- 250 - 275- 300 - 325 - 350 - 400 - 450 - 500 cm (other: consult)
Example: how to order A60 - 1AG2A1 - AB - A100 - 140/40 (lever without lock, 100 cm cable)
H: Flexible cable and handle options controls for joystick

A B C D E
Two On-Off-On Two On-Off-On switches and
Joystick handle options Without switches On-Off switch On-Off-On switch
switches one On-Off switch
Standard cables 100 - 125 - 150 - 175 - 200 - 250 - 275 - 300 - 325 - 350 - 400 - 450 - 500 cm (other: consult)
Example: how to order A60 - 1AH2A1 - AB - A100 - 140/40 (handle without switches, 100 cm cable)
J: Electrical spool voltage and termination options

Voltage A 12 VDC -lead wires B 24 VDC - lead wires E 12 VDC - DIN 43650 conn. F 24 VDC - DIN 43650 conn.
Example: how to order A60 - 1AJ3L1 - AC - A 140/40 (12 VDC coil with lead wires)
Force requirements Electrical specifications

kgf [lbf ] CDS 60 CDS 100 Voltage Amperage (A) Resistance (Ω)
Push/pull min. 2 [4.4] 3.5 [7.7] 12 VDC 1.75 6.85
Max. tension 250 [551] 250 [551] 24 VDC 0.88 27
Power: 21 W
Actuation mounting 1 Actuation on A port side (RH inlet shown) 2 Actuation on B port side (LH inlet shown)
side
CDS100 CDS60
A A A A T
B B P
P B B
T A A P B B T
P101 796
P101 822
CDS100 CDS60

CDS 60 and 100

Spool centering and detent options A100 1 A E 2 A 1 A B A100 140/40*
A Spring centered B 3 position detent C Spring center in, detent out

32 32 56
[1.25] CDS 60 [1.25] CDS 60 [2.20]
CDS 60
40 40 73
[1.57] CDS 100 [1.57] CDS 100 [2.87] CDS 100
Spring force
CDS 60: 145-155 N [32-35 lbf ]
CDS 100: 240-245 N [54-55 lbf ]
D Spring center out, detent in E Spring centered, detent in A and B F Spring centered, hydraulic unlock
56 56 92
CDS 60
[2.20] [2.20]
CDS 60 [3.62] CDS 60
73 73 96
[2.87] CDS 100 [2.87] CDS 100 [3.78] CDS 100
Note: Unlock body section

required for use with hydraulic
unlock kit.
G Spring centered, adjustable stroke H Spring centered, female extension I Spring centered, male extension
70 CDS 60 88±5 88±5
[2.76] [3.46±0.2] CDS 60 [3.46±0.2] CDS 60
81 93 ±5 93 ±5
[3.19]
CDS 100
[3.66± 0.2] CDS 100 [3.66± 0.2] CDS 100
Ø 8 8
[0.31] Ø
[0.31]
CDS 60
6.4
[0.251]
8.4
[0.331] 20.5 8.3 20
CDS 100 [0.81] [0.33] [0.79]
Note: Adjustable in both F

directions.
J Spring centered, floatation spool Note: Float body section required
65 82 CDS 60
CDS 60
[2.56] [3.23]
78 CDS 100 10 CDS 60 101 CDS 100
[3.07] [0.39] [3.97]
12.5 CDS 100
[0.49]
Float in Float out

mm [in]

CDS 60 and 100

Spool centering and detent options (continued) A100 1 A E 2 A 1 A B A100 140/40*
M Spring offset N Two-position detent: O Two-position detent:

neutral and spool in neutral and spool out
32 32 32
[1.26] CDS 60 [1.26] CDS 60 [1.26] CDS 60
40 40 40
[1.57] CDS 100 [1.57] CDS 100 [1.57] CDS 100
P Spring centered with switch: Q Spring centered with switch: R Spring centered with switch:
activates on spool in activates on spool in and out activates two motors
CDS 60 32
[1.26]
CDS 100 40
32 CDS 60 [1.57]
[1.26]
6.5 [0.26] CDS 60
40 CDS 100
CDS 60 CDS 60 8.0 [0.32] CDS 100
6.5 [0.26] [1.57]
6.5 [0.26]
8.0 [0.32] 8.0 [0.32]
CDS 100 CDS 100
P106 330E
mm [in]
CDS 60 and 100

Auxiliary valves A100 1 A E 2 A 1 A B A100 140/40*
J¹ 11
[0.43]
A¹ 11
[0.43]
K² 10
[0.39]
1 in 1 in 1 in
For 3 ways spools. For valves B, C, F, G, and I For valves D and E.
B³ 1 in 11/16 7/16
T P
67
[2.64]
Max
C 1 in
47
[1.85] Standard
29 Short version
[1.14] (use with electrical
Central body for use with auxiliary valves actuation)
D4 1 in
16
[0.63]
E4 1 in 7/8
5/8
62 CDS 60
[2.44] Knob
Max
F 1 in
12
[0.47]
¹ Order code H for plastic plug in auxiliary port of 3-way G³ 1 in 11/16 7/16
spool and body for valves B, C, F, G, and I.
² Order code L for plastic plug in auxiliary port for valve E

(flow control L). Order code M for plastic plug in auxiliary
70
port for valve D(pilot retaining). [2.76]
Max
³ Don’t use valves B and G with electrical actuation.
I 1 in
4
When using options D and E, electrical actuators must
be mounted upside down.
P101 746E
29
mm [in] [1.14]

CDS 60 and 100

Auxiliary valves (continued) A100 1 A E 2 A 1 A B A100 140/40*
Auxiliary valves compatibility

A B C D E F G I J K
A    — —    — —
B    — —   —  —
C    — —     —
D — — —  — — — — — 
E — — — —  — — — — 
F    — —     —
G    — —   —  —
I  —  — —  —   —
J —   — —    — —
K — — —   — — — — 
— Not compatible  Compatible

 Compatible (EXCEPT electrical)  Compatible (ONLY electrical)
Dimensions CDS 100

Y 152
[5.98]
30 46 82
[1.18] [1.81] [3.23]
46
[1.81]
142
[5.59]
38
[1.49]
100
[3.94]
25 25 127
15
[0.98] [0.98] [5.00]
[0.59]
X
Reference dimensions
10
[0.39] Number of
X Y
sections
R 5.5 1 95 [3.74] 137 [5.39]
[0.22]
A A 2 139 [5.47] 181 [7.13]
3 184 [7.24] 226 [8.89]
4 229 [9.02] 270 [10.63]
t 27 N•m 5 273 [10.75] 314 [12.36]
20 lbf•ft
6 318 [12.52] 359 [14.13]
P B B T
7 362 [14.25] 403 [15.87]
8 406 [15.98] 448 [17.64]
9 451 [17.76] 492 [19.37]
10 495 [19.49] 537 [21.14]
11 540 [21.26] 581 [22.87]
12 584 [22.99] 626 [24.65]
44.5
[1.75]
mm [in]
CDS 60 and 100
120
Dimensions CDS 60 [4.72]
Y 56 74*
[2.20] [2.91]
24
[0.94]
38 38
[1.50] [1.50]
119
[4.69]
82
[3.23]
32
[1.26]
14
[0.55] 98
[3.86]
18 18
[0.71] [0.71] Reference dimensions
X Number of
X Y
sections
1 72 [2.83] 112 [4.41]
2 108 [4.25] 148 [5.83]
3 144 [5.67] 184 [7.42]
A A 4 180 [7.09] 220 [8.66]
T 5 216 [8.50] 256 [10.08]
6 252 [9.92] 292 [11.50]
28.5
[1.12] 7 288 [11.34] 328 [12.91]
8 324 [12.76] 364 [14.33]
26 P B B
[1.02] 9 360 [14.17] 400 [15.75]
t 18 N•m 10 396 [15.59] 436 [17.17]
13 lbf•ft
11 432 [17.01] 472 [18.58]
r. 4.5
[0.18] 12 468 [18.43] 508 [20.00]
13
[0.51]
P101 795
36
[1.42]
Mounting requirements
A
B
77 78
P106 331E
Flatness 0.5-0.8 [0.02 to 0.03] max Flatness 0.5-0.8 [0.02 to 0.03] max

CDS 60 and 100

Circuit types A100 1 A E 2 A 1 A B A100 140/40*
1 Parallel circuit (no priority)

P A B A B T
Bypass
P101 696
Pressure

When two or more sections operate simultaneously, flow favors the lowest pressure.
2 Tandem circuit (priority)

P A B A B T
Bypass
P101 697
Pressure
When two or more sections operate simultaneously, only the section closest to the inlet receives flow.
3 Series circuit (no priority)

T P A B A B T
Bypass
P101 698
Inlet and Outlet Work Sections Outlet

When two or more sections operate simultaneously, the section closest to the inlet receives flow. Return
flow feeds the sections downstream.

CDS 60 and 100

Spool types A100 1 A E 2 A 1 A B A100 140/40*
Standard central body Bypass core
Ref. Description Symbol
A 4-way closed center A B
L 4-way closed center

metering spool P T
B 4-way open center

A B
P101 743
Pressure core
M 4-way open center
Tank (x2) metering spool P T
C 4-way closed center

port A plugged A B
Pump load check
N 4-way closed center
port A plugged P T
metering spool
D 4-way closed center

A B
port B plugged
P 4-way closed center

port B plugged P T
metering spool
E 3-way closed center

A B
port A plugged
Q 3-way closed center

port A plugged
metering spool P T
Central body for use with auxiliary valves
F 3-way closed center
A B
port B plugged
R 3-way closed center

port B plugged
metering spool P T
G 4-way open center

A B
port A plugged
S 4-way open center

port A plugged
metering spool P T
H 4-way open center

A B
port B plugged
T 4-way open center

port B plugged
metering spool P T
I Float spool in (inner

A B
inverter)
Pump load check
P T
J Float spool out (outer

A B
inverter)
P T
CDS 60 and 100

Actuation options A100 1 A E 2 A 1 A B A100 140/40*
30 CDS 60
A Without spool end B Female spool end (clevis) [1.18]
34
[1.34] CDS 100
8
[0.31] CDS 100 6.4
CDS 60
6.5 [0.25]
CDS 60
[0.26] 8.4
CDS 100
[0.33]
M8 x 1.25
M10 x 1.5
F
ø8
[0.31]
66
D With support CDS 60 [2.60]
70
CDS 100 [2.76]
C Male spool end (tang)

M10 x 1.5
30
[1.18] CDS 60
34
[1.34] CDS 100
8.3
[0.33]
M
F Pneumatic
ø8 50
[0.31] [1.97]
1/8" NPT (2x)
E With lever
113
[4.45]
15º
15º
213
[8.39]
Maximum air pressure: 12 bar [174 psi]
56
CDS 60 [2.20]
L Hydraulic 60
CDS 100 [2.36]
7/16 in UNF
SAE # 4 (2x)

mm [in] * Default relief setting if not specified
Maximum pressure: 100 bar [1450 psi]
SCHEDA TECNICA
TECHNICAL SHEET
Next Hydraulics
Cod.: MP.0.105
Rev.: 0
DIMENSIONI - DIMENSIONS
GRU - CRANE A B1 B2
260.1 1550 820 860
260.2 1550 820 860
260.3 1550 820 860
GRU - CRANE A B C D L max

260.1 510 130 670 510 3300
260.2 520 150 700 600 3300
260.3 560 180 810 840 4360
DATI TECNICI - TECHNICAL DATA VERSIONE – VERSION
MODELLO - TYPE 260 260.1 260.2 260.3
CAPACITA’ DI SOLLEVAMENTO
KNm 25
CRANE RATING
N° SFILATE STANDARD (IDRAULICHE - MANUALI)
N° 1H +1M 2H 3H
STANDARD EXTENSIONS Nr (HYDRAULICS - MANUALS)
SBRACCIO STANDARD
m 3.30 3.30 4.36
STANDARD OUTREACH
ANGOLO DI ROTAZIONE
° 360°
SLEWING ANGLE
INCLINAZIONE MASSIMA
° 4°
MAXIMUM ANGLE SLOPE
200.3
COPPIA DI ROTAZIONE
SLEWING TORQUE
KNm 3.5
ALTEZZA SOLLEVAMENTO MAX. DALLA BASE

m 4.50 4.50 5.50
MAX. LIFTING HEIGHT FROM CRANE BASE
PORTATA CONSIGLIATA
l/min 10 – 12
SUGGESTED OIL FLOW
PRESSIONE MAX. DI ESERCIZIO
Bar 190
MAX. WORKING PRESSURE
PESO GRU BASE VERS. “H” 215 225 250
Kg
BASIC CRANE WEIGHT VERS. “E” 235 245 270
PESO BASAMENTO CON STABILIZZATORI ESTENDIBILI
Kg 120 – 130
BASE WEIGHT WITH EXTENDABLE STABILIZERS
PESO TRAVERSA 2 STABILIZZATORI ESTENDIBILI
Kg 50
BEAM WEIGHT WITH 2 EXTENDABLE STABILIZERS
ASSORBIMENTO MOTORE GRU ELETTROIDR. 12V A
MOTOR ABSORPTION FOR ELECTROHYDR. CRANE 12V min/max 80/250 80/250 80/250
ASSORBIMENTO MOTORE GRU ELETTROIDR. 24V A
MOTOR ABSORPTION FOR ELECTROHYDR. CRANE 24V min/max 50/120 50/120 50/120
SPECIFICHE ARGANO -WINCH SPECIFICATIONS U.M.

ARGANO TIRO DIRETTO MAX. (3°STRATO)
Kg 700
MAX. WINCH SINGLE LINE CAPACITY (3rd LAYER)
VERSION DESCRIZIONE – DESCRIPTION

“E” 12V ELETTROIDRAULICA ELECTROHYDRAULIC
“E” 24V ELETTROIDRAULICA ELECTROHYDRAULIC
“H” IDRAULICA (PTO) HYDRAULIC (PTO)
TEMPI DI FUNZIONAMENTO OPERATING TIMES

ROTAZIONE SOLLEVAMENTO DISCESA USCITA RIENTRO
VERSIONE
SLEWING LIFTING LOWERING EXTENSION OUT EXTENSION IN
(rpm) (sec) (sec) (sec) (sec)
VERSION
Pmin Pmax 260.1 260.2 260.3 260.1 260.2 260.3
260 "E" 12/24V 1.5 23 35 18 12 25 35 9 16 26
260 "H" (P.T.O) 1.8 16 18 12 25 35 9 16 26
Pmax: pressione max. di esercizio - max. working pressure
Pmin: pressione min. di esercizio - min. working pressure
Classe
Lifting class
H2–B3
DIN 15018
260.1 260.2 260.3
by
Next Hydraulics
Via Mediterraneo n°6, 42022 Boretto (R.E.) Italy
Tel.: 0522-963008, Fax: 0522-963039
http:www.maxiliftcrane.com E-mail:
[email protected]
Mechanical
Temperature Measurement
Bimetal Thermometer
Model 45
WIKA Data Sheet TM 45.01
Applications
! For domestic and industrial heating systems

! Hot water boilers
! Solar power systems
! Heat transfer systems
Special Features
! Reliable and economical
! Nominal size 63, 80 and 100
! Scale ranges up to -30 … 120 °C
Bimetal Thermometer Model 45
Description
Nominal size Thermowell
63, 80 and 100 mm Length l1 = 40, 60, 100 mm
Cu-alloy
Temperature element
Coiled bimetal
Stem
Bulb Aluminium, 9 mm
Stem with detaching thermowell (friction retained)
Dial
Working range
White Aluminium with black lettering
Maximum scale value
Pointer
Pressure rating of thermowell
Black aluminium
6 bar maximum
Window
Location of stem Acrylic plastic
Centre back
Zero adjustment
Case At bottom of stem
Aluminium
Connection Optional extras

Thermowell G ½ B
! Other scale ranges
WIKA Data Sheet TM 45.01 · 10/2005 Page 1 of 2

Special versions S c ale rang es
S c ale range °C S cale spa cing °C
Clip-on thermometer with fin and strap -30 … 50 1
63 and 80 mm -20 … 60 1
0 ... 60 1
0 … 80 1
0 ... 120 2
M o d e ls
N o m inal size Location of stem / M odel
C onnection
63 C entre back A 4500
80 C entre back A 4501
1 00 C entre back A 4502
63 C lip-on fin w ith strap A 4550
80 C lip-on fin w ith strap A 4551
Dimensions in mm
Location of stem: centre back Clip-on thermometer with fin and strap
3072 932
3072 940
NS Dimensions in mm Weight in kg
b1 b2 Õd ÕD G l1 SW Centre back Clip-on
1)
63 23 21 12 63 G½B 40, 60, 100 21 0.065 0.040
1)
80 25 22 12 80 G½B 40, 60, 100 21 0.080 0.060
1)
100 30 - 12 100 G½B 40, 60, 100 21 0.105 -
1) Õ d = 11 mm with thermowell length l1 ≥100 mm
Ordering information
Model / Nominal size / Scale range / Size of connection / Length of stem l1 / Optional extras required
Specifications and dimensions given in this leaflet represent the state of engineering at the time of printing.
Modifications may take place and materials specified may be replaced by others without prior notice.
9019120 07/2005 GB
Page 2 of 2 WIKA Data Sheet PM 45.01 · 10/2005
WIKA Alexander Wiegand GmbH & Co. KG

Alexander-Wiegand-Straße 30
63911 Klingenberg/Germany
Phone (+49) 93 72/132-0
Fax (+49) 93 72/132-406
E-Mail [email protected]
www.wika.de
SECTION 6
HYDRAULIC
HANDPUMPS
Flowfit Handpumps have been developed and manufactured for high performance and reliability.
They are used in many different sectors such as transport, industry and agriculture.
Flowfit Hand Pumps can be installed in both horizontal and vertical position.
INLINE HANDPUMPS......................................................................48
MINI-FLOW HANDPUMPS ..............................................................49
FOOTPUMP.....................................................................................49
SINGLE ACTING HANDPUMPS .......................................................50
DOUBLE ACTING HANDPUMPS ......................................................50
HYDRAULIC TANKS FOR HANDPUMPS ..........................................51
HANDPUMP LEVERS ......................................................................48
TAKE
50% OFF ALL
PRICES
OIL – Use only ISO 6743/4 (DIN 51524) hydraulic mineral oil
VISCOSITY – Viscosity must be according to ISO 3448 (DIN
51519) standards
Minimum viscosity: ISO VG 15, Maximum viscosity: ISO VG 100
Advised viscosity: ISO VG 46
FILTRATION CONTAMINATION – The main cause for
failure in most hydraulic installations is due to excessive
fluid contamination.
Advised filtration: 50-80 microns
Contamination class 18/14 ISO 4406 (9 NAS 1638)
TEMPERATURE – Working temperature: from -20˚c to +80˚c
DOWNLOAD TECHNICAL PDFs AT www.flowfitonline.com HYDRAULIC HANDPUMPS • 47

TAKE
FLOWFIT HP20VIS INLINE HANDPUMP 50%
OFF AL
PRICESL
• All handpumps are fully interchangeable with other leading Italian manufacturers.
OEM
PRICING
• Supplied with rubber protection for the piston, pressure relief valve inside release hand knob and
mounting kit.
AVAILABLE
• This handpump pumps both ways.
• Designed for fixing to a wall.
PART NUMBER DISPLACEMENT MAX WORKING PRESSURE WEIGHT PRICE

HP20VIS 20CM3 350 BAR 2.9 KG £151.60
ZINC PLATED LEVERS FOR HAND PUMPS

ZINC L A WEIGHT
PART NUMBER PRICE
PLATED mm mm (KG)
LV27x330 white 330 27 0.5 £10.93
LV27x400 white 400 27 0.6 £10.93
LV27x600 STANDARD white 600 27 0.9 £10.93
LV27x850 white 850 27 1.02 £15.19
LV27x1000 white 1000 27 1.5 £18.22
LV27X600 BENT white SEE DRAWING 0.9 £15.92
TAKE
FLOWFIT HP50VIS INLINE HANDPUMP 50%
OFF AL
PRICESL
• Supplied with rubber protection for the piston, pressure relief valve inside release hand knob and
mounting kit.

HP50VIS 43CM3 280 BAR 3.8 KG £168.29

ZINC L A WEIGHT
PART NUMBER PRICE
PLATED mm mm (KG)
LV27x330 white 330 27 0.5 £10.93
LV27x400 white 400 27 0.6 £10.93
LV27x850 white 850 27 1.02 £15.19
LV27x1000 white 1000 27 1.5 £18.22
48 • HYDRAULIC HANDPUMPS DOWNLOAD TECHNICAL PDFs AT www.flowfitonline.com

TAKE
FLOWFIT HP70EVS INLINE HANDPUMP 50%
OFF AL
PRICESL
• Supplied with rubber protection for the piston, pressure relief valve and mounting kit.
• No release handknob.

HP70EVS 69CM3 220 BAR 5.5 KG £235.05

ZINC L A WEIGHT
PART NUMBER PRICE
PLATED mm mm (KG)
LV27x330 white 330 27 0.5 £10.93
LV27x400 white 400 27 0.6 £10.93
LV27x850 white 850 27 1.02 £15.19
LV27x1000 white 1000 27 1.5 £18.22
TAKE
FLOWFIT HPBSE MINI-FLOW SERIES HANDPUMP 50% OFF AL
PRICESL
• 2.5cm3 handpump
NO LET
DOWN VALVE for single acting
function and fixing
to wall.
MAX WORKING WEIGHT

OEM
PRICING
PART NUMBER DISPLACEMENT
PRESSURE (KG)
PRICE
AVAILABLE HPBSE2.5E 2.5cm3 250 BAR 1.2 £144.64
TAKE
FLOWFIT HPSE20 FOOTPUMP 50%
OFF AL
PRICESL
• 14cm3 FOOTpump to operate single

acting function complete with 1.5 litre
steel reservoir and unloading pedal. Zinc
plated steel body, chromed steel rod.
PART MAX WORKING

DISPLACEMENT WEIGHT (KG) PRICE
NUMBER PRESSURE
FPSE20 14cm3 200 BAR 11 £382.47

TAKE
FLOWFIT HPTCV SINGLE ACTING HANDPUMP 50%
OFF AL
PRICESL
• All handpumps are fully interchangeable with

other leading Italian manufacturers.
• Supplied with rubber protection for the piston,
pressure relief valve, check valve to lock a single
acing cylinder, release knob and mounting kit to
bolt handpump to a tank.
OEM
PRICING SEE TANKS
AVAILABLE
ON PAGE 51

HPTCV6VS 6CM3 500 BAR 3.1 KG £273.99
HPTCV12VS 12CM3 380 BAR 3.0 KG £155.77
HPTCV25VS 25CM3 350 BAR 3.1 KG £158.55
HPTCV45VS 45CM3 280 BAR 3.2 KG £161.33

ZINC L A WEIGHT
PART NUMBER PRICE
PLATED mm mm (KG)
LV27x330 white 330 27 0.5 £10.93
LV27x400 white 400 27 0.6 £10.93
LV27x850 white 850 27 1.02 £15.19
LV27x1000 white 1000 27 1.5 £18.22
TAKE
FLOWFIT HPTD DOUBLE ACTING HANDPUMP 50%
OFF AL
PRICESL
• All handpumps are fully interchangeable with

other leading Italian manufacturers.
• Supplied with rubber protection for the piston,
4/3 diverter lever operated and mounting kit to
bolt handpump to a tank and operate a double
acting cylinder.
SEE TANKS
ON PAGE 51
OEM
PRICING
AVAILABLE

HPTD6DCCS 6CM3 500 BAR 3.1 KG £226.70

ZINC L A WEIGHT
PART NUMBER PRICE
PLATED mm mm (KG)
LV27x330 white 330 27 0.5 £10.93
LV27x400 white 400 27 0.6 £10.93
LV27x850 white 850 27 1.02 £15.19
LV27x1000 white 1000 27 1.5 £18.22
50 • HYDRAULIC HANDPUMPS DOWNLOAD TECHNICAL PDFs AT www.flowfitonline.com

TAKE
FLOWFIT HPTDV DOUBLE ACTING HANDPUMP 50% OFF AL
PRICESL
• All handpumps are fully interchangeable with other leading Italian

OEM
PRICING
manufacturers.
AVAILABLE • Supplied with rubber protection for the piston, pressure relief valve,
double pilot check valve, 4/3 diverter lever operated and mounting
kit to bolt handpump to a tank.
SEE TANKS BELOW

HPTDVB6VS 6CM3 500 BAR 3.1 KG £290.68
SEE LEVERS ON PAGE 50

TAKE
PAINTED STEEL HYDRAULIC TANKS FOR HANDPUMPS 50% OFF AL
PRICESL
PART TANK CAPACITY A B C D H WEIGHT

PRICE
NUMBER LITRES mm mm mm mm mm (KG)
SR01FE 1 100 120 150 90 120 2 £46.59
SR02FE 2 100 120 150 90 180 2.2 £51.32
SR03FE 3 100 120 150 90 245 2.5 £54.52
SR05FE 5 175 195 175 110 200 4.5 £68.84
SR07FE 7 175 195 175 110 269 5.4 £75.38
SR10FE 10 175 195 175 110 376 6.8 £79.83
RAL 9005 BLACK OIL PROOF PAINTING
TAKE
ALUMINIUM HYDRAULIC TANKS FOR HANDPUMPS 50% OFF AL

PRICESL
• ONE LITRE ALUMINUM OIL TANKS FOR ALL HANDPUMPS
TANK WEIGHT
PART NUMBER PRICE
CAPACITY (KG)
SR01AL 1 1 £57.72
• 2-3-5 LITRE ALUMINUM OIL TANKS FOR ALL HANDPUMPS
PART NUMBER PART NUMBER PRICE

TANK WEIGHT H PRICE WITH
WITHOUT OIL WITH OIL WITHOUT OIL
CAPACITY (KG) mm OIL LEVEL
LEVEL LEVEL LEVEL
SR02AL SR02ALO 2 1.5 25 £67.45 £75.38
SR03AL SR03ALO 3 1.6 70 £72.32 £80.67
SR05AL SR05ALO 5 1.8 180 £79.55 £87.90

FILTROS
Filtro de succión
ITALIA
ISO 9001
Para montar en la succión de las bombas dentro de los depósitos.

Caudal de 12 a 500 Lts/min.
Filtración standard 125 µm.
Rango de temperatura de -40 a +90ºC
C
Puede ser utilizado con aceites minerales, sintéticos y líquidos refrigerantes. 01
Malla de bronce - Cabezal aluminio Malla de acero inoxidable - Cabezal plástico
125 µm A B C CH 130 µm A B C
TIPO Lt/min BSP TIPO Lt/min BSP
ST-38 12 3/8 90 46 24 FSS - 003 12 1/4” 62 70
ST-12 15 1/2 105 46 30 FSS - 005 20 3/4” 62 70
ST-34 25 3/4 109 64 36 FSS - 007 28 3/4” 87 70
ST-100A 50 1 139 64 46 FSS - 010 40 1” 112 70
ST-100B 80 1 139 86 52 FSS - 015 60 1 1/4” 137 100
ST-114 90 1 1/4 139 86 52 FSS - 020 80 1 1/2” 162 100
ST-112A 95 1 1/2 139 86 60 FSS - 030 120 1 1/2” 192 100
ST-112B 130 1 1/2 200 86 60 FSS - 040 160 2” 212 100
ST-112C 220 1 1/2 151 150 70 FSS - 050 200 2” 237 100
ST-200A 180 2 260 86 70 FSS - 075 300 2 1/2” 195 140
ST-200B 225 2 151 150 70 FSS - 100 400 3” 240 140
ST-212 350 2 1/2 211 150 90 FSS - 150 600 3” 240 140
ST-300 500 3 272 150 100
Caída de presión con aceite 36 CST/40º

DESIGNACIÓN
PARA ORDENAR:
TIPO ST---
MALLA
INOXIDABLE
AISI 304 S BSP B
MALLA BRONCE B NPT N
DESIGNACIÓN
PARA ORDENAR:
TIPO FSS----
TAMAÑO

FILTROS
Filtro a cartucho
ITALIA
ISO 9001
para montaje en línea
Filtros a cartucho con elemento descartable para succión y/o retorno.
Presión contínua 12 BAR. Presión máxima 30 BAR.
Caudal hasta 300 lt/min. Temperatura de trabajo -40 a +90ºC.
C
03
Para montaje en tanque

BSP
FILTRO ELEMENTO A B C D E F G H J K L M N P
I O
S0T-5 SOET-5 74 70 7 90 25 98 201 25 20 50 129 80 36 95 3/4” 3/4”
S0T-10 SOET-10 105 100 9 123 25 136 254 36 20 70 166 100 60 129 1 1/4” 1 1/4”
Para montaje en línea

FILTRO ELEMENTO A B C D E F G H I L M N O PESO
BSP KG
S0-5 SOE-5 3/4 95 160 20 38 22 65 - - M8 - - - 0,9
S0-10 SOE-10 1 1/4 133 210 25 50 30 80 - - M8 - - - 1,9
S0-15 SOE-15 1 1/4 133 255 25 50 30 80 - - M8 - - - 2,2
S0-20 SOE-10 1 1/2 140 215 25 65 70 80 - - M10 - - - 3,6
S0-25 SOE-15 1 1/2 140 260 25 65 70 80 - - M10 - - - 4
S0-30 SOE-10 1 1/2 130 220 25 60 45 90 150 285 M10 - - - 4,7
S0-30F SOE-10 - 130 220 25 60 45 90 150 285 M10 70 35,7 M12 4,7
S0-35 SOE-15 1 1/2 130 265 25 60 45 90 150 285 M10 70 35,7 M12 5,4
S0-35F SOE-15 - 130 265 25 60 45 90 150 285 M10 70 35,7 M12 5,4
Caída de presión con aceite 36 ST/40ºC DESIGNACIÓN PARA ORDENAR:

Con elemento de papel de 10 micrones en retorno. ELEMENTO TIPO SOE
Eficiencia βx= 75 (10 µm) FILTRO COMPLETO
SO 5 10 VCI R
TAMAÑO
5 5 5 µm MICRO FIBRA
10 10 10 µm PAPEL
15 25 25 µm PAPEL
60 60 µm MALLA AISI 304 S.S.
125 125 µm MALLA BRONCE
MANÓMETRO VCIP
VACUÓMETRO VCIV
INDICADOR ELÉCTRICO EIP
VACUOMETRO ELÉCTRICO EIV
SIN INDICADOR X
Nota: RETORNO CON VÁLVULA DE BY-PASS 1,7 BAR R

Para utilizar nuestros elementos en succión SUCCION CON VÁLVULA DE BY-PASS 0,2 BAR A
calcular que admiten sólo 1/5 SIN VÁLVULA DE BY-PASS X
del caudal indicado en la curva.

FILTROS
ITALIA
ISO 9001
Filtros “SOT” Filtros “SO”

para montaje en tanque para montaje en línea
C
04
Elementos Filtrantes
Nota:
Los elementos
pueden
suministrase
con o sin
BY-PASS.
Tipo Gresen
ELEMENTO TIPO ROSCA “A” øB C ELEMENTO TIPO ROSCA “A” øB C

SOE 5 3/4 BSP sin válvula BY PASS 97 150 PE FA 10 1-12 UN con BY PASS 95 150
SOET 5 3/4 BSP con válvula BY PASS 97 150 G SOE 5 10 1-12 UN con BY PASS 95 150
SOE 10 1 1/4 BSP sin válvula BY PASS 130 185 G SOE 5 5 1-12 UN con BY PASS 95 150
SOET 10 1 1/4 BSP con válvula BY PASS 130 185 PE FB 10 11/2 -16 UNF con BY PASS 130 170
SOE 15 1 1/4 BSP sin válvula BY PASS 130 185 G SOE 10 5 11/2 -16 UNF con BY PASS 130 170
G SOE 10 10 11/2 -16 UNF con BY PASS 130 170
Presión contínua 12 BAR
G SOE 10 25 11/2 -16 UNF con BY PASS 130 170
Elementos Filtrantes para bombas Linde y Sundstrand Presión contínua 12 BAR
ELEMENTO ROSCA “A” øB C
L-000.983.0615 BPV 70/100 1” UNF x 12 78 140
L-000.983.06.23 BPV 35/50 3/4” UNF x 16 93 170
SUNDSTRAND 1 3/8 -12 UN 94 150
SUNDSTRAND 1 3/8 -12 UN 94 240
Presión máxima 30 BAR
VÁLVULAS EN LÍNEA
F.LLI TOGNELLA S.p.A.

Válvula de retención
ITALIA
ISO 9001
en línea
DESIGNACIÓN
PARA ORDENAR:
FT 257/6 14 / 2
TAMAÑO
PRESIÓN DE APERTURA
Válvula de retención 2 - 4 - 6 - 8 - 10 BAR
Tipo a pistón asiento -0,35 BAR (STANDARD) SIN CÓDIGO
metal/metal
Presión máxima 400 bar

material acero
K
a pedido en acero inoxidable 17
∆P AL CAUDAL ROSCA
CAUDAL GAS PESO
TAMAÑO INDICADO UNI 338 B C CH
lts/min kg
bar A
18 10 1 1/8”G 8,5 46 17 0,075
14 20 1 1/4” G 12,5 63 22 0,165
38 30 1 3/8” G 12,5 69 27 0,260
12 40 1 1/2” G 15,5 80,5 32 0,415
34 60 1,5 3/4” G 17 99,5 36 0,605
100 100 2 1” G 20 117 46 1,170
114 300 3 1 1/4” G 22 134,5 55 1,850
112 500 5 1 1/2” G 24 159 65 3,130
200 700 3 2” G 27 198 75 4,900

VÁLVULAS EN LÍNEA
F.LLI TOGNELLA S.p.A.

Válvula de aguja con flujo inverso libre
ITALIA montaje en línea o panel
ISO 9001
DESIGNACIÓN
PARA ORDENAR:
FT 257/5 14 -
TAMAÑO
- SIN CÓDIGO STANDARD
cuerpo acero G = CON TUERCA P/MONTAJE EN PANEL
manopla aluminio V = SELLOS VITON ESPECIAL
MP = MANOPLA PLÁSTICA (A PEDIDO)
PRESIÓN CAUDAL ∆P AL CAUDAL ROSCA

GAS PESO
TAMAÑO MÁXIMA MÁXIMO INDICADO UNI 338 B C D E F F1 G H CH
A kg
bar lts/min bar
18 400 8 20 1/8”G 8,5 50 59 64 22 40 13,5 M17x1 16 0,130
14 400 12 15 1/4” G 12,5 66 71 78 27 50 17 M20x1 20 0,250
38 400 35 18 3/8” G 12,5 79 84 93 33 70 19,5 M25x1,5 25 0,500
12 400 50 18 1/2” G 15,5 94,5 97 107 38 80 21 M30x1,5 30 0,750
34 400 80 20 3/4” G 17 115 120,5 132,5 47 100 26,5 M40x1,5 40 1,600
100 320 180 15 1” G 20 138,5 151,5 167,5 58 120 35 M50x1,5 50 3,050
114 320 180 9 1 1/4” G 22 157 156,5 172,5 58 120 35 M50x1,5 55 3,750
112 320 180 5 1 1/2” G 24 190 167 181 58 120 35 M55x2 65 5,760
200 320 200 2 2” G 27 228 188 202 85 - 44 M65x2 75 10,000
VÁLVULAS INSERTABLES A CARTUCHO
Válvula reguladora de caudal compensada

en presión con flujo inverso libre
K
DESIGNACIÓN 03
- Válvula compensada en presión
- Baja histeresis. PARA ORDENAR:
- Posee escala graduada y tornillo
para traba. FT 270/5 14 -
- Puede ser montada en panel a
través de tuerca “G”. TAMAÑO
- Presión de trabajo 210 bar. - SIN CÓDIGO STANDARD

G = CON TUERCA P/MONTAJE EN PANEL
cuerpo acero
manopla aluminio
PRESIÓN CAUDAL ∆P AL CAUDAL ROSCA

GAS PESO
TAMAÑO MÁXIMA MÁXIMO INDICADO UNI 338 B C D E F G H CH
kg
bar lts/min bar A
14 400 20 5 1/4” G 12,5 94 81,5 88,5 27 15 M20x1 30 0,580
38 400 40 7 3/8” G 13 110,5 94,5 103 33 17 M25x1,5 35 0,940
12 400 100 10 1/2” G 15,5 137 112 122 38 18 M30x1,5 45 1,830
34 400 140 10 3/4” G 17 163 138 150 47 24 M40x1,5 55 3,350
100 320 180 6 1” G 21 214 175 192 58 32 M50x1,5 70 7,000

VÁLVULAS EN LÍNEA
Válvula reguladora de caudal

ITALIA
ISO 9001
3 vías con válvula prioritaria
VRF C3/V/VS..
DESIGNACIÓN PARA ORDENAR:

V R F C3 / V / V S
ROSCAS G 3/8 38
ROSCAS G 1/2 12
ROSCAS G 3/4 34
60
Q (l/min)
12
50
38-12
40
30
38-12
20
10
0
40 80 120 160 200
P (bar)
100
34
Q (l/min)
90
80
70
K
34
60 11
50
40
34
30
20
10
0
40 80 120 160 200
P (bar)
CAUDAL l/min PRESIÓN

TIPO G A B C D E F J H I K L M
conección E conección CF NOMINAL (bar)
VRF C3(V) VS38 G 3/8 50 40
90 110,5 78 72,5 6,5 30 48 129 6 40 71 40
VRF C3(V) VS12 G 1/2 90 50 210
VRF C3(V) VS34 G 3/4 150 90 110 145 94 85 8,5 35 55,5 144 8 44 80 49
Ajustar la válvula de alivio 15-20 bar por sobre la presión de trabajo.
Esta válvula reguladora de caudal compensada en presión, limita la salida de caudal a través de la
conección “CF” independientemente de la carga y los cambios de presión. Es del tipo de 3 vías, una
vez regulada el caudal excedente es derivado al tanque por la conección “T”.
Una válvula de alivio ventea el compensador a la presión seleccionada y drena todo el flujo al tanque.

B-Componentes
Piping
3-1-529
GARDNER DENVER® TH
7 EDITION
JUNE 2008
TRIPLEX PISTON PUMP
5” STROKE
MODEL
TEE
PARTS LIST
MAINTAIN PUMP RELIABILITY AND PERFORMANCE
WITH GENUINE GARDNER DENVER®
PARTS AND SUPPORT SERVICES
Gardner Denver® genuine pump parts are manufactured to design tolerances and are developed for
optimum dependability. Design and material innovations are the result of years of experience with
hundreds of different pump applications. Reliability in materials and quality assurance are incorporated in
our genuine replacement parts.
Your authorized Gardner Denver distributor offers all the backup you’ll need. A worldwide network
of authorized distributors provides the finest product support in the pump industry. Your local authorized
distributor maintains a large inventory of genuine parts and he is backed up for emergency parts issues
with access to Oklahoma City, OK. and the factory in Quincy, IL.
Your authorized distributor can support all your Gardner Denver pump needs.
Trained parts specialists are available to assist you in selecting the correct replacement parts.
ALL ORDERS for PARTS should be placed with the NEAREST Authorized Distributor.
To find your nearest distributor you may use one of the following choices:
* Log onto the Gardner Denver web site: www.gardnerdenver.com
* Send an E-Mail request to: [email protected]
* Contact one of our sales offices listed below.
The Gardner Denver Sales Offices are located as follows:
DOMESTIC INTERNATIONAL
Gardner Denver Gardner Denver
2200 South Prospect 1800 Gardner Expressway
Oklahoma City, OK. 73129 Quincy, IL 62301
Phone: (405) 677-5736 Phone: (217) 222-5400
Fax: (405) 677-5807 Fax: (217) 223-1581
INSTRUCTIONS FOR ORDERING REPAIR PARTS:
When ordering parts, specify Pump MODEL and SERIAL NUMBER (see nameplate on unit).
The Serial Number is also stamped on top of the frame at the connecting end.
(Between the cradle opening and the fluid cylinder)
SPECIFY THE NUMBER OF PARTS REQUIRED, EXACTLY.
DO NOT ORDER BY SETS OR GROUPS.
To determine the Right Hand and Left-Hand side of a pump, stand at the power end and look toward the
fluid end. Right Hand and Left Hand are indicated in parenthesis following the part name, i.e. (RH) and
(LH), when appropriate.
For Operating and Service Instructions see:
SERVICE MANUAL 3-1-606
3-1-529 Page i
3-1-529
GARDNER DENVER® TH
7 EDITION
JUNE 2008
TRIPLEX PISTON PUMP
5” STROKE
MODEL
TEE
PARTS LIST
MAINTAIN PUMP RELIABILITY AND PERFORMANCE
WITH GENUINE GARDNER DENVER®
PARTS AND SUPPORT SERVICES
Gardner Denver® genuine pump parts are manufactured to design tolerances and are developed for
optimum dependability. Design and material innovations are the result of years of experience with
hundreds of different pump applications. Reliability in materials and quality assurance are incorporated in
our genuine replacement parts.
Your authorized Gardner Denver distributor offers all the backup you’ll need. A worldwide network
of authorized distributors provides the finest product support in the pump industry. Your local authorized
distributor maintains a large inventory of genuine parts and he is backed up for emergency parts issues
with access to Oklahoma City, OK. and the factory in Quincy, IL.
Your authorized distributor can support all your Gardner Denver pump needs.
Trained parts specialists are available to assist you in selecting the correct replacement parts.
ALL ORDERS for PARTS should be placed with the NEAREST Authorized Distributor.
To find your nearest distributor you may use one of the following choices:
* Log onto the Gardner Denver web site: www.gardnerdenver.com
* Send an E-Mail request to: [email protected]
* Contact one of our sales offices listed below.
The Gardner Denver Sales Offices are located as follows:
DOMESTIC INTERNATIONAL
Gardner Denver Gardner Denver
2200 South Prospect 1800 Gardner Expressway
Oklahoma City, OK. 73129 Quincy, IL 62301
Phone: (405) 677-5736 Phone: (217) 222-5400
Fax: (405) 677-5807 Fax: (217) 223-1581
INSTRUCTIONS FOR ORDERING REPAIR PARTS:
When ordering parts, specify Pump MODEL and SERIAL NUMBER (see nameplate on unit).
The Serial Number is also stamped on top of the frame at the connecting end.
(Between the cradle opening and the fluid cylinder)
SPECIFY THE NUMBER OF PARTS REQUIRED, EXACTLY.
DO NOT ORDER BY SETS OR GROUPS.
To determine the Right Hand and Left-Hand side of a pump, stand at the power end and look toward the
fluid end. Right Hand and Left Hand are indicated in parenthesis following the part name, i.e. (RH) and
(LH), when appropriate.
For Operating and Service Instructions see:
SERVICE MANUAL 3-1-606
3-1-529 Page i
TABLE OF CONTENTS
Maintain Pump Reliability And Performance with Genuine Gardner Denver Parts and Support Services ..... i
Instructions For Ordering Repair Parts ............................................................................................................ i
Table of Contents............................................................................................................................................ ii
Frame Group...................................................................................................................................................1
Eccenttric, Shaft and Bearing Group ..............................................................................................................2
Oil Circulating Pump .......................................................................................................................................3
Oil Filter ...........................................................................................................................................................4
Connecting Rod ..............................................................................................................................................5
Crosshead & Oil Stop Head Group.................................................................................................................6
Oil Pump and Piping ................................................................................................................................ 7 & 8
Crosshead Lubrication Piping - LEFT HAND DRIVE......................................................................................9
Crosshead Lubrication Piping - RIGHT HAND DRIVE .................................................................................10
Fluid End - Low Pressure Cast Aluminum Bronze Cylinder (4 x 5) ..............................................................11
Fluid End - Medium Pressure Cast Aluminum Bronze Cylinder (3 x 5)........................................................12
Fluid End - High Pressure Block Steel Cylinder (2 x 5) ................................................................................13
Fluid End - High Pressure Cast Steel Cylinder (3 x 5)..................................................................................15
Stuffing Box, Plunger and Packing .................................................................................................. 16 thru 25
Piston and Liners ..........................................................................................................................................26
Delrin Disc Fluid Valves for Low Pressure Cast Aluminum Bronze Cylinder (4 x 5) ....................................27
Wing Guided Fluid Valves Low Pressure Cast Aluminum Bronze Cylinder (4 x 5) ......................................28
Delrin Disc Fluid Valves for Medium Pressure Cast Aluminum Bronze Cyl (3 x 5) ......................................29
Wing Guided Fluid Valves Medium Pressure Cast Aluminum Bronze Cyl (3 x 5)........................................30
Delrin Disc Suction Fluid Valves for High Pressure Block Steel Cylinder (2 x 5) .........................................31
Delrin Disc Discharge Fluid Valves for High Pressure Block Steel Cylinder (2 x 5) .....................................32
Wing Guided S&D Fluid Valves for High Pressure Block Steel Cylinder (2 x 5) ............................. 33 thru 36
Stem Guided S&D Fluid Valves, Stainless Steel, Abrasion Resistant for High Pressure
Block Steel Cylinder (4 x 5).........................................................................................41
Wing Guided S&D Fluid Valves for High Pressure Cast Steel Cylinder (3 x 5)............................... 42 thru 44
Stem Guided S&D Fluid Valves, SS, Abrasion Resistant for High Pressure Cast Steel Cylinder (3 x 5) ....45
Lubricator Group (Optional Equipment) ........................................................................................................46
Piston Rod Wash Piping (Optional Equipment) ................................................................................... 47 & 48
Valve Seat Puller (Optional Equipment) .......................................................................................................49
Customer Repair Information ........................................................................................................................50
Customer NOTES .........................................................................................................................................51
Gardner Denver Unit Record .............................................................................................. Inside Back Cover
3-1-529 Page ii
Order by Part Number and Description. Reference Numbers are shown for your convenience only.
Ref. Drawing - 301TEE810

FRAME GROUP
Ref. No. Description Qty. Part No.
1 FRAME (POWER END) ......................................................... 1 304TEE001
2 INSPECTION PLATE, With Oil Manifold (Crosshead)........... 1 301TEE052
2A INSPECTION PLATE (Crosshead) ........................................ 1 302TEE052
3 SCREW, Inspection Plate ...................................................... 12 75A136
4 GASKET, Inspection Plate ..................................................... 2 25C1941
5 GASKET, Crankcase Flange.................................................. 2 25C157N
6 SCREW, Crankcase Flange................................................... 4 655ED030
7 FLANGE, Crankcase Oil Drain............................................... 2 29AUX27
8 PLUG, Crankcase Flange ...................................................... 2 64AA7
9 PLUG, Oil Level...................................................................... 2 64AA5
10 PIPE ELBOW, Oil Level ......................................................... 1 64D2
11 RETAINER PLATE (Includes next item) ................................ 1 PE1400
STUD...................................................................................... 3 79A69
12 NUT-ACORN.......................................................................... 3 50Q14
13 GASKET- COPPER, Retainer Stud Nut................................. 3 25F44
14 INSPECTION PLATE (Frame End)........................................ 1 200TEE052
15 GASKET (Frame End Inspection Plate)................................. 1 200TEE715
16 HOOD..................................................................................... 1 201TEE053
17 SCREW, Hood ....................................................................... 12 75A136
18 GASKET, Hood ...................................................................... 1 201TEE715
19 PLUG (OPPOSITE SIDE) ...................................................... 1 64B3
20 LIFTING EYE ......................................................................... 2 200TEE263
21 BREATHER............................................................................ 1 5C7
22 INSPECTION PLATE (CRADLE COVER) *........................... 1 201TEE052
23 STUD...................................................................................... 2 79A466
24 WING NUT ............................................................................. 2 50H1
* See page 50 for all cradle cover options.
3-1-529 Page 1
Ref Drawing - 313TEE799
ECCENTRIC, SHAFT & BEARING GROUP

Ref No. Description Qty. Part No.
1 ECCENTRIC, Includes the next item ..................................... 1 200TEE255
2 ORIFICE ................................................................................. 2 200TEE814
3 KEY, Eccentric to Shaft .......................................................... 1 35K17
4 SHAFT-ECCENTRIC ............................................................. 1 1PE367
5 BEARING, Eccentric Shaft ..................................................... 1 12C60
6 HOUSING-BEARING, Oil Pump End..................................... 1 2PE266
7 SCREW, Bearing Housing to Frame...................................... 12 655EF050
8 GASKET, Bearing Housing .................................................... 2 25C1945
9 HOUSING-BEARING, Drive End ........................................... 1 3PE366
10 SEAL-OIL, Eccentric Shaft ..................................................... 1 60G63
11 BEARING, Eccentric Shaft ..................................................... 1 12BA64
12 KEY, Drive .............................................................................. 1 35B72
3-1-529 Page 2
Ref. Drawing – 311TEE799
OIL CIRCULATING PUMP

OIL CIRCULATING PUMP, Includes Ref No’s 1 thru 10 1 200PEE188
1 ROTOR ................................................................................... 1 2109376
2 BUSHING, Bracket.................................................................. 1 2118594
3 GASKET, Cover ...................................................................... 2 54C222
4 SCREW, Cover Cap................................................................ 8 2118595
5 COVER.................................................................................... 1 2109371
6 IDLER CARRIER ASSEMBLY, Includes Ref No’s 7............... 1 2109372
7 PIN, Idler ................................................................................. 1 2109373
8 GEAR, Idler ............................................................................. 1 2118596
9 BRACKET ASSEMBLY, Includes Ref No. 2 ........................... 1 2109370
10 HOUSING................................................................................ 1 2118597
11 SCREW, Housing.................................................................... 4 2118598
12 SCREW, Housing.................................................................... 4 2118599
13 NUT, Housing screw ............................................................... 4 2118600
14 SPRING, Ball........................................................................... 1 2118601
15 BALL........................................................................................ 1 2118602
The Part Numbers that are listed are for those parts that are provided for repair.
3-1-529 Page 3
OIL FILTER
OIL FILTER ASSEMBLY, Includes next 2 items 1 26C51
1 HEAD ASSEMBLY .................................................................. 1 2118128
2 ELEMENT ............................................................................... 1 2118384
3-1-529 Page 4
CONNECTING ROD
Ref.
No. Description Qty. Part No.
1 CONNECTING ROD, Includes the next 4 items ..................... 3 PE417
2 BUSHING, Eccentric ............................................................... 3 PE421
3 BUSHING, Crosshead Pin ...................................................... 3 PE229
4 PLUG....................................................................................... 3 64AC2
5 LOCK SCREW ........................................................................ 3 75LM162N
3-1-529 Page 5
CROSSHEAD & OIL STOP HEAD GROUP

1 CROSSHEAD (Standard Size) ................................................................ 3 300TEE005
CROSSHEAD (0.125” Oversized – Optional) ***..................................... 3 301TEE005
2 CROSSHEAD PIN.................................................................................... 3 2005051
3 RING, Crosshead Pin Retainer ................................................................ 6 65W19
4 GASKET, Oil Stop Head to Frame........................................................... 3 25C1948
OIL STOP HEAD ASSEMBLY, Includes Ref No’s 5, 6 & 7 ..................... 3 PE226A
5 OIL STOP HEAD...................................................................................... 3 PE226
6 STUD, Gland ............................................................................................ 6 79A238
7 NUT, Gland .............................................................................................. 6 50F5
8 SCREW, Oil Stop Head to Frame ............................................................ 12 655EE050
9 PACKING, Oil Stop Head......................................................................... 3 60DD99
10 GLAND, Oil Stop Head ............................................................................ 3 PE238
11 ROD-EXTENSION ................................................................................... 3 300TEE839
12 BAFFLE, Piston Rod ** ............................................................................ 3 200TAE840
13 PLUNGER COUPLING ASSEMBLY, Includes Ref No’s 14 & 15............ 3 201TAE092A
14 SCREW, Coupling.................................................................................... 6 655EE17S
15 NUT, Coupling.......................................................................................... 6 50AW35
* See Note Number 1, page 50, for customer repair information

** See Note Number 2, page 50, for customer repair information
*** See Note Number 3, page 50, for customer repair information
3-1-529 Page 6
OIL PUMP AND PIPING
3-1-529
Page 7

OIL PUMP AND PIPING
Ref. Ref.
No. Name of Part Qty. Part No. No. Name of Part Qty. Part No.
1 * OIL PUMP (Includes next item) .................... 1 200PEE188 24 HOSE ADAPTOR ....................................... 1 29Q6
2 SCREW, Oil Pump to Adaptor......................... 4 655ED190 25 PIPE BUSHING .......................................... 1 64E95
3 ** OIL FILTER ................................................. 1 26C51 26 LIQUID RELIEF VALVE.............................. 1 90Q22
4 OIL SCREEN................................................... 1 2WAJ511 27 PIPE STREET ELBOW .............................. 1 64D6
5 STUD, Connector to Frame............................. 2 79A204 28 PIPE TEE.................................................... 2 64G7
6 GASKET, Oil Drain Flange.............................. 1 25C157N 29 PIPE NIPPLE .............................................. 3 63U12X14
3-1-529
7 CONNECTOR ................................................. 1 200PEE284 30 PIPE BUSHING .......................................... 1 64E6

8 NUT, Connector to Frame Stud ...................... 2 50B3 31 HOSE ADAPTOR ....................................... 2 29Q16
9 PIPE NIPPLE .................................................. 1 64H4 32 HOSE ASSEMBLY ..................................... 1 29R26
Page 8
10 PIPE CROSS .................................................. 1 64K18 33 PIPE PLUG ................................................. 1 64A24

11 PIPE PLUG...................................................... 1 64A25 34 FILTER BRACKET...................................... 1 200TEE389
12 BUSHING ........................................................ 1 64E15 35 SCREW, Filter to Bracket ........................... 4 75LM51
13 GAUGE............................................................ 1 27H11 36 HOSE ASSEMBLY ..................................... 1 29E12
14 PIPE NIPPLE .................................................. 1 64H4 37 PIPE TEE.................................................... 1 64P78
15 CHECK VALVE ............................................... 1 300TEE308 38 GASKET, Oil Pump to Adaptor................... 1 201PEE715
16 PIPE NIPPLE .................................................. 1 304TEE126 39 ADAPTOR, Oil Pump.................................. 1 200PEE170
17 COUPLING...................................................... 1 300TEE572 40 SCREW, Adaptor to Bearing Housing ........ 6 655EE050
18 PIPE NIPPLE .................................................. 1 303TEE126 41 PRESSURE GAUGE .................................. 1 27A13
20 PIPE NIPPLE .................................................. 1 63H29 43 OIL SEAL, Main Shaft................................. 1 1PE447
21 PIPE BUSHING............................................... 1 64E7 44 PISTON RING, Oil Seal.............................. 2 65A33
22 PIPE STREET ELBOW ................................... 1 64D5 45 SHIM ........................................................... 2 77G16
23 HOSE ASSEMBLY.......................................... 1 29430
* For Oil Pump and Component Parts – See Page 3

** For Oil Filter and Component Parts – See Page 4
LEFT HAND DRIVE - CROSSHEAD LUBRICATION PIPING

1 ADAPTOR ............................................................................... 6 29Z207
2 ADAPTOR ............................................................................... 6 29Z242
3 HOSE ASSEMBLY.................................................................. 2 1000T29
4 HOSE ASSEMBLY.................................................................. 2 301TEE127
5 HOSE ASSEMBLY.................................................................. 1 1000T09
6 HOSE ASSEMBLY.................................................................. 1 30031008
7 ADAPTOR ............................................................................... 1 29Z224
8 ADAPTOR ............................................................................... 1 142635
9 PLUG....................................................................................... 1 64B3
10 HOSE ASSEMBLY.................................................................. 1 1001T55
3-1-529 Page 9
RIGHT HAND DRIVE - CROSSHEAD LUBRICATION PIPING

1 ADAPTOR ............................................................................... 6 29Z207
2 ADAPTOR ............................................................................... 6 29Z242
3 HOSE ASSEMBLY.................................................................. 2 1000T29
5 HOSE ASSEMBLY.................................................................. 1 1000T09
6 HOSE ASSEMBLY.................................................................. 1 30031008
7 ADAPTOR ............................................................................... 1 29Z224
8 ADAPTOR ............................................................................... 1 142635
9 PLUG....................................................................................... 1 64B3
10 HOSE ASSEMBLY.................................................................. 1 1001T55
3-1-529 Page 10
FLUID END (TEEA) (4x5)

Low Pressure Cast Aluminum Bronze Cylinder – 4”

FLUID CYLINDER ASSEMBLY, Includes Ref No’s: 1 thru 6 1 2PE29B
1 FLUID CYLINDER .................................................................................... 1 2PE29
2 STUD, Cylinder to Frame ......................................................................... 12 79AB9
3 NUT, Cylinder to Frame............................................................................ 12 50B34
4 NUT, Valve Cover Stud ............................................................................ 12 50B10
5 STUD, Valve Cover to Cylinder ................................................................ 12 79L1
6 NUT, Cylinder Stuffing Box....................................................................... 12 50B32
7 COVER-VALVE ........................................................................................ 6 3PE147
8 GASKET, Valve Cover ............................................................................. 6 25AL36
9 GASKET, Manifold to Cylinder ................................................................. 3 25AL62
10 MANIFOLD, Suction ................................................................................. 1 8PE110
11 SCREW, Manifold to Cylinder .................................................................. 12 655EF060
12 PLUG, Manifold ........................................................................................ 3 64AJ16
14 FLANGE, Suction (Steel - Threaded) ....................................................... 2 64CA13 *
15 GASKET, Flange ...................................................................................... 2 25C861N *
16 SCREW, Suction Flange .......................................................................... 16 655EG080 *
17 NUT, Flange Screw .................................................................................. 16 50B8 *
* These parts are not standard equipment, but are furnished when ordered.
3-1-529 Page 11
FLUID END (TEEB) (3x5)

Medium Pressure Cast Aluminum Bronze Cylinder – 3”

FLUID CYLINDER ASSEMBLY, Includes Ref No’s: 1 thru 6................... 1 3PE29B
1 FLUID CYLINDER ................................................................................... 1 3PE29
2 STUD, Valve Cover to Cylinder ................................................................ 24 79AJ5
4 NUT, Cylinder to Frame Stud ................................................................... 12 50B34
5 NUT, Cylinder Stuffing Box....................................................................... 12 50C9
7 COVER-VALVE ........................................................................................ 6 4PE147
9 GASKET, Manifold to Cylinder ................................................................. 3 25BE27
12 PLUG, Manifold ........................................................................................ 3 64AJ16
15 GASKET, Flange ...................................................................................... 2 25C121N *
16 SCREW, Suction Flange .......................................................................... 16 655EF100 *
3-1-529 Page 12
FLUID END (TEEC) (2x5)

High Pressure Block Steel Cylinder – 2”
FLUID CYLINDER ASSEMBLY, Includes Ref No’s: 1 thru 9................... 3 200PEE029B
1 FLUID CYLINDER .................................................................................... 3 200PEE029
2 STUD, Cylinder to Discharge Manifold..................................................... 12 79AJ1
3 STUD, Valve Cover .................................................................................. 12 79AJ5
4 STUD, Cylinder to Frame & Stuffing Box ................................................. 12 79AK8
5 NUT, Cylinder to Discharge Manifold Stud............................................... 12 50B31
7 NUT, Cylinder to Frame & Stuffing Box Stud ........................................... 24 50B32
8 WASHER, Cylinder to Stuffing Box .......................................................... 12 95U8
9 SPACER, Fluid Cylinder to Frame ........................................................... 6 80C44
10 COVER-VALVE ........................................................................................ 3 7PE147
12 MANIFOLD-SUCTION.............................................................................. 1 9PE110
13 SCREW, Suction Manifold to Cylinder ..................................................... 12 655EF060
14 GASKET, Suction Manifold to Cylinder .................................................... 3 25C1271N
15 PLUG, Suction Manifold ........................................................................... 3 64AA3
16 MANIFOLD-DISCHARGE ........................................................................ 1 200PEE071
17 GASKET, Cylinder to Discharge Manifold................................................ 3 25BC86
19 FLANGE, SUCTION (Steel - Threaded)................................................... 2 64CA11 *
20 GASKET, Suction Flange ......................................................................... 2 25C121N *
22 NUT, Suction Flange Screw ..................................................................... 16 50B7 *
23 FLANGE, Discharge Manifold (Steel – Weld Neck) ................................. 2 2009760 *
24 GASKET, Discharge Manifold Flange ...................................................... 2 2009761 *
25 SCREW, Discharge Manifold Flange ....................................................... 16 655EG180 *
26 NUT, Discharge Manifold Flange Screw .................................................. 16 50B32
3-1-529 Page 13
FLUID END (TEED & TEEE) (4x5)

FLUID CYLINDER ASSEMBLY, Includes Ref No’s: 1 thru 7 ................... 3 200TEE029B
1 FLUID CYLINDER .................................................................................... 3 200TEE029
2 STUD, Valve Cover .................................................................................. 48 201TEE110
3 STUD, Cylinder to Discharge Manifold..................................................... 12 79L96
8 NUT, Cylinder to Frame & Stuffing Box.................................................... 12 50AQ30
9 STUD, Cylinder to Frame & Stuffing Box ................................................. 12 200TEE110
10 COVER-VALVE, Suction .......................................................................... 3 200TEE147
11 GASKET, Valve Cover.............................................................................. 6 303TEE718
12 MANIFOLD-SUCTION.............................................................................. 1 200PEE069
16 MANIFOLD-DISCHARGE ........................................................................ 1 200TEE071
17 GASKET, Cylinder to Discharge Manifold ................................................ 3 25AL59
18 FLANGE, Discharge (Steel – Weld Neck) ................................................ 2 64EB37 *
19 SCREW, Flange to Discharge Manifold ................................................... 16 75A231
20 NUT, Discharge Flange ............................................................................ 16 50B9 *
21 GASKET, Discharge Flange..................................................................... 2 25BC42 *
22 COVER-VALVE, Discharge...................................................................... 3 PP1005549 *
3-1-529 Page 14
FLUID END (TEEF & TEEG) (3x5)

High Pressure Cast Steel Cylinder – 3”

6 NUT, Cylinder to Frame & Stuffing Box.................................................... 12 50T90
7 PLUG, Manifold ........................................................................................ 3 64AA3
9 COVER-VALVE ........................................................................................ 6 7PE147
11 MANIFOLD, Suction 4 inch (Standard) .................................................... 1 4PE110
MANIFOLD, Suction 6 inch (Optional)...................................................... 1 200PEE069
3-1-529 Page 15

STUFFING BOX, PLUNGERS & PACKING (TEEA)
Low Pressure Cast Aluminum Bronze Cylinder
STYLE 838 PACKING
Ref. 4.00" 3.50" 3.25" 3.00"
No. Name of Part Qty. Part No. Part No. Part No. Part No.
1 GASKET ............................................. 3 25AL36 25AL36 25AL36 25AL36
2 STUFFING BOX, Includes Ref No.3 3 8PE14 9PE14 23PE14 10PE14
3 LUBE FITTING .................................... 3 40E7 40E7 40E7 40E7
STYLE 838 PACKING GROUP
Includes Ref. Numbers 4 thru 7.......... 3 63PE1600 64PE1600 51PE1600 65PE1600
4 JUNK RING ........................................ 3 38PE317 36PE317 41PE317 26PE317
5 PACKING – STYLE 838..................... 3 60BU72 60BU73 60BU71 60BU74
6 LANTERN SPACER ............................ 3 31PE445 33PE445 28PE445 34PE445
7 GLAND BUSHING............................... 3 28PE152 29PE152 41PE152 30PE152
8 GLAND NUT ........................................ 3 2PE113 2PE113 3PE113 3PE113
9* PIN, Gland Nut tightening................... 3 62L72 62L72 62L72 62L72
10 PLUNGER (Colmonoy)........................ 3 1PE3840 1PE3835 1PE3832 302TEE038
10 PLUNGER (Ceramic) ......................... 3 PE3840 PE3835 PE3832 PE3830
10 PLUNGER (Chrome Plated)............... 3 3PE3840 3PE3835 3PE3832 3PE3830
STYLE 858 PACKING

Ref. 4.00" 3.50" 3.25" 3.00"
1 GASKET ............................................. 3 25AL36 25AL36 25AL36 25AL36
Includes Ref. Numbers 4 thru 7.......... 3 300TEE4060 301TEE4060 302TEE4060 303TEE4060
5 PACKING – STYLE 858..................... 3 60DD763 60DD761 60DD760 60DD759
* Not shown
3-1-529 Page 16

STUFFING BOX, PLUNGERS & PACKING (TEEB)
Medium Pressure Cast Aluminum Bronze Cylinder
STYLE 838 PACKING
Ref. 3.00" 2.75" 2.50" 2.25"
1 GASKET ............................................. 3 25AL36 25AL35 25AL35 25AL35
10 PLUNGER (Colmonoy)........................ 3 302TEE038 1PE3827 1PE3825 1PE3822
STYLE 858 PACKING

Ref. 3.00" 2.75" 2.50" 2.25"
1 GASKET ............................................. 3 25AL36 25AL35 25AL35 25AL35
* Not shown
3-1-529 Page 17

STUFFING BOX, PLUNGERS & PACKING (TEEC)
3 Piece High Pressure Block Steel Cylinder
STYLE 838 PACKING
Ref. 2.00" 1.75" 1.50"
No. Name of Part Qty. Part No. Part No. Part No.
1 GASKET ............................................. 3 25BD3 25BD3 25BD3
2 STUFFING BOX, Includes Ref No.3 3 34PE14 35PE14 35PE14
3 LUBE FITTING .................................... 3 40E7 40E7 40E7
Includes Ref. Numbers 4 thru 7 ......... 3 PS160020 PS160017 PS160015
4 JUNK RING ........................................ 3 PQ31720 PQ31717 PQ31715
5 PACKING – STYLE 838..................... 3 60BU97 60BU31 60BU98
6 LANTERN SPACER............................ 3 PQ44520 PQ44517 PQ44515
7 GLAND BUSHING............................... 3 PS15220 PS15217 PS15215
8 GLAND NUT........................................ 3 2011555 2011555 2011555
9* PIN, Gland Nut tightening .................. 3 62L45 62L45 62L45
10 PLUNGER (Colmonoy) ....................... 3 11PE3820 11PE3817 11PE3815
10 PLUNGER (Tungsten Carbide).......... 3 200TEE038 202TEE038 204TEE038
STYLE 858 PACKING

Ref. 2.00" 1.75" 1.50"
1 GASKET ............................................. 3 25BD3 25BD3 25BD3
3 LUBE FITTING .................................... 3 40E7 40E7 40E7
Includes Ref. Numbers 4 thru 7 ......... 3 307TEE4060 308TEE4060 309TEE4060
4 JUNK RING ........................................ 3 PQ31720 PQ31717 PQ31715
5 PACKING – STYLE 858..................... 3 60DD768 60DD754 60DD766
8 GLAND NUT........................................ 3 2011555 2011555 2011555
* Not shown
3-1-529 Page 18

STYLE 838 PACKING

Ref. 1.25"
No. Name of Part Qty. Part No.
1 GASKET .............................................. 3 25BD3
2 STUFFING BOX, Includes Ref No.3 3 36PE14
3 LUBE FITTING.................................... 3 40E7
Includes Ref. Numbers 4 thru 7 ........... 3 PS160012
4 JUNK RING.......................................... 3 PQ31712
5 PACKING – STYLE 838 ...................... 3 60BU33
6 LANTERN SPACER ........................... 3 PQ44512
7 GLAND BUSHING .............................. 3 PS15212
8 GLAND NUT ....................................... 3 2011555
9* PIN, Gland Nut tightening .................... 3 62L45
10 PLUNGER (Colmonoy)....................... 3 11PE3812
10 PLUNGER (Tungsten Carbide) ........... 3 206TEE038
STYLE 858 PACKING

Ref. 1.25"
1 GASKET .............................................. 3 25BD3
3 LUBE FITTING.................................... 3 40E7
Includes Ref. Numbers 4 thru 7 ........... 3 310TEE4060
4 JUNK RING.......................................... 3 PQ31712
5 PACKING – STYLE 858 ...................... 3 60DD752
7 GLAND BUSHING .............................. 3 PS15212
8 GLAND NUT ....................................... 3 2011555
* Not shown
3-1-529 Page 19

STUFFING BOX, PLUNGERS & PACKING (TEED)
STYLE 838 PACKING
Ref. 4.00" 3.50" 3.00" 2.75"
1 GASKET ............................................. 3 303TEE718 303TEE718 303TEE718 303TEE718
2 STUFFING BOX, Includes Ref No.3 3 200TEE014 201TEE014 202TEE014 203TEE014
8 GLAND NUT ........................................ 3 200PEE008 200PEE008 4PE113 4PE113
10 PLUNGER (Colmonoy)........................ 3 1PE3840 1PE3835 302TEE038 1PE3827
STYLE 838 PACKING

Ref. 2.50" 2.25" 2.00" 1.75"
10 PLUNGER (Colmonoy)........................ 3 1PE3825 1PE3822 1PE3820 1PE3817
* Not shown
3-1-529 Page 20

STYLE 1067 PACKING
Ref. 4.00" 3.50" 3.00" 2.75"
Includes Ref. Numbers 4 thru 7.......... 3 TEE77906 TEE77907 TEE77908 TEE77909
4 JUNK RING ........................................ 3 200TEE317 201TEE317 202TEE317 203TEE317
5 PACKING – STYLE 1067................... 3 60DD116 60DD115 60DD113 60DD112
6 LANTERN SPACER ............................ 3 200TEE445 201TEE445 202TEE445 203TEE445
7 GLAND BUSHING............................... 3 200TEE152 201TEE152 202TEE152 203TEE152
STYLE 1067 PACKING

Ref. 2.50" 2.25" 2.00" 1.75"
* Not shown
3-1-529 Page 21

STYLE 858 PACKING
Ref. 4.00" 3.50" 3.00" 2.75"
STYLE 858 PACKING

Ref. 2.50" 2.25" 2.00" 1.75"
* Not shown
3-1-529 Page 22

STUFFING BOX, PLUNGERS & PACKING (TEEF)
1 Piece High Pressure Cast Steel Cylinder
STYLE 838 PACKING
Ref. 3.00" 2.75" 2.50"
1 GASKET ............................................. 3 25AL53 25AL53 25AL53
3 LUBE FITTING .................................... 3 40E7 40E7 40E7
Includes Ref. Numbers 4 thru 7 ......... 3 65PE1600 66PE1600 67PE1600
4 JUNK RING ........................................ 3 26PE317 27PE317 28PE317
6 LANTERN SPACER............................ 3 34PE445 35PE445 36PE445
7 GLAND BUSHING............................... 3 30PE152 31PE152 32PE152
8 GLAND NUT........................................ 3 4PE113 4PE113 4PE113
10 PLUNGER (Colmonoy) ....................... 3 302TEE038 1PE3827 1PE3825
10 PLUNGER (Ceramic) ......................... 3 PE3830 PE3827 PE3825
10 PLUNGER (Chrome Plated) .............. 3 3PE3830 3PE3827 3PE3825
STYLE 838 PACKING

Ref. 2.25" 2.00" 1.75"
1 GASKET ............................................. 3 25AL53 25AL53 25AL53
3 LUBE FITTING .................................... 3 40E7 40E7 40E7
4 JUNK RING ........................................ 3 25PE317 29PE317 30PE317
8 GLAND NUT........................................ 3 4PE113 4PE113 4PE113
* Not shown
3-1-529 Page 23

STYLE 1067 PACKING
Ref. 3.00" 2.75" 2.50"
1 GASKET ............................................. 3 25AL53 25AL53 25AL53
3 LUBE FITTING .................................... 3 40E7 40E7 40E7
Includes Ref. Numbers 4 thru 7 ......... 3 TEE77908 TEE77909 TEE77910
4 JUNK RING ........................................ 3 202TEE317 203TEE317 204TEE317
5 PACKING – STYLE 1067................... 3 60DD113 60DD112 60DD111
6 LANTERN SPACER............................ 3 202TEE445 203TEE445 204TEE445
7 GLAND BUSHING............................... 3 202TEE152 203TEE152 204TEE152
8 GLAND NUT........................................ 3 4PE113 4PE113 4PE113
STYLE 1067 PACKING

Ref. 2.25" 2.00" 1.75"
1 GASKET ............................................. 3 25AL53 25AL53 25AL53
3 LUBE FITTING .................................... 3 40E7 40E7 40E7
8 GLAND NUT........................................ 3 4PE113 4PE113 4PE113
* Not shown
3-1-529 Page 24

STYLE 858 PACKING
Ref. 3.00" 2.75" 2.50"
1 GASKET ............................................. 3 25AL53 25AL53 25AL53
3 LUBE FITTING .................................... 3 40E7 40E7 40E7
4 JUNK RING ........................................ 3 26PE317 27PE317 28PE317
8 GLAND NUT........................................ 3 4PE113 4PE113 4PE113
STYLE 858 PACKING

Ref. 2.25" 2.00" 1.75"
1 GASKET ............................................. 3 25AL53 25AL53 25AL53
3 LUBE FITTING .................................... 3 40E7 40E7 40E7
4 JUNK RING ........................................ 3 25PE317 29PE317 30PE317
8 GLAND NUT........................................ 3 4PE113 4PE113 4PE113
* Not shown
3-1-529 Page 25

PISTONS AND LINERS (TEEE)
Well Service – High Pressure Block Steel – 4”
Ref. 4.00" 3.50" 3.00" 2.75"
1 PISTON BODY ASSEMBLY................ 3 232TBA045A 230TBA045A 228TBA045A 227TBA045A
Includes Ref No’s 2 & 3
2 O-RING................................................ 3 25AH1 25AH1 25AH1 25AH1
3 INSERT GROUP, Includes Ref. .......... 3 TBA76008 TBA76006 TBA76004 TBA76003
Numbers 4 and 5
4 PLATE-RETAINER.............................. 3 * * * *
5 RING-RETAINER ................................ 3 * * * *
6 GASKET-HYDRAULIC RING .............. 3 25AL36 25AL36 25AL36 25AL36
7 CLAMP-LINER..................................... 3 200PEE455 200PEE455 200PEE455 200PEE455
8 PISTON ROD ASM, Includes item 9 ... 3 200PEE060 200PEE060 200PEE060 200PEE060
9 NUT, Piston Rod.................................. 3 50V3 50V3 50V3 50V3
10 LINER .................................................. 3 203PEE456 202PEE456 201PEE456 200PEE456
PISTONS AND LINERS (TEEG)

Well Service – High Pressure Cast Steel – 3”
Ref. 3.00" 2.75" 2.50"
1 PISTON BODY ASSEMBLY ............... 3 228TBA045A 227TBA045A 45R1
2 O-RING............................................... 3 25AH1 25AH1 ***
3 INSERT GROUP, Includes Ref.......... 3 TBA76004 TBA76003 45R8
Numbers 4 and 5
4 PLATE-RETAINER.............................. 3 * * ***
5 RING-RETAINER ................................ 3 * * ***
6 GASKET-HYDRAULIC RING.............. 3 25AL35 25AL35 25AL35
7 CLAMP-LINER ................................... 3 1PE217 1PE217 1PE217
8 PISTON ROD ASM, Includes item 9.. 3 200PEE060 200PEE060 200PEE060
9 NUT, Piston Rod ................................. 3 50V3 50V3 50V3
10 LINER ................................................. 3 PE13930 2011248 PE13925
* Not to be sold separately
*** 2, 4 and 5 are not applicable for 2.50” size
3-1-529 Page 26
DELRIN DISC FLUID VALVE

LOW PRESSURE - CAST ALUMINUM BRONZE CYLINDER – 4”
SUCTION and DISCHARGE
Ref.
Aluminum Stainless Monel

Bronze Steel
FLUID VALVE ASSEMBLY 6 200VLH482 201VLH482 202VLH482
(Includes Items 1 thru 7)
1 RETAINER ............................. 6 2010582 2010583 2010584
2 FASTENER ............................ 6 2010598 2010598 2010598
3 PLUG-THREAD LOCK .......... 6 2010602 2010602 2010602
4 SPRING (Inner)...................... 6 2010604 2010604 2010604
5 SPRING (Outer) ..................... 6 2010607 2010607 2010607
6 VALVE DISC .......................... 6 2010611 2010611 2010611
7 VALVE SEAT ......................... 6 2010623 2010624 2010625
VALVE SEAT PULLER: Use one (1) TEE68700 Valve Puller Group & one (1) 100E6 Puller Head.
3-1-529 Page 27
WING GUIDED FLUID VALVE

ALUMINUM BRONZE – WITHOUT INSERT
Ref.
FLUID VALVE ASSEMBLY .................................... 6 208VWH482A

1 VALVE SEAT ......................................................... 6 200VWH039
2 VALVE CAGE......................................................... 6 200VWH054
3 FLUID VALVE ........................................................ 6 3PA206
4 SPRING.................................................................. 6 78H29
VALVE SEAT PULLER: Use one (1) TEE68699 Valve Puller Group & one (1) 200PEE219 Puller Head.
VALVE CAGE WRENCH: 200TEE933
3-1-529 Page 28

MEDIUM PRESSURE - CAST ALUMINUM BRONZE CYLINDER – 4”
Ref.

Bronze Steel
FLUID VALVE ASSEMBLY 6 200VLF482 201VLF482 202VLF482
1 RETAINER ............................. 6 2010585 2010586 2010587
2 FASTENER ............................ 6 2010598 2010598 2010598
3 PLUG-THREAD LOCK .......... 6 2010602 2010602 2010602
4 SPRING (Inner)...................... 6 2010605 2010605 2010605
5 SPRING (Outer) ..................... 6 2010608 2010608 2010608
6 VALVE DISC .......................... 6 2010612 2010612 2010612
7 VALVE SEAT ......................... 6 2010629 2010630 2010631
3-1-529 Page 29

Ref.
FLUID VALVE ASSEMBLY .................................... 6 208VWF482A

1 VALVE SEAT ......................................................... 6 200VWF039
2 VALVE CAGE......................................................... 6 200VWF054
3 FLUID VALVE ........................................................ 6 PT206
4 SPRING.................................................................. 6 78H22
VALVE SEAT PULLER: Use one (1) TEE68699 Valve Puller Group & one (1) 209TAE219 Puller Head.
VALVE CAGE WRENCH: 16AUX219
3-1-529 Page 30

HIGH PRESSURE - BLOCK STEEL CYLINDER – 2”
SUCTION VALVE ONLY

Ref.

Bronze Steel
FLUID VALVE ASSEMBLY 3 200VHC482 201VHC482 202VHC482
1 RETAINER ............................. 3 2010591 2010592 2010593
2 FASTENER ............................ 3 2010600 2010600 2010600
3 PLUG-THREAD LOCK .......... 3 2010603 2010603 2010603
4 SPRING (Inner)...................... 3 2010606 2010606 2010606
5 SPRING (Outer) ..................... 3 2116348 2116348 2116348
6 VALVE DISC .......................... 3 2010829 2010829 2010829
7 VALVE SEAT ......................... 3 2010653 2010654 2010655
VALVE SEAT PULLER: Use one (1) TEE68699 Valve Puller Group & one (1) 205TAE219A Puller Head.
3-1-529 Page 31

DISCHARGE VALVE ONLY

Ref.

Bronze Steel
FLUID VALVE ASSEMBLY 3 210VHF482 211VHF482 212VHF482
1 RETAINER ............................. 3 2010588 2010828 2010590
2 FASTENER ............................ 3 2010599 2010599 2010599
3 PLUG-THREAD LOCK .......... 3 2010603 2010603 2010603
4 SPRING (Inner)...................... 3 2010606 2010606 2010606
5 SPRING (Outer) ..................... 3 2116348 2116348 2116348
6 VALVE DISC .......................... 3 2010829 2010829 2010829
7 VALVE SEAT ......................... 3 2109442 2109449 2109445
3-1-529 Page 32
Ref Drawing: Ref Drawing:

305TEE799 307TEE799
SUCTION VALVE DISCHARGE VALVE
SUCTION VALVE
HIGH PRESSURE – BLOCK STEEL CYLINDER – 2”
Ref No. Name of Part Qty. Part No.
FLUID VALVE ASSEMBLY .................................... 3 208VWC482A

1 VALVE SEAT ......................................................... 3 200VWC039
2 VALVE CAGE......................................................... 3 200VWC054
3 FLUID VALVE ........................................................ 3 3PG206
4 SPRING.................................................................. 3 78H24
DISCHARGE VALVE

1 VALVE SEAT ......................................................... 3 200VWF039
2 VALVE CAGE......................................................... 3 200VWF054
3 FLUID VALVE ........................................................ 3 PT206
4 SPRING.................................................................. 3 78H22
3-1-529 Page 33

305TEE799 302TEE799
SUCTION VALVE
** HARDENED STEEL – WITHOUT INSERT

FLUID VALVE ASSEMBLY ...................................................... 3 210VWC482A
(Includes items 1 thru 4)
1 VALVE SEAT ........................................................................... 3 201VWC039
2 VALVE CAGE .......................................................................... 3 201VWC054
3 FLUID VALVE .......................................................................... 3 6PG206
4 SPRING ................................................................................... 3 78H22
** This steel wing guided valve without an insert is for services requiring a discharge pressure
over 6500 PSIG.
DISCHARGE VALVE
HARDENED STEEL – WITHOUT INSERT

FLUID VALVE ASSEMBLY ...................................................... 3 210VWF482A
1 FLUID VALVE .......................................................................... 3 1PT206
2 VALVE SEAT ........................................................................... 3 201VWF039
3 VALVE CAGE .......................................................................... 3 201VWF054
4 SPRING ................................................................................... 3 78C39
3-1-529 Page 34

304TEE799 303TEE799

SUCTION VALVE
HARDENED STEEL – WITH A REMOVABLE RUBBER INSERT

FLUID VALVE GROUP, Includes items 1 thru 8 ..................... 3 211VWC482A
1 FLUID VALVE ASSEMBLY, Includes items 2 thru 5 ............... 3 PG206A
2 FLUID VALVE .......................................................................... 3 PG206
3 INSERT, Rubber...................................................................... 3 PG452
4 WASHER, Retainer ................................................................. 3 95D166
5 NUT.......................................................................................... 3 50AF3
6 VALVE SEAT ........................................................................... 3 201VWC039
7 SPRING ................................................................................... 3 78A148
8 VALVE CAGE .......................................................................... 3 201VWC054
DISCHARGE VALVE

FLUID VALVE GROUP, Includes items 1 thru 8 ..................... 3 211VWF482A
1 FLUID VALVE ASSEMBLY, Includes items 2 thru 5 ............... 3 1PT206C
2 FLUID VALVE .......................................................................... 3 1PT206
3 WASHER, Retainer ................................................................. 3 PT279
4 INSERT, Rubber...................................................................... 3 2PT452
5 RETAINER, Ring ..................................................................... 3 65W19
6 VALVE SEAT ........................................................................... 3 201VWF039
7 SPRING ................................................................................... 3 78C39
8 VALVE CAGE .......................................................................... 3 201VWF054
3-1-529 Page 35

300TEE799 301TEE799
SUCTION VALVE

HARDENED STEEL – WITH A MOLDED ON INSERT

FLUID VALVE ASSEMBLY ...................................................... 3 VWG90867
1 FLUID VALVE .......................................................................... 3 215VWG482
2 VALVE SEAT ........................................................................... 3 201VWC039
3 VALVE CAGE .......................................................................... 3 201VWC054
4 SPRING ................................................................................... 3 78H22
DISCHARGE VALVE


1 FLUID VALVE .......................................................................... 3 213VWG482
2 VALVE SEAT ........................................................................... 3 201VWF039
3 VALVE CAGE .......................................................................... 3 201VWF054
4 SPRING ................................................................................... 3 78C39
3-1-529 Page 36
SUCTION AND DISCHARGE

CAST STEEL – WITHOUT INSERT
Ref.
FLUID VALVE ASSEMBLY.......................................................... 6 TGE90021

1 FLUID VALVE .............................................................................. 6 202TEE482
2 VALVE SEAT ............................................................................... 6 200PEE039
3 VALVE CAGE .............................................................................. 6 200PEE054
4 SPRING ....................................................................................... 6 78H26
3-1-529 Page 37

CAST STEEL – WITH MOLDED ON INSERT
(CARBOXYLATED RUBBER INSERT)
Ref.
FLUID VALVE ASSEMBLY ................................................................ 6 TEE90020

1 FLUID VALVE..................................................................................... 6 203TEE482
2 VALVE SEAT...................................................................................... 6 200PEE039
3 VALVE CAGE ..................................................................................... 6 200PEE054
4 SPRING .............................................................................................. 6 78H26
3-1-529 Page 38

CAST STEEL – WITH REMOVABLE INSERT
(URETHANE INSERT)
Ref.
FLUID VALVE GROUP, Includes Ref No. 1 thru 8 ............................ 6 200PEE482B

1 FLUID VALVE ASSEMBLY, Includes Ref No. 2thru 5 ....................... 6 200PEE482A
2 FLUID VALVE..................................................................................... 6 200PEE482
3 VALVE INSERT .................................................................................. 6 1PA452
4 WASHER ............................................................................................ 6 PA1272
5 RETAINER RING................................................................................ 6 74D43
6 VALVE SEAT...................................................................................... 6 200PEE039
7 SPRING .............................................................................................. 6 78H26
8 VALVE CAGE ..................................................................................... 6 200PEE054
3-1-529 Page 39

(POLYURETHANE RUBBER INSERT)
Ref.

1 FLUID VALVE..................................................................................... 6 204TEE482
2 VALVE SEAT...................................................................................... 6 200PEE039
3 VALVE CAGE ..................................................................................... 6 200PEE054
4 SPRING .............................................................................................. 6 78H26
3-1-529 Page 40
STAINLESS STEEL FLUID VALVE

ABRASION RESISTANT
Ref.
FLUID VALVE ASSEMBLY ............................................................ 6 209TEE482

1 VALVE SEAT.................................................................................. 6 2116687
2 O-RING........................................................................................... 6 2116520
3 VALVE INSERT .............................................................................. 6 2116521
4 VALVE, Abrasion Resistant............................................................ 6 2116522
5 SPRING .......................................................................................... 6 2116523
6 VALVE CAGE ................................................................................. 6 2116524
3-1-529 Page 41
SUCTION and DISCHARGE VALVE


2 FLUID VALVE .......................................................................... 6 1PT206
4 INSERT, Rubber...................................................................... 6 2PT452
5 RETAINER, Ring ..................................................................... 6 65W19
6 VALVE SEAT ........................................................................... 6 201VWF039
7 SPRING ................................................................................... 6 78C39
8 VALVE CAGE .......................................................................... 6 201VWF054
3-1-529 Page 42

HIGH PRESSURE – CAST STEEL CYLINDER – 3”

1 FLUID VALVE .......................................................................... 6 1PT206
2 VALVE SEAT ........................................................................... 6 201VWF039
3 VALVE CAGE .......................................................................... 6 201VWF054
4 SPRING ................................................................................... 6 78C39
3-1-529 Page 43


1 FLUID VALVE .......................................................................... 6 213VWG482
2 VALVE SEAT ........................................................................... 6 201VWF039
3 VALVE CAGE .......................................................................... 6 201VWF054
4 SPRING ................................................................................... 6 78C39
3-1-529 Page 44

HIGH PRESSURE - CAST STEEL CYLINDER – 3”
ABRASION RESISTANT
Ref.

1 VALVE SEAT.................................................................................. 6 2116561
2 O-RING........................................................................................... 6 2116284
3 VALVE INSERT .............................................................................. 6 2116283
5 SPRING .......................................................................................... 6 2116348
6 VALVE CAGE ................................................................................. 6 2116282
3-1-529 Page 45
LUBRICATOR GROUP (Optional Equipment)

LUBRICATOR GROUP Includes the Following Items. 1 TEE90984

1 BRACKET, Lubricator ............................................................................... 1 200TEE403
2 SCREW, Bracket to Frame ....................................................................... 2 655EE040
3 WASHER................................................................................................... 2 95A5
4 SCREW, Bracket to Frame (Cradle Area)................................................. 2 75LM51
5 LUBRICATOR, (Ratchet Type) ................................................................. 1 40G99
6 SCREW, Lubricator to Bracket.................................................................. 4 75LM50
7 BRACKET, Lubricator Drive ...................................................................... 1 200PEE017
8 SCREW, Plunger Coupling ....................................................................... 2 655EE18Z
9 END, Control Rod...................................................................................... 1 BM11210A
10 SCREW, Rod End to Drive Bracket .......................................................... 1 655ED060
11 WASHER................................................................................................... 2 95A3
12 CONTROL ROD, Lubricator...................................................................... 1 2005879
13 LOCKNUT, Control Rod ............................................................................ 1 50B3
14 CONNECTOR, Tube - 90 Degree............................................................. 3 86A25
15 TUBING, Lubricator to Stuffing boxes (Length Required for 1 Pump) ...... 20 Ft. 85E4A
16 CONNECTOR, Tube - Straight ................................................................. 3 86A1
17 CHECK VALVE ......................................................................................... 3 90AR373
18 STUD, Cradle Cover ................................................................................. 2 79A466
19 WINGNUT, Cradle Cover .......................................................................... 2 50H1
20 INSPECTION PLATE, Cradle Cover......................................................... 1 202TEE052
21 SIGHT GLASS, (Included with Lubricator)................................................ 1 40P15
3-1-529 Page 46
PISTON ROD WASH PIPING (Optional Equipment)
3-1-529 Page 47

1 SHEAVE, Driven ....................................................................................... 1 73K1A30

2 BUSHING, Sheave.................................................................................... 1 22E16B
3 CENTRIFUGAL PUMP.............................................................................. 1 CA122
4 SCREW, Pump to Skid.............................................................................. 4 655ED040
5 LOCK WASHER........................................................................................ 4 95B3
6 WASHER................................................................................................... 4 95A3
7 NUT ........................................................................................................... 4 50B3
8 OIL SCREEN............................................................................................. 1 3WAJ511
9 PIPE REDUCER ....................................................................................... 1 64N7
10 PIPE NIPPLE ............................................................................................ 2 63H1
11 PIPE COUPLING ...................................................................................... 1 64AB4
12 ADAPTOR ................................................................................................. 2 29Q9
13 VALVE, Regulator ..................................................................................... 1 90AR299
14 PIPE NIPPLE ............................................................................................ 1 63H25
15 PIPE ELBOW, 90 Deg............................................................................... 1 64S5
16 PIPE NIPPLE ............................................................................................ 3 63G15
17 PIPE TEE .................................................................................................. 3 64P39
18 VALVE, Shut-Off ....................................................................................... 1 90A35
19 PIPE NIPPLE ............................................................................................ 2 63G1
20 PIPE COUPLING ...................................................................................... 1 64AB3
21 CLAMP, Pipe............................................................................................. 2 98H4
22 SCREW, Clamp to Frame ......................................................................... 2 655EC020
23 HYDRAULIC HOSE ASSEMBLY.............................................................. 3 29R32
24 HOSE ADAPTOR...................................................................................... 3 29Q7
25 PIPE BUSHING......................................................................................... 3 64E2
26 BAFFLE ..................................................................................................... 3 200TEE840
27 TANK ASSEMBLY, Recovery (Includes the Next Item)............................ 1 PA252A
TANK COVER ........................................................................................... 1 PA253
28 SCREW, Tank to Skid ............................................................................... 4 655EE070
29 LOCK WASHER........................................................................................ 4 95B5
30 NUT ........................................................................................................... 4 50B5
31 PLUG......................................................................................................... 1 64A6
32 PLUG......................................................................................................... 1 64AA7
33 INSPECTION PLATE (Slotted Cradle Cover) ........................................... 1 304TEE052
The Following Will Be Furnished By the Customer: ...........................
SHEAVE, Auxiliary Drive........................................................................... 1

BELT, Single ............................................................................................. 1
HYDRAULIC HOSE ASSEMBLY (1” with 1” fittings) ................................ 1
DRAIN, Return .......................................................................................... 1
3-1-529 Page 48
Ref.
VALVE SEAT PULLER GROUP ........... 1 TEE68699 TEE68700 TEE73494

1 ROD ....................................................... 1 200TAE193 200TEE193 200TAE193
2 PULLER PLATE .................................... 1 200TEE340 200TEE340 202TEE340
3 WASHER ............................................... 1 200TAE244 200TAE244 200TAE244
4 WEDGE ................................................. 1 200TAE091 200TAE091 200TAE091
5 WASHER ............................................... 1 95U14 95U14 95U14
6 NUT........................................................ 1 200TAE086 200TAE086 200TAE086
* INSTRUCTION TAG 1 201TAE304 201TAE304 201TAE304
* Not Shown on Illustration
3-1-529 Page 49
CUSTOMER REPAIR INFORMATION
NOTE:
1. TEE Pump with a Serial Number 917132 and Later are equipped with the Two Piece
Crosshead / extension rod, as shown on page 6.
Pumps with Serial Numbers previous to 917132 have a One Piece Crosshead /
Extension Rod.
For pumps with the earlier Serial Numbers, the 300TEE6005 conversion kit must be
used when a repair crosshead is required.
The 300TEE6005 conversion kit includes:

(1) 300TEE005 CROSSHEAD
(1) 300TEE839 EXTENSION ROD
(1) 200TAE840 BAFFLE
2. The PE840 Extension Rod Baffle is required for pumps that do not have the Two Piece
Crosshead / Extension Rod construction.
3. Oversized Crossheads are available for pumps with Serial Numbers 917132 and later.
(301TEE005)
An Oversized Crosshead Conversion Kit is available for pumps that are equipped with
One Piece Crosshead / Extension Rod. (301TEE6005)

4. Available Cradle Covers:

a. 201TEE052 – Standard
b. 202TEE052 – Used with Lubricator Option
c. 204TEE052 – Plexiglas (See Through)
d. 303TEE052 – Ventilated
e. 304TEE052 – Used with Rod Wash Option
5. MODEL CYLINDER SIZE x STROKE

TEEA 4x5
TEEB 3x5
TEEC 2x5
TEED 4x5
TEEE 4x5
TEEF 3x5
TEEG 3x5
3-1-529 Page 50
NOTES
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3-1-529 Page 51
GARDNER DENVER PUMP UNIT RECORD
The following unit identification plate is provided as a convenience to you,

our valued Gardner Denver customer. Please take the time to copy all the
information from the actual nameplate on your unit. The model number,
date manufactured and serial number will be required when contacting the
company or your distributor for information or replacement parts.
Ref. Drawing – 200OPA496

For additional information contact your local distributor or
Gardner Denver - Fluid Transfer Division,
1800 Gardner Expressway, Quincy, Illinois 62301
Customer Service Department Telephone:
(800) 682-9868 FAX: (217) 223-1581
Specifications subject to change without notice. For Domestic parts information Contact:
Copyright © 2008 Gardner Denver, Inc. DJC Litho in U.S.A. Gardner Denver – Fluid Transfer Division,
2200 South Prospect, Oklahoma City, OK. 73129
http://www.gardnerdenver.com [email protected] Telephone: (405) 677-5736 FAX: (405) 677-5807
TABLE OF CONTENTS
Maintain Pump Reliability And Performance with Genuine Gardner Denver Parts and Support Services ..... i
Instructions For Ordering Repair Parts ............................................................................................................ i
Table of Contents............................................................................................................................................ ii
Frame Group...................................................................................................................................................1
Eccenttric, Shaft and Bearing Group ..............................................................................................................2
Oil Circulating Pump .......................................................................................................................................3
Oil Filter ...........................................................................................................................................................4
Connecting Rod ..............................................................................................................................................5
Crosshead & Oil Stop Head Group.................................................................................................................6
Oil Pump and Piping ................................................................................................................................ 7 & 8
Crosshead Lubrication Piping - LEFT HAND DRIVE......................................................................................9
Crosshead Lubrication Piping - RIGHT HAND DRIVE .................................................................................10
Fluid End - Low Pressure Cast Aluminum Bronze Cylinder (4 x 5) ..............................................................11
Fluid End - Medium Pressure Cast Aluminum Bronze Cylinder (3 x 5)........................................................12
Fluid End - High Pressure Cast Steel Cylinder (3 x 5)..................................................................................15
Stuffing Box, Plunger and Packing .................................................................................................. 16 thru 25
Piston and Liners ..........................................................................................................................................26
Delrin Disc Fluid Valves for Low Pressure Cast Aluminum Bronze Cylinder (4 x 5) ....................................27
Wing Guided Fluid Valves Low Pressure Cast Aluminum Bronze Cylinder (4 x 5) ......................................28
Delrin Disc Fluid Valves for Medium Pressure Cast Aluminum Bronze Cyl (3 x 5) ......................................29
Wing Guided Fluid Valves Medium Pressure Cast Aluminum Bronze Cyl (3 x 5)........................................30
Delrin Disc Suction Fluid Valves for High Pressure Block Steel Cylinder (2 x 5) .........................................31
Delrin Disc Discharge Fluid Valves for High Pressure Block Steel Cylinder (2 x 5) .....................................32
Stem Guided S&D Fluid Valves, Stainless Steel, Abrasion Resistant for High Pressure
Block Steel Cylinder (4 x 5).........................................................................................41
Wing Guided S&D Fluid Valves for High Pressure Cast Steel Cylinder (3 x 5)............................... 42 thru 44
Stem Guided S&D Fluid Valves, SS, Abrasion Resistant for High Pressure Cast Steel Cylinder (3 x 5) ....45
Lubricator Group (Optional Equipment) ........................................................................................................46
Piston Rod Wash Piping (Optional Equipment) ................................................................................... 47 & 48
Valve Seat Puller (Optional Equipment) .......................................................................................................49
Customer Repair Information ........................................................................................................................50
Customer NOTES .........................................................................................................................................51
Gardner Denver Unit Record .............................................................................................. Inside Back Cover
3-1-529 Page ii

FRAME GROUP
1 FRAME (POWER END) ......................................................... 1 304TEE001
2 INSPECTION PLATE, With Oil Manifold (Crosshead)........... 1 301TEE052
2A INSPECTION PLATE (Crosshead) ........................................ 1 302TEE052
3 SCREW, Inspection Plate ...................................................... 12 75A136
4 GASKET, Inspection Plate ..................................................... 2 25C1941
5 GASKET, Crankcase Flange.................................................. 2 25C157N
6 SCREW, Crankcase Flange................................................... 4 655ED030
7 FLANGE, Crankcase Oil Drain............................................... 2 29AUX27
8 PLUG, Crankcase Flange ...................................................... 2 64AA7
9 PLUG, Oil Level...................................................................... 2 64AA5
10 PIPE ELBOW, Oil Level ......................................................... 1 64D2
11 RETAINER PLATE (Includes next item) ................................ 1 PE1400
STUD...................................................................................... 3 79A69
12 NUT-ACORN.......................................................................... 3 50Q14
13 GASKET- COPPER, Retainer Stud Nut................................. 3 25F44
14 INSPECTION PLATE (Frame End)........................................ 1 200TEE052
15 GASKET (Frame End Inspection Plate)................................. 1 200TEE715
16 HOOD..................................................................................... 1 201TEE053
17 SCREW, Hood ....................................................................... 12 75A136
18 GASKET, Hood ...................................................................... 1 201TEE715
19 PLUG (OPPOSITE SIDE) ...................................................... 1 64B3
20 LIFTING EYE ......................................................................... 2 200TEE263
21 BREATHER............................................................................ 1 5C7
22 INSPECTION PLATE (CRADLE COVER) *........................... 1 201TEE052
23 STUD...................................................................................... 2 79A466
24 WING NUT ............................................................................. 2 50H1
* See page 50 for all cradle cover options.
3-1-529 Page 1
ECCENTRIC, SHAFT & BEARING GROUP

1 ECCENTRIC, Includes the next item ..................................... 1 200TEE255
2 ORIFICE ................................................................................. 2 200TEE814
3 KEY, Eccentric to Shaft .......................................................... 1 35K17
4 SHAFT-ECCENTRIC ............................................................. 1 1PE367
5 BEARING, Eccentric Shaft ..................................................... 1 12C60
6 HOUSING-BEARING, Oil Pump End..................................... 1 2PE266
7 SCREW, Bearing Housing to Frame...................................... 12 655EF050
8 GASKET, Bearing Housing .................................................... 2 25C1945
9 HOUSING-BEARING, Drive End ........................................... 1 3PE366
10 SEAL-OIL, Eccentric Shaft ..................................................... 1 60G63
11 BEARING, Eccentric Shaft ..................................................... 1 12BA64
12 KEY, Drive .............................................................................. 1 35B72
3-1-529 Page 2
OIL CIRCULATING PUMP

OIL CIRCULATING PUMP, Includes Ref No’s 1 thru 10 1 200PEE188
1 ROTOR ................................................................................... 1 2109376
2 BUSHING, Bracket.................................................................. 1 2118594
3 GASKET, Cover ...................................................................... 2 54C222
4 SCREW, Cover Cap................................................................ 8 2118595
5 COVER.................................................................................... 1 2109371
6 IDLER CARRIER ASSEMBLY, Includes Ref No’s 7............... 1 2109372
7 PIN, Idler ................................................................................. 1 2109373
8 GEAR, Idler ............................................................................. 1 2118596
9 BRACKET ASSEMBLY, Includes Ref No. 2 ........................... 1 2109370
10 HOUSING................................................................................ 1 2118597
11 SCREW, Housing.................................................................... 4 2118598
12 SCREW, Housing.................................................................... 4 2118599
13 NUT, Housing screw ............................................................... 4 2118600
14 SPRING, Ball........................................................................... 1 2118601
15 BALL........................................................................................ 1 2118602
The Part Numbers that are listed are for those parts that are provided for repair.
3-1-529 Page 3
OIL FILTER
OIL FILTER ASSEMBLY, Includes next 2 items 1 26C51
1 HEAD ASSEMBLY .................................................................. 1 2118128
2 ELEMENT ............................................................................... 1 2118384
3-1-529 Page 4
CONNECTING ROD
Ref.
No. Description Qty. Part No.
1 CONNECTING ROD, Includes the next 4 items ..................... 3 PE417
2 BUSHING, Eccentric ............................................................... 3 PE421
3 BUSHING, Crosshead Pin ...................................................... 3 PE229
4 PLUG....................................................................................... 3 64AC2
5 LOCK SCREW ........................................................................ 3 75LM162N
3-1-529 Page 5
CROSSHEAD & OIL STOP HEAD GROUP

1 CROSSHEAD (Standard Size) ................................................................ 3 300TEE005
CROSSHEAD (0.125” Oversized – Optional) ***..................................... 3 301TEE005
2 CROSSHEAD PIN.................................................................................... 3 2005051
3 RING, Crosshead Pin Retainer ................................................................ 6 65W19
4 GASKET, Oil Stop Head to Frame........................................................... 3 25C1948
OIL STOP HEAD ASSEMBLY, Includes Ref No’s 5, 6 & 7 ..................... 3 PE226A
5 OIL STOP HEAD...................................................................................... 3 PE226
6 STUD, Gland ............................................................................................ 6 79A238
7 NUT, Gland .............................................................................................. 6 50F5
8 SCREW, Oil Stop Head to Frame ............................................................ 12 655EE050
9 PACKING, Oil Stop Head......................................................................... 3 60DD99
10 GLAND, Oil Stop Head ............................................................................ 3 PE238
11 ROD-EXTENSION ................................................................................... 3 300TEE839
12 BAFFLE, Piston Rod ** ............................................................................ 3 200TAE840
13 PLUNGER COUPLING ASSEMBLY, Includes Ref No’s 14 & 15............ 3 201TAE092A
14 SCREW, Coupling.................................................................................... 6 655EE17S
15 NUT, Coupling.......................................................................................... 6 50AW35
* See Note Number 1, page 50, for customer repair information

** See Note Number 2, page 50, for customer repair information
*** See Note Number 3, page 50, for customer repair information
3-1-529 Page 6
OIL PUMP AND PIPING
3-1-529
Page 7

OIL PUMP AND PIPING
Ref. Ref.
No. Name of Part Qty. Part No. No. Name of Part Qty. Part No.
1 * OIL PUMP (Includes next item) .................... 1 200PEE188 24 HOSE ADAPTOR ....................................... 1 29Q6
2 SCREW, Oil Pump to Adaptor......................... 4 655ED190 25 PIPE BUSHING .......................................... 1 64E95
3 ** OIL FILTER ................................................. 1 26C51 26 LIQUID RELIEF VALVE.............................. 1 90Q22
4 OIL SCREEN................................................... 1 2WAJ511 27 PIPE STREET ELBOW .............................. 1 64D6
5 STUD, Connector to Frame............................. 2 79A204 28 PIPE TEE.................................................... 2 64G7
6 GASKET, Oil Drain Flange.............................. 1 25C157N 29 PIPE NIPPLE .............................................. 3 63U12X14
3-1-529
7 CONNECTOR ................................................. 1 200PEE284 30 PIPE BUSHING .......................................... 1 64E6

8 NUT, Connector to Frame Stud ...................... 2 50B3 31 HOSE ADAPTOR ....................................... 2 29Q16
9 PIPE NIPPLE .................................................. 1 64H4 32 HOSE ASSEMBLY ..................................... 1 29R26
Page 8
10 PIPE CROSS .................................................. 1 64K18 33 PIPE PLUG ................................................. 1 64A24

11 PIPE PLUG...................................................... 1 64A25 34 FILTER BRACKET...................................... 1 200TEE389
12 BUSHING ........................................................ 1 64E15 35 SCREW, Filter to Bracket ........................... 4 75LM51
13 GAUGE............................................................ 1 27H11 36 HOSE ASSEMBLY ..................................... 1 29E12
14 PIPE NIPPLE .................................................. 1 64H4 37 PIPE TEE.................................................... 1 64P78
15 CHECK VALVE ............................................... 1 300TEE308 38 GASKET, Oil Pump to Adaptor................... 1 201PEE715
16 PIPE NIPPLE .................................................. 1 304TEE126 39 ADAPTOR, Oil Pump.................................. 1 200PEE170
17 COUPLING...................................................... 1 300TEE572 40 SCREW, Adaptor to Bearing Housing ........ 6 655EE050
18 PIPE NIPPLE .................................................. 1 303TEE126 41 PRESSURE GAUGE .................................. 1 27A13
20 PIPE NIPPLE .................................................. 1 63H29 43 OIL SEAL, Main Shaft................................. 1 1PE447
21 PIPE BUSHING............................................... 1 64E7 44 PISTON RING, Oil Seal.............................. 2 65A33
22 PIPE STREET ELBOW ................................... 1 64D5 45 SHIM ........................................................... 2 77G16
23 HOSE ASSEMBLY.......................................... 1 29430
* For Oil Pump and Component Parts – See Page 3

** For Oil Filter and Component Parts – See Page 4
LEFT HAND DRIVE - CROSSHEAD LUBRICATION PIPING

1 ADAPTOR ............................................................................... 6 29Z207
2 ADAPTOR ............................................................................... 6 29Z242
3 HOSE ASSEMBLY.................................................................. 2 1000T29
5 HOSE ASSEMBLY.................................................................. 1 1000T09
6 HOSE ASSEMBLY.................................................................. 1 30031008
7 ADAPTOR ............................................................................... 1 29Z224
8 ADAPTOR ............................................................................... 1 142635
9 PLUG....................................................................................... 1 64B3
10 HOSE ASSEMBLY.................................................................. 1 1001T55
3-1-529 Page 9
RIGHT HAND DRIVE - CROSSHEAD LUBRICATION PIPING

1 ADAPTOR ............................................................................... 6 29Z207
2 ADAPTOR ............................................................................... 6 29Z242
3 HOSE ASSEMBLY.................................................................. 2 1000T29
5 HOSE ASSEMBLY.................................................................. 1 1000T09
6 HOSE ASSEMBLY.................................................................. 1 30031008
7 ADAPTOR ............................................................................... 1 29Z224
8 ADAPTOR ............................................................................... 1 142635
9 PLUG....................................................................................... 1 64B3
10 HOSE ASSEMBLY.................................................................. 1 1001T55
3-1-529 Page 10
FLUID END (TEEA) (4x5)

Low Pressure Cast Aluminum Bronze Cylinder – 4”

FLUID CYLINDER ASSEMBLY, Includes Ref No’s: 1 thru 6 1 2PE29B
3 NUT, Cylinder to Frame............................................................................ 12 50B34
5 STUD, Valve Cover to Cylinder ................................................................ 12 79L1
6 NUT, Cylinder Stuffing Box....................................................................... 12 50B32
7 COVER-VALVE ........................................................................................ 6 3PE147
9 GASKET, Manifold to Cylinder ................................................................. 3 25AL62
12 PLUG, Manifold ........................................................................................ 3 64AJ16
15 GASKET, Flange ...................................................................................... 2 25C861N *
16 SCREW, Suction Flange .......................................................................... 16 655EG080 *
3-1-529 Page 11
FLUID END (TEEB) (3x5)

Medium Pressure Cast Aluminum Bronze Cylinder – 3”

1 FLUID CYLINDER ................................................................................... 1 3PE29
5 NUT, Cylinder Stuffing Box....................................................................... 12 50C9
7 COVER-VALVE ........................................................................................ 6 4PE147
9 GASKET, Manifold to Cylinder ................................................................. 3 25BE27
12 PLUG, Manifold ........................................................................................ 3 64AJ16
15 GASKET, Flange ...................................................................................... 2 25C121N *
3-1-529 Page 12
FLUID END (TEEC) (2x5)

FLUID CYLINDER ASSEMBLY, Includes Ref No’s: 1 thru 9................... 3 200PEE029B
1 FLUID CYLINDER .................................................................................... 3 200PEE029
2 STUD, Cylinder to Discharge Manifold..................................................... 12 79AJ1
3 STUD, Valve Cover .................................................................................. 12 79AJ5
4 STUD, Cylinder to Frame & Stuffing Box ................................................. 12 79AK8
7 NUT, Cylinder to Frame & Stuffing Box Stud ........................................... 24 50B32
8 WASHER, Cylinder to Stuffing Box .......................................................... 12 95U8
9 SPACER, Fluid Cylinder to Frame ........................................................... 6 80C44
10 COVER-VALVE ........................................................................................ 3 7PE147
12 MANIFOLD-SUCTION.............................................................................. 1 9PE110
16 MANIFOLD-DISCHARGE ........................................................................ 1 200PEE071
17 GASKET, Cylinder to Discharge Manifold................................................ 3 25BC86
19 FLANGE, SUCTION (Steel - Threaded)................................................... 2 64CA11 *
20 GASKET, Suction Flange ......................................................................... 2 25C121N *
22 NUT, Suction Flange Screw ..................................................................... 16 50B7 *
23 FLANGE, Discharge Manifold (Steel – Weld Neck) ................................. 2 2009760 *
24 GASKET, Discharge Manifold Flange ...................................................... 2 2009761 *
25 SCREW, Discharge Manifold Flange ....................................................... 16 655EG180 *
26 NUT, Discharge Manifold Flange Screw .................................................. 16 50B32
3-1-529 Page 13
FLUID END (TEED & TEEE) (4x5)

FLUID CYLINDER ASSEMBLY, Includes Ref No’s: 1 thru 7 ................... 3 200TEE029B
1 FLUID CYLINDER .................................................................................... 3 200TEE029
2 STUD, Valve Cover .................................................................................. 48 201TEE110
3 STUD, Cylinder to Discharge Manifold..................................................... 12 79L96
8 NUT, Cylinder to Frame & Stuffing Box.................................................... 12 50AQ30
9 STUD, Cylinder to Frame & Stuffing Box ................................................. 12 200TEE110
10 COVER-VALVE, Suction .......................................................................... 3 200TEE147
11 GASKET, Valve Cover.............................................................................. 6 303TEE718
12 MANIFOLD-SUCTION.............................................................................. 1 200PEE069
16 MANIFOLD-DISCHARGE ........................................................................ 1 200TEE071
17 GASKET, Cylinder to Discharge Manifold ................................................ 3 25AL59
18 FLANGE, Discharge (Steel – Weld Neck) ................................................ 2 64EB37 *
19 SCREW, Flange to Discharge Manifold ................................................... 16 75A231
20 NUT, Discharge Flange ............................................................................ 16 50B9 *
21 GASKET, Discharge Flange..................................................................... 2 25BC42 *
22 COVER-VALVE, Discharge...................................................................... 3 PP1005549 *
3-1-529 Page 14
FLUID END (TEEF & TEEG) (3x5)

High Pressure Cast Steel Cylinder – 3”

6 NUT, Cylinder to Frame & Stuffing Box.................................................... 12 50T90
7 PLUG, Manifold ........................................................................................ 3 64AA3
9 COVER-VALVE ........................................................................................ 6 7PE147
11 MANIFOLD, Suction 4 inch (Standard) .................................................... 1 4PE110
MANIFOLD, Suction 6 inch (Optional)...................................................... 1 200PEE069
3-1-529 Page 15

STUFFING BOX, PLUNGERS & PACKING (TEEA)
Low Pressure Cast Aluminum Bronze Cylinder
STYLE 838 PACKING
Ref. 4.00" 3.50" 3.25" 3.00"
1 GASKET ............................................. 3 25AL36 25AL36 25AL36 25AL36
STYLE 858 PACKING

Ref. 4.00" 3.50" 3.25" 3.00"
1 GASKET ............................................. 3 25AL36 25AL36 25AL36 25AL36
* Not shown
3-1-529 Page 16

STUFFING BOX, PLUNGERS & PACKING (TEEB)
Medium Pressure Cast Aluminum Bronze Cylinder
STYLE 838 PACKING
Ref. 3.00" 2.75" 2.50" 2.25"
1 GASKET ............................................. 3 25AL36 25AL35 25AL35 25AL35
STYLE 858 PACKING

Ref. 3.00" 2.75" 2.50" 2.25"
1 GASKET ............................................. 3 25AL36 25AL35 25AL35 25AL35
* Not shown
3-1-529 Page 17

STYLE 838 PACKING
Ref. 2.00" 1.75" 1.50"
1 GASKET ............................................. 3 25BD3 25BD3 25BD3
3 LUBE FITTING .................................... 3 40E7 40E7 40E7
Includes Ref. Numbers 4 thru 7 ......... 3 PS160020 PS160017 PS160015
4 JUNK RING ........................................ 3 PQ31720 PQ31717 PQ31715
8 GLAND NUT........................................ 3 2011555 2011555 2011555
STYLE 858 PACKING

Ref. 2.00" 1.75" 1.50"
1 GASKET ............................................. 3 25BD3 25BD3 25BD3
3 LUBE FITTING .................................... 3 40E7 40E7 40E7
4 JUNK RING ........................................ 3 PQ31720 PQ31717 PQ31715
8 GLAND NUT........................................ 3 2011555 2011555 2011555
* Not shown
3-1-529 Page 18

STYLE 838 PACKING

Ref. 1.25"
1 GASKET .............................................. 3 25BD3
3 LUBE FITTING.................................... 3 40E7
Includes Ref. Numbers 4 thru 7 ........... 3 PS160012
4 JUNK RING.......................................... 3 PQ31712
5 PACKING – STYLE 838 ...................... 3 60BU33
7 GLAND BUSHING .............................. 3 PS15212
8 GLAND NUT ....................................... 3 2011555
STYLE 858 PACKING

Ref. 1.25"
1 GASKET .............................................. 3 25BD3
3 LUBE FITTING.................................... 3 40E7
Includes Ref. Numbers 4 thru 7 ........... 3 310TEE4060
4 JUNK RING.......................................... 3 PQ31712
5 PACKING – STYLE 858 ...................... 3 60DD752
7 GLAND BUSHING .............................. 3 PS15212
8 GLAND NUT ....................................... 3 2011555
* Not shown
3-1-529 Page 19

STYLE 838 PACKING
Ref. 4.00" 3.50" 3.00" 2.75"
STYLE 838 PACKING

Ref. 2.50" 2.25" 2.00" 1.75"
* Not shown
3-1-529 Page 20

STYLE 1067 PACKING
Ref. 4.00" 3.50" 3.00" 2.75"
STYLE 1067 PACKING

Ref. 2.50" 2.25" 2.00" 1.75"
* Not shown
3-1-529 Page 21

STYLE 858 PACKING
Ref. 4.00" 3.50" 3.00" 2.75"
STYLE 858 PACKING

Ref. 2.50" 2.25" 2.00" 1.75"
* Not shown
3-1-529 Page 22

STYLE 838 PACKING
Ref. 3.00" 2.75" 2.50"
1 GASKET ............................................. 3 25AL53 25AL53 25AL53
3 LUBE FITTING .................................... 3 40E7 40E7 40E7
4 JUNK RING ........................................ 3 26PE317 27PE317 28PE317
8 GLAND NUT........................................ 3 4PE113 4PE113 4PE113
STYLE 838 PACKING

Ref. 2.25" 2.00" 1.75"
1 GASKET ............................................. 3 25AL53 25AL53 25AL53
3 LUBE FITTING .................................... 3 40E7 40E7 40E7
4 JUNK RING ........................................ 3 25PE317 29PE317 30PE317
8 GLAND NUT........................................ 3 4PE113 4PE113 4PE113
* Not shown
3-1-529 Page 23

STYLE 1067 PACKING
Ref. 3.00" 2.75" 2.50"
1 GASKET ............................................. 3 25AL53 25AL53 25AL53
3 LUBE FITTING .................................... 3 40E7 40E7 40E7
8 GLAND NUT........................................ 3 4PE113 4PE113 4PE113
STYLE 1067 PACKING

Ref. 2.25" 2.00" 1.75"
1 GASKET ............................................. 3 25AL53 25AL53 25AL53
3 LUBE FITTING .................................... 3 40E7 40E7 40E7
8 GLAND NUT........................................ 3 4PE113 4PE113 4PE113
* Not shown
3-1-529 Page 24

STYLE 858 PACKING
Ref. 3.00" 2.75" 2.50"
1 GASKET ............................................. 3 25AL53 25AL53 25AL53
3 LUBE FITTING .................................... 3 40E7 40E7 40E7
4 JUNK RING ........................................ 3 26PE317 27PE317 28PE317
8 GLAND NUT........................................ 3 4PE113 4PE113 4PE113
STYLE 858 PACKING

Ref. 2.25" 2.00" 1.75"
1 GASKET ............................................. 3 25AL53 25AL53 25AL53
3 LUBE FITTING .................................... 3 40E7 40E7 40E7
4 JUNK RING ........................................ 3 25PE317 29PE317 30PE317
8 GLAND NUT........................................ 3 4PE113 4PE113 4PE113
* Not shown
3-1-529 Page 25

PISTONS AND LINERS (TEEE)
Well Service – High Pressure Block Steel – 4”
Ref. 4.00" 3.50" 3.00" 2.75"
1 PISTON BODY ASSEMBLY................ 3 232TBA045A 230TBA045A 228TBA045A 227TBA045A
2 O-RING................................................ 3 25AH1 25AH1 25AH1 25AH1
3 INSERT GROUP, Includes Ref. .......... 3 TBA76008 TBA76006 TBA76004 TBA76003
Numbers 4 and 5
4 PLATE-RETAINER.............................. 3 * * * *
5 RING-RETAINER ................................ 3 * * * *
6 GASKET-HYDRAULIC RING .............. 3 25AL36 25AL36 25AL36 25AL36
7 CLAMP-LINER..................................... 3 200PEE455 200PEE455 200PEE455 200PEE455
8 PISTON ROD ASM, Includes item 9 ... 3 200PEE060 200PEE060 200PEE060 200PEE060
9 NUT, Piston Rod.................................. 3 50V3 50V3 50V3 50V3
10 LINER .................................................. 3 203PEE456 202PEE456 201PEE456 200PEE456
PISTONS AND LINERS (TEEG)

Well Service – High Pressure Cast Steel – 3”
Ref. 3.00" 2.75" 2.50"
1 PISTON BODY ASSEMBLY ............... 3 228TBA045A 227TBA045A 45R1
2 O-RING............................................... 3 25AH1 25AH1 ***
3 INSERT GROUP, Includes Ref.......... 3 TBA76004 TBA76003 45R8
Numbers 4 and 5
4 PLATE-RETAINER.............................. 3 * * ***
5 RING-RETAINER ................................ 3 * * ***
6 GASKET-HYDRAULIC RING.............. 3 25AL35 25AL35 25AL35
7 CLAMP-LINER ................................... 3 1PE217 1PE217 1PE217
8 PISTON ROD ASM, Includes item 9.. 3 200PEE060 200PEE060 200PEE060
9 NUT, Piston Rod ................................. 3 50V3 50V3 50V3
10 LINER ................................................. 3 PE13930 2011248 PE13925
* Not to be sold separately
*** 2, 4 and 5 are not applicable for 2.50” size
3-1-529 Page 26

Ref.

Bronze Steel
FLUID VALVE ASSEMBLY 6 200VLH482 201VLH482 202VLH482
1 RETAINER ............................. 6 2010582 2010583 2010584
2 FASTENER ............................ 6 2010598 2010598 2010598
3 PLUG-THREAD LOCK .......... 6 2010602 2010602 2010602
4 SPRING (Inner)...................... 6 2010604 2010604 2010604
5 SPRING (Outer) ..................... 6 2010607 2010607 2010607
6 VALVE DISC .......................... 6 2010611 2010611 2010611
7 VALVE SEAT ......................... 6 2010623 2010624 2010625
3-1-529 Page 27

Ref.
FLUID VALVE ASSEMBLY .................................... 6 208VWH482A

1 VALVE SEAT ......................................................... 6 200VWH039
2 VALVE CAGE......................................................... 6 200VWH054
3 FLUID VALVE ........................................................ 6 3PA206
4 SPRING.................................................................. 6 78H29
3-1-529 Page 28

Ref.

Bronze Steel
FLUID VALVE ASSEMBLY 6 200VLF482 201VLF482 202VLF482
1 RETAINER ............................. 6 2010585 2010586 2010587
2 FASTENER ............................ 6 2010598 2010598 2010598
3 PLUG-THREAD LOCK .......... 6 2010602 2010602 2010602
4 SPRING (Inner)...................... 6 2010605 2010605 2010605
5 SPRING (Outer) ..................... 6 2010608 2010608 2010608
6 VALVE DISC .......................... 6 2010612 2010612 2010612
7 VALVE SEAT ......................... 6 2010629 2010630 2010631
3-1-529 Page 29

Ref.

1 VALVE SEAT ......................................................... 6 200VWF039
2 VALVE CAGE......................................................... 6 200VWF054
3 FLUID VALVE ........................................................ 6 PT206
4 SPRING.................................................................. 6 78H22
VALVE CAGE WRENCH: 16AUX219
3-1-529 Page 30

SUCTION VALVE ONLY

Ref.

Bronze Steel
FLUID VALVE ASSEMBLY 3 200VHC482 201VHC482 202VHC482
1 RETAINER ............................. 3 2010591 2010592 2010593
2 FASTENER ............................ 3 2010600 2010600 2010600
3 PLUG-THREAD LOCK .......... 3 2010603 2010603 2010603
4 SPRING (Inner)...................... 3 2010606 2010606 2010606
5 SPRING (Outer) ..................... 3 2116348 2116348 2116348
6 VALVE DISC .......................... 3 2010829 2010829 2010829
7 VALVE SEAT ......................... 3 2010653 2010654 2010655
3-1-529 Page 31

DISCHARGE VALVE ONLY

Ref.

Bronze Steel
FLUID VALVE ASSEMBLY 3 210VHF482 211VHF482 212VHF482
1 RETAINER ............................. 3 2010588 2010828 2010590
2 FASTENER ............................ 3 2010599 2010599 2010599
3 PLUG-THREAD LOCK .......... 3 2010603 2010603 2010603
4 SPRING (Inner)...................... 3 2010606 2010606 2010606
5 SPRING (Outer) ..................... 3 2116348 2116348 2116348
6 VALVE DISC .......................... 3 2010829 2010829 2010829
7 VALVE SEAT ......................... 3 2109442 2109449 2109445
3-1-529 Page 32

305TEE799 307TEE799
SUCTION VALVE
FLUID VALVE ASSEMBLY .................................... 3 208VWC482A

1 VALVE SEAT ......................................................... 3 200VWC039
2 VALVE CAGE......................................................... 3 200VWC054
3 FLUID VALVE ........................................................ 3 3PG206
4 SPRING.................................................................. 3 78H24
DISCHARGE VALVE

1 VALVE SEAT ......................................................... 3 200VWF039
2 VALVE CAGE......................................................... 3 200VWF054
3 FLUID VALVE ........................................................ 3 PT206
4 SPRING.................................................................. 3 78H22
3-1-529 Page 33

305TEE799 302TEE799
SUCTION VALVE
** HARDENED STEEL – WITHOUT INSERT

FLUID VALVE ASSEMBLY ...................................................... 3 210VWC482A
1 VALVE SEAT ........................................................................... 3 201VWC039
2 VALVE CAGE .......................................................................... 3 201VWC054
3 FLUID VALVE .......................................................................... 3 6PG206
4 SPRING ................................................................................... 3 78H22
** This steel wing guided valve without an insert is for services requiring a discharge pressure
over 6500 PSIG.
DISCHARGE VALVE

1 FLUID VALVE .......................................................................... 3 1PT206
2 VALVE SEAT ........................................................................... 3 201VWF039
3 VALVE CAGE .......................................................................... 3 201VWF054
4 SPRING ................................................................................... 3 78C39
3-1-529 Page 34

304TEE799 303TEE799

SUCTION VALVE

FLUID VALVE GROUP, Includes items 1 thru 8 ..................... 3 211VWC482A
1 FLUID VALVE ASSEMBLY, Includes items 2 thru 5 ............... 3 PG206A
2 FLUID VALVE .......................................................................... 3 PG206
3 INSERT, Rubber...................................................................... 3 PG452
4 WASHER, Retainer ................................................................. 3 95D166
5 NUT.......................................................................................... 3 50AF3
6 VALVE SEAT ........................................................................... 3 201VWC039
7 SPRING ................................................................................... 3 78A148
8 VALVE CAGE .......................................................................... 3 201VWC054
DISCHARGE VALVE

2 FLUID VALVE .......................................................................... 3 1PT206
4 INSERT, Rubber...................................................................... 3 2PT452
5 RETAINER, Ring ..................................................................... 3 65W19
6 VALVE SEAT ........................................................................... 3 201VWF039
7 SPRING ................................................................................... 3 78C39
8 VALVE CAGE .......................................................................... 3 201VWF054
3-1-529 Page 35

300TEE799 301TEE799
SUCTION VALVE


1 FLUID VALVE .......................................................................... 3 215VWG482
2 VALVE SEAT ........................................................................... 3 201VWC039
3 VALVE CAGE .......................................................................... 3 201VWC054
4 SPRING ................................................................................... 3 78H22
DISCHARGE VALVE


1 FLUID VALVE .......................................................................... 3 213VWG482
2 VALVE SEAT ........................................................................... 3 201VWF039
3 VALVE CAGE .......................................................................... 3 201VWF054
4 SPRING ................................................................................... 3 78C39
3-1-529 Page 36

CAST STEEL – WITHOUT INSERT
Ref.
FLUID VALVE ASSEMBLY.......................................................... 6 TGE90021

1 FLUID VALVE .............................................................................. 6 202TEE482
2 VALVE SEAT ............................................................................... 6 200PEE039
3 VALVE CAGE .............................................................................. 6 200PEE054
4 SPRING ....................................................................................... 6 78H26
3-1-529 Page 37

(CARBOXYLATED RUBBER INSERT)
Ref.

1 FLUID VALVE..................................................................................... 6 203TEE482
2 VALVE SEAT...................................................................................... 6 200PEE039
3 VALVE CAGE ..................................................................................... 6 200PEE054
4 SPRING .............................................................................................. 6 78H26
3-1-529 Page 38

CAST STEEL – WITH REMOVABLE INSERT
(URETHANE INSERT)
Ref.
FLUID VALVE GROUP, Includes Ref No. 1 thru 8 ............................ 6 200PEE482B

1 FLUID VALVE ASSEMBLY, Includes Ref No. 2thru 5 ....................... 6 200PEE482A
2 FLUID VALVE..................................................................................... 6 200PEE482
3 VALVE INSERT .................................................................................. 6 1PA452
4 WASHER ............................................................................................ 6 PA1272
5 RETAINER RING................................................................................ 6 74D43
6 VALVE SEAT...................................................................................... 6 200PEE039
7 SPRING .............................................................................................. 6 78H26
8 VALVE CAGE ..................................................................................... 6 200PEE054
3-1-529 Page 39

(POLYURETHANE RUBBER INSERT)
Ref.

1 FLUID VALVE..................................................................................... 6 204TEE482
2 VALVE SEAT...................................................................................... 6 200PEE039
3 VALVE CAGE ..................................................................................... 6 200PEE054
4 SPRING .............................................................................................. 6 78H26
3-1-529 Page 40

ABRASION RESISTANT
Ref.

1 VALVE SEAT.................................................................................. 6 2116687
2 O-RING........................................................................................... 6 2116520
3 VALVE INSERT .............................................................................. 6 2116521
5 SPRING .......................................................................................... 6 2116523
6 VALVE CAGE ................................................................................. 6 2116524
3-1-529 Page 41


2 FLUID VALVE .......................................................................... 6 1PT206
4 INSERT, Rubber...................................................................... 6 2PT452
5 RETAINER, Ring ..................................................................... 6 65W19
6 VALVE SEAT ........................................................................... 6 201VWF039
7 SPRING ................................................................................... 6 78C39
8 VALVE CAGE .......................................................................... 6 201VWF054
3-1-529 Page 42


1 FLUID VALVE .......................................................................... 6 1PT206
2 VALVE SEAT ........................................................................... 6 201VWF039
3 VALVE CAGE .......................................................................... 6 201VWF054
4 SPRING ................................................................................... 6 78C39
3-1-529 Page 43


1 FLUID VALVE .......................................................................... 6 213VWG482
2 VALVE SEAT ........................................................................... 6 201VWF039
3 VALVE CAGE .......................................................................... 6 201VWF054
4 SPRING ................................................................................... 6 78C39
3-1-529 Page 44

HIGH PRESSURE - CAST STEEL CYLINDER – 3”
ABRASION RESISTANT
Ref.

1 VALVE SEAT.................................................................................. 6 2116561
2 O-RING........................................................................................... 6 2116284
3 VALVE INSERT .............................................................................. 6 2116283
5 SPRING .......................................................................................... 6 2116348
6 VALVE CAGE ................................................................................. 6 2116282
3-1-529 Page 45
LUBRICATOR GROUP (Optional Equipment)

LUBRICATOR GROUP Includes the Following Items. 1 TEE90984

1 BRACKET, Lubricator ............................................................................... 1 200TEE403
2 SCREW, Bracket to Frame ....................................................................... 2 655EE040
3 WASHER................................................................................................... 2 95A5
4 SCREW, Bracket to Frame (Cradle Area)................................................. 2 75LM51
5 LUBRICATOR, (Ratchet Type) ................................................................. 1 40G99
6 SCREW, Lubricator to Bracket.................................................................. 4 75LM50
7 BRACKET, Lubricator Drive ...................................................................... 1 200PEE017
8 SCREW, Plunger Coupling ....................................................................... 2 655EE18Z
9 END, Control Rod...................................................................................... 1 BM11210A
10 SCREW, Rod End to Drive Bracket .......................................................... 1 655ED060
11 WASHER................................................................................................... 2 95A3
12 CONTROL ROD, Lubricator...................................................................... 1 2005879
13 LOCKNUT, Control Rod ............................................................................ 1 50B3
14 CONNECTOR, Tube - 90 Degree............................................................. 3 86A25
15 TUBING, Lubricator to Stuffing boxes (Length Required for 1 Pump) ...... 20 Ft. 85E4A
16 CONNECTOR, Tube - Straight ................................................................. 3 86A1
17 CHECK VALVE ......................................................................................... 3 90AR373
18 STUD, Cradle Cover ................................................................................. 2 79A466
19 WINGNUT, Cradle Cover .......................................................................... 2 50H1
20 INSPECTION PLATE, Cradle Cover......................................................... 1 202TEE052
21 SIGHT GLASS, (Included with Lubricator)................................................ 1 40P15
3-1-529 Page 46
3-1-529 Page 47

1 SHEAVE, Driven ....................................................................................... 1 73K1A30

2 BUSHING, Sheave.................................................................................... 1 22E16B
3 CENTRIFUGAL PUMP.............................................................................. 1 CA122
4 SCREW, Pump to Skid.............................................................................. 4 655ED040
5 LOCK WASHER........................................................................................ 4 95B3
6 WASHER................................................................................................... 4 95A3
7 NUT ........................................................................................................... 4 50B3
8 OIL SCREEN............................................................................................. 1 3WAJ511
9 PIPE REDUCER ....................................................................................... 1 64N7
10 PIPE NIPPLE ............................................................................................ 2 63H1
11 PIPE COUPLING ...................................................................................... 1 64AB4
12 ADAPTOR ................................................................................................. 2 29Q9
13 VALVE, Regulator ..................................................................................... 1 90AR299
14 PIPE NIPPLE ............................................................................................ 1 63H25
15 PIPE ELBOW, 90 Deg............................................................................... 1 64S5
16 PIPE NIPPLE ............................................................................................ 3 63G15
17 PIPE TEE .................................................................................................. 3 64P39
18 VALVE, Shut-Off ....................................................................................... 1 90A35
19 PIPE NIPPLE ............................................................................................ 2 63G1
20 PIPE COUPLING ...................................................................................... 1 64AB3
21 CLAMP, Pipe............................................................................................. 2 98H4
22 SCREW, Clamp to Frame ......................................................................... 2 655EC020
23 HYDRAULIC HOSE ASSEMBLY.............................................................. 3 29R32
24 HOSE ADAPTOR...................................................................................... 3 29Q7
25 PIPE BUSHING......................................................................................... 3 64E2
26 BAFFLE ..................................................................................................... 3 200TEE840
27 TANK ASSEMBLY, Recovery (Includes the Next Item)............................ 1 PA252A
TANK COVER ........................................................................................... 1 PA253
28 SCREW, Tank to Skid ............................................................................... 4 655EE070
29 LOCK WASHER........................................................................................ 4 95B5
30 NUT ........................................................................................................... 4 50B5
31 PLUG......................................................................................................... 1 64A6
32 PLUG......................................................................................................... 1 64AA7
33 INSPECTION PLATE (Slotted Cradle Cover) ........................................... 1 304TEE052
The Following Will Be Furnished By the Customer: ...........................
SHEAVE, Auxiliary Drive........................................................................... 1

BELT, Single ............................................................................................. 1
DRAIN, Return .......................................................................................... 1
3-1-529 Page 48
Ref.
VALVE SEAT PULLER GROUP ........... 1 TEE68699 TEE68700 TEE73494

1 ROD ....................................................... 1 200TAE193 200TEE193 200TAE193
2 PULLER PLATE .................................... 1 200TEE340 200TEE340 202TEE340
3 WASHER ............................................... 1 200TAE244 200TAE244 200TAE244
4 WEDGE ................................................. 1 200TAE091 200TAE091 200TAE091
5 WASHER ............................................... 1 95U14 95U14 95U14
6 NUT........................................................ 1 200TAE086 200TAE086 200TAE086
* INSTRUCTION TAG 1 201TAE304 201TAE304 201TAE304
* Not Shown on Illustration
3-1-529 Page 49
CUSTOMER REPAIR INFORMATION
NOTE:
1. TEE Pump with a Serial Number 917132 and Later are equipped with the Two Piece
Crosshead / extension rod, as shown on page 6.
Pumps with Serial Numbers previous to 917132 have a One Piece Crosshead /
Extension Rod.
For pumps with the earlier Serial Numbers, the 300TEE6005 conversion kit must be
used when a repair crosshead is required.

2. The PE840 Extension Rod Baffle is required for pumps that do not have the Two Piece
Crosshead / Extension Rod construction.
3. Oversized Crossheads are available for pumps with Serial Numbers 917132 and later.
(301TEE005)
An Oversized Crosshead Conversion Kit is available for pumps that are equipped with
One Piece Crosshead / Extension Rod. (301TEE6005)

4. Available Cradle Covers:

a. 201TEE052 – Standard
b. 202TEE052 – Used with Lubricator Option
c. 204TEE052 – Plexiglas (See Through)
d. 303TEE052 – Ventilated
e. 304TEE052 – Used with Rod Wash Option
5. MODEL CYLINDER SIZE x STROKE

TEEA 4x5
TEEB 3x5
TEEC 2x5
TEED 4x5
TEEE 4x5
TEEF 3x5
TEEG 3x5
3-1-529 Page 50
NOTES
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____________________________________________________________________________
3-1-529 Page 51
GARDNER DENVER PUMP UNIT RECORD
The following unit identification plate is provided as a convenience to you,

our valued Gardner Denver customer. Please take the time to copy all the
information from the actual nameplate on your unit. The model number,
date manufactured and serial number will be required when contacting the
company or your distributor for information or replacement parts.
Ref. Drawing – 200OPA496

For additional information contact your local distributor or
Gardner Denver - Fluid Transfer Division,
1800 Gardner Expressway, Quincy, Illinois 62301
Customer Service Department Telephone:
(800) 682-9868 FAX: (217) 223-1581
Specifications subject to change without notice. For Domestic parts information Contact:
Copyright © 2008 Gardner Denver, Inc. DJC Litho in U.S.A. Gardner Denver – Fluid Transfer Division,
2200 South Prospect, Oklahoma City, OK. 73129
http://www.gardnerdenver.com [email protected] Telephone: (405) 677-5736 FAX: (405) 677-5807
07/31/2003
INSTALLATION, OPERATION
AND MAINTENANCE MANUAL FOR ROPER®
5600 SERIES TYPE 1
PUMPS:
5638
5658
Roper Pump Company

PO Box 269
Commerce, Georgia 30529
USA
Telephone: (706) 335-5551

TeleFAX: (706) 335-5490
Email: [email protected]
Web: www.roperpumps.com
2003 Roper Pump Company
PART NO. G12-405

Section 1.0
TABLE OF CONTENTS
Section Page
1.1 Nameplate Data ………………………………………………………… 1 - 1
1.2 Maximum Pump Ratings..…...………………………………………... 1 - 2
Page 1 – i
1.1 NAMEPLATE DATA • The second digit (6) indicates shaft
sealing.
Roper Pump Company identifies each pump
manufactured by a metal nameplate 6 − Packing
attached to the pump. This nameplate
describes the pump as built at the factory. • The third and fourth digits (58) indicate
Copy the nameplate data from your pump in the approximate theoretical displace-
the area provided below. Use this for ready ment in US gallons per 100 revolutions.
reference when ordering repair parts or when Gallons/100 Rev. [Liters/100 Rev.]
consulting with Roper Pump Company or an
authorized distributor about this pump. 38 [143.8]
FIGURE NUMBER: 58 [219.6]
SPEC NUMBER: • The letter (H) indicates the pump

head arrangement.
TYPE:
H Pump with inboard bushing
SERIAL NUMBER:
• The letter (F) indicates port style.
PUMP NOMENCLATURE
No letter − Pump with threaded ports
Example: 5658 HFL SPEC XXX
TYPE 1 SERIAL NO. ZZZ F − Pump with ROPER® standard
flange ports
1. The FIGURE number consists of a
seven digit number. • The letter (L) indicates shaft position.
• The first digit (5) indicates the series. No letter − High Drive
L − Low Drive
Example:
5658*HFL SPEC XXX TY 1 S/N XXX
5 6 58 * H F L
Shaft position
Port style
Pump head arrangement
Motor mounted unit *
Theoretical displacement
Shaft Sealing
Port arrangement
* The letter (M) may be used in this space indicating the pump is mounted with motor.
The letter (E) may be used in this space indicating the pump is mounted on a base
with or without engine.
Page 1 – 1
As stated in the explanation of the pump 1.2 MAXIMUM PUMP
nomenclature, all characters may not
appear on every pump nameplate. RATINGS
NOTE: The preceding description of the The maximum pressure and speed limits for
figure number is to assist in identifying your this pump SERIES are shown below.
ROPER® 5600 series pump only. DO NOT
attempt to derive any ratings or The maximum rating of a pump with a
performance from the figure number. DO SPEC number may be lower depending on
NOT use the explanation of the figure the materials of construction.
number to construct your own pump. Not all
combinations are possible. For assistance Maximum limits for this SERIES:
in pump selection, it is recommended that
you consult Roper Pump Company or an 100 psi [689 kPa] Maximum Inlet
authorized distributor. Pressure
2. Occasionally, special pumps or 100 psi [689 kPa] Maximum Discharge

configurations are required which are Pressure
unique for a particular application.
These modifications are clarified by a 99 psi [683 kPa] Maximum
SPECification number. Identification of Differential Pressure
any items different than a standard
pump can be made by consulting Roper 420 rpm Maximum Speed
Pump Company or an authorized
distributor. Maximum Temperature Limits for standard
pumps (no spec number) are:
3. The TYPE number is a number used by
Roper Pump Company for in-house Packed Box Pumps: 160°F [71°C]
identification of construction and
hydraulics. Always include the type
number in any references to the pump.
4. The SERIAL number is a unique

number assigned to each pump built by
Roper Pump Company.
In any communication concerning this

pump, always by sure to include the Figure,
Spec, Type, and Serial numbers so proper
identification of the pump can be assured.
Page 1 – 2
Section 2.0
TABLE OF CONTENTS
Section Page
2. 1 Introduction ……………………….……..…………………………….. 2 - 1
2. 2 Safety Precautions …..………...……………………………………… 2 - 2
2. 3 Preoperation Checks…..………….…..…………..…………………… 2 - 3
2. 4 Preparation of Foundation…..………….……..……………………… 2 - 4
2. 5 Aligning Driver and Pump….………….……………………………… 2 - 5
2. 6 Additional Important Warnings and Information..….……..……… 2 - 9
2. 7 Installation of Pipes…..……….….……………………..…..………… 2 - 10
2. 8 Threaded Port Connections………………………..………………….2 - 11
2. 9 Checking Pump Performance…………………..……………………..2 - 12
2. 10 Replacement Parts…………………………………………….………...2 - 13
2. 11 Index ……………………….……………..………...……………..………2 - 14
Page 2 – i
2.1 INTRODUCTION
! IMPORTANT
! IMPORTANT
Read the following before starting the pump!
THIS MANUAL MUST ACCOMPANY THE Failure to heed these warnings may result in
PUMP UPON ALL TRANSFERALS. MAKE an accident causing physical damage, serious
SURE THE OPERATOR OF THE personal injury, or death!
EQUIPMENT HAS READ AND • Read and understand all tags and
UNDERSTANDS THIS MANUAL BEFORE installation and operating instructions.
OPERATING THE PUMP OR ANY RELATED
EQUIPMENT. • WARNING! Install proper guard(s). DO
NOT operate pump without guard(s)
When properly selected, installed, operated, installed, always use caution near rotating
and maintained, ROPER® pumps will provide parts including the drive system for the
long, dependable service. Remember, faulty pump. Serious injuries and death have
selection and installation form the basis of occurred from becoming entangled in
more pump troubles than all other causes rotating shafts.
combined. No amount of maintenance can
compensate for selection and installation • WARNING! DO NOT operate this
mistakes. Read this manual carefully and equipment in excess of its rated capacity,
understand it totally before installing or pressure, speed, and temperature, or
operating the pump which it accompanies. other than according to the instructions
contained in this manual.
This pump is satisfactory for its rated
conditions. Its operation beyond these • WARNING! Install and properly set
conditions may subject it to stresses and devices into the system to prevent the
strains that it is not designed to withstand. chance of too much pressure, high
temperature, and driver overload. The
Install ample coupling or belt guards for the pump is not provided with these devices.
protection of personnel.
• WARNING! Proper measures and
This manual will cover standard pumps and safeguards must be taken to avoid spillage
most SPECification number pumps. and overflow from overfilling or putting too
Appearance may vary among pumps and much pressure on any component of the
construction may vary on spec. number system. This includes the receiver and
pumps. Specification numbers are assigned to lines.
pumps with other than standard features.
Roper Pump Company produces specific • Know the operating conditions.
manuals for most standard line pump models.
• Open all lines before starting pump.
Contact Roper Pump Company to find out if
the pump model you have has a specific This manual contains general information
manual and to request a copy. concerning the use, inspection, adjustment,
and test of the pump furnished. For certain
If there is any question concerning the ratings,
applications and installations, other
instructions, or compatibility of the pump with
precautions and safety measures may be
the pumped liquid, consult an authorized
appropriate and are the responsibility of the
distributor or:
product installer and user. Users of this
Roper Pump Company
pump must have ample knowledge and
PO Box 269
training to apply sound safety and operating
Commerce, Georgia 30529 USA
practices that may not be mentioned in the
Telephone: (706) 335−5551 manual, and the sale of this pump is in
TeleFAX: (706) 335-5490 reliance on such user knowledge and
Email: [email protected] training.
Page 2 – 1
2.2 SAFETY PRECAUTIONS
• DO NOT work on a pump while it is
WHEN LIQUID BEING PUMPED IS operating or if there is a chance of the
HAZARDOUS OR VOLATILE, ALWAYS driver becoming energized except to
TAKE FULL PRECAUTIONS. THIS adjust the relief valve.
INCLUDES THE RUN-IN PERIOD AND • DO NOT adjust packing while the pump is
DURING DISASSEMBLY AND ASSEMBLY operating or if there is a chance of the
OF PUMP. driver becoming energized.
Controls, guards, walkways, machine • DO NOT adjust the integral relief valve
arrangement, crew training, etc., are all without coupling guards in place.
necessary factors in the creation of a safe,
practical installation and are generally not a • DO NOT place hands, feet, head, or any
part of our services. It is the responsibility of other part of your body in any pump
the contractor, installer, owner, and user to opening while the pump can be operated.
add to the materials furnished by Roper Pump • DO NOT poke or prod material in the
Company to result in a safe installation and to pump.
comply with OSHA, state and local laws, and
the ANSI/NFPA Life Safety Code. • DO NOT start to disassemble the pump if
there is the slightest chance of it becoming
There are many kinds of devices for pumps energized by accident. Lock out the
and systems such that if one component in a energy source to the driver and disconnect
system is stopped, other equipment feeding or the coupling before performing
following it also can be automatically stopped. maintenance to the equipment.
Serious thought should be given to the
installation of these types of devices in every • DO NOT wear loose or dangling clothing
pump system. or jewelry near the equipment. It could
become caught and possibly cause
• DO NOT attempt to install, operate, or serious injury or death.
perform maintenance on this equipment
without first reading and understanding the • DO NOT use metallic or hard faced
material in this manual. Also, read and striking tools when the need for tapping
understand all tags and any other parts into position arises. Hard faced
documentation accompanying the pump. striking tools may damage parts or they
may fracture or chip and send particles
• DO NOT operate this equipment in excess flying that could cause possible injury.
of its rated capacity, pressure, speed, and
temperature, or other than according to the • DO NOT allow spills to remain in the work
instructions contained in this manual. area. Clean up spills immediately. Oils,
greases, and other fluids used in the
• DO NOT continue to operate this equipment may create hazards if not
equipment if there is a failure of any part of cleaned up immediately after a spill.
the equipment or system. Correct the
failure before operating the equipment. • DO NOT spin bearings with compressed
air. This is highly dangerous and can
• DO NOT bypass safety controls or guards. cause the bearing to fragment with
Their purpose is to protect and they must explosive force, possibly causing serious
be in proper working order. injury or death.
• DO NOT operate equipment without • DO NOT attempt to install, use, or repair
proper guards in place. this equipment while under the influence of
• DO NOT walk, stand, sit, or lean on any substance that may impair physical or
guards. mental abilities. This includes, but is not
Page 2 – 2
limited to, alcohol and prescription and • DO be aware of your location relative to
nonprescription drugs. the equipment.
• DO NOT dispose of fluoroelastomers by • DO wear proper clothing near the
burning. Toxic vapors are released by this equipment. Safety glasses or goggles, and
compound upon combustion. safety shoes are recommended. They will
help reduce the chance of injury.
• DO NOT suspend pumps from the ports
unless they have been specifically • DO use soft faced striking tools when the
designed for this type of mounting. need for tapping parts into position arises.
Rubber or plastic faced striking tools are
recommended.
• DO completely read and understand the
information contained in this manual. The • DO practice good housekeeping. Clean up
operator of the equipment must be familiar spills immediately. Keep the work area
with these instructions. clean to avoid hazards. Always be sure of
your footing around the equipment to avoid
• DO stop the pump in a manner that there a possible fall and injury.
is no chance of the driver becoming
energized while any kind of work is being • DO use proper tools. Avoid cheater bars
performed on the pump or system. as they are a source for serious injury
should they slip or break.
• DO always keep safety in mind.
• DO mount pumps in the manner they were
• DO know the operating conditions of the designed to be mounted.
equipment.
• DO take proper measures and precautions
to avoid spillage and overflow from 2.3 PREOPERATION CHECKS
overfilling or putting too much pressure on Read and understand the instructions and
any component of the system. recommendations contained in this manual.
• DO identify all possible hazards and Disconnect the coupling between the driver
decide what controls are needed. and pump.
Remember, only you understand your
Test the rotation of the driver to make sure it
product and system characteristics fully.
will operate the pump in the desired direction
The ultimate responsibility for the
of rotation. Rotation is shown on the pump in
application and safety is with you.
relation to the integral relief valve. When an
• DO install and properly set devices into the integral relief valve is used, make sure it is
system to prevent the chance of dry positioned and adjusted as discussed in the
operation, overpressure, excessive section titled, DIRECTION OF ROTATION
temperature, and driver overload. AND RELIEF VALVES. After the unit is
mounted and the piping is connected, the
• DO provide guards for all exposed rotating
pump should be checked to be sure it
parts, including all parts of the drive
operates freely without binding. After
system, to prevent possible injury.
operation is proved satisfactory, both pump
• DO be careful when working near an and driver should be tightly secured and the
operating pump. Contacting or getting alignment rechecked before operation.
caught in rotating parts may cause serious
Before starting, make sure all guards are in
or fatal injury.
place and the inlet and discharge valves are
• DO keep equipment in good working opened. After starting the unit, check to see
order, especially safety devices and that the pump is delivering liquid. If not, stop
guards.
Page 2 – 3
the driver immediately and refer to Section 2.4 PREPARATION OF
2.9, CHECKING PUMP PERFORMANCE.
After the pump is delivering liquid, check the FOUNDATION
unit for excessive vibration, localized heating, Locate the pump so that it is as low and as
and excessive shaft seal leakage. Check the close to the fluid source as practical and so
pressure or vacuum by installing gauges at that piping to and from the pump will be as
both the inlet and discharge sides of the pump short and simple as practical. The pump and
to make sure the pressure or vacuum conform its driver must be accessible for inspection
to specifications. and maintenance. Accessibility to the unit and
adequate clearance should be a major thought
in any installation. The driver must be suitable
for the environment (for example; open,
splash proof, totally enclosed, or explosion
proof electric motor). If the driver is not
If there is no pressure relief device in the suitable, choose a different location or obtain
system, NEVER block the discharge line. If another driver.
there is a relief valve in the system, NEVER For best pump-driver unit life, mount each unit
block the discharge line between the relief on a strong, fabricated, structural steel
valve and pump. High pressure will occur, baseplate with a proper foundation. A good
resulting in possible damage or breakage foundation is of major importance to the total
to the pump or system parts and possible installation. A thick, heavy concrete foundation
injury to personnel. DO NOT operate the is best since it is heavy enough to support the
pump for more than one minute with the baseplate rigidly and absorb strain and shock.
discharge line blocked downstream of the Locate anchor bolts for the baseplate in the
relief valve. Rapid heating and possible foundation. Use a pipe sleeve, two to three
damage will occur. Even an open times as large as the anchor bolts, around the
discharge line does not prevent the anchor bolts to allow some lateral bolt
possibility of high pressure. Discharge line movement during final positioning of the unit.
length, diameter, and arrangement along
with fluid viscosity and velocity also can
Place the unit, with the pump and driver
create a high pressure situation at the
mounted on the baseplate, on the foundation
pump.
and disconnect the coupling (flexible coupling,
belts, and sheaves, etc.). DO NOT reconnect
the coupling unit until all alignment operations
are complete. Support the baseplate on
rectangular metal blocks and shims or on
metal wedges having a small taper. Place the
support pieces close to the anchor bolts and
directly under the part of the baseplate
carrying the greatest weight. Space the
support pieces close enough to give uniform
support. Allow a gap of about 3/4 inch [19 mm]
to 1-1/2 inches [38mm] between the
foundation and baseplate for grouting. Refer
to Fig. 2.4.1.
Adjust the metal supports or wedges until the
WARNING! DO NOT overpressurize pump or
shafts of the pump and driver are level. At this
system.
time, check the faces of the inlet and
discharge connections of the pump for
horizontal or vertical position using a level.
Page 2 – 4
Correct the positions, if necessary, by Normal mounting for this pump is horizontal
adjusting the supports or wedges under the with the pump above the baseplate, properly
baseplate as required. grouted to a concrete foundation placed in or
on solid earth. Mountings other than described
For maximum rigidity and lower noise levels,
above (such as vertical mounting, wall
grout the baseplate to the foundation. Use a
mounting, ceiling mounting, etc.) may require
good grade of nonshrink grout. When all
special components and precautions. Extra
alignments are correct (refer to Section 2.5,
pump supports, special drivers, and extra
ALIGNING DRIVER AND PUMP), tighten the
anchor bolts may be necessary in unusual
anchor bolts evenly but not too firmly. Then
mountings. If your application requires other
grout the unit to the foundation. Completely fill
than normal mounting, as described above,
the baseplate with grout. It is desirable to
you are urged to consult Roper Pump
grout the leveling pieces, shims, or wedges in
Company for assistance in determining any
place. Fill the spaces between the anchor
special needs that may be required.
bolts and sleeves with grout, also. Allow the
grout to dry according to the manufacturer's
instructions. DO NOT fully tighten the anchor
bolts until the grout has hardened. 2.5 ALIGNING DRIVER AND
PUMP
The flexible coupling or belts and sheaves

must be accurately realigned during and after
installation. Refer to the flexible coupling or
belt and sheave manufacturer's
recommendations and instructions for the
requirements for proper alignment. Also refer
to Section 2.4, PREPARATION OF
FOUNDATION, for additional information.
FLEXIBLE COUPLING
DO NOT use a flexible coupling to
Fig. 2.4.1: Typical Baseplate Anchoring
compensate for misalignment of the driver and
After the grout has hardened and the anchor pump shafts. The purpose of the flexible
bolts have been properly tightened, check the coupling is to compensate for temperature
unit for parallel and angular misalignment, and changes and to permit end movement of the
if necessary, take corrective measures. After shafts without interference with each other
the piping to the unit has been connected, while transmitting power from the driver to the
check the alignment again. pump.
NOTE: Attempts to correct alignment in one The faces of the coupling halves should be
direction may alter the alignment in the other spaced far enough apart so that they cannot
direction. Therefore, it is necessary to check strike each other when the driver rotor is
alignment in all directions after making any moved hard over toward the pump. The
adjustments. necessary tools for approximate checking of
the alignment of a flexible coupling are a
Schedule semiannual inspections and checks
straight edge and a taper gauge or a set of
of the foundation anchor bolts as part of a
feeler gauges.
preventive maintenance program. If loose
foundation bolts are found, tighten them and
check the unit alignment.
Page 2 – 5
Make sure there is no chance of the driver
becoming energized while aligning driver
and pump. Getting caught in rotating parts
of the drive system will cause serious
personal injury or death. DO NOT start or
operate pump without guards in place.
WARNING! DO NOT operate without guards in

place.
There are two forms of misalignment between
the driver shaft and the pump shaft. The first is
angular misalignment, where the axes of the
shafts are concentric but not parallel. The
other is parallel misalignment, where the axes
of the shafts are parallel but not concentric.
Refer to Fig. 2.5.1.
Make the check for angular alignment by Fig. 2.5.1 Misalignments: Top, Angular; Center,
inserting the taper gauge or feeler gauges Parallel; Bottom, Both.
between the coupling faces and comparing
the distance between the faces at four points Make the check for parallel alignment by
spaced at 90° intervals around the coupling. placing a straight edge across both coupling
The unit will be in angular alignment when the halves at the top, bottom, and at both sides.
measurements show that the coupling faces The unit will be in parallel alignment when the
are the same distance apart at all points. straight edge rests evenly on the coupling
halves at all positions. Allowance may be
necessary for temperature changes and for
coupling halves that DO NOT have the same
outside diameter. Take care to have the
straight edge parallel to the axes of the shafts.
Page 2 – 6
Correct angular and parallel misalignment by Misalignment will cause undue belt wear, or
placing shims under the mounting feet of the turn-over in the grooves. Approximate
equipment. After each change, it is necessary alignment should be checked by placing a
to recheck the alignment of the coupling long straight edge evenly across the rims of
halves. Adjustment in one direction may both sheaves. If the faces of the sheaves are
disturb adjustments already made in another not of equal width, the alignment may be
direction. checked by resting the straight edge across
the rim of the widest sheave and measuring
BELTS AND SHEAVES the distance from the straight edge to the
Some applications on gear pumps involving nearest belt groove with a scale. Adjust either
low discharge pressure and slow speeds may sheave on the shaft to equalize these
permit the mounting of the driven sheave dimensions.
directly on the pump shaft. However, it is
The driver should be mounted with adequate
recommended that all belt drive assemblies be
provision for belt center distance adjustment.
designed with a separate jackshaft mounted
Provide a minus adjustment to permit belt
on pillow blocks to carry the side loads of the
installation without stretching and a plus
sheaves and belts and a flexible coupling
allowance to provide belt take-up.
connecting the jackshaft to the pump shaft.
DO NOT pry, twist, or force the belts over the
sheave grooves. This will damage the belts
and greatly reduce the belt life. Shorten the
drive by moving the driver enough to permit
fitting the belts in the proper grooves. When
the belts are in place, increase the center
Make sure there is no chance of the driver
distance until proper belt tension is obtained.
becoming energized while aligning and
Adjust take-up until only a slight bow appears
adjusting the belts. Getting caught in
on the slack side of the drive when it is
rotating parts of the drive system will
operating. All the belts must be pulling evenly.
cause serious personal injury or death. DO
Belt tension should be reasonable. It is not
NOT start or operate pump without guards
necessary to have belts excessively tight.
in place.
During the first few days of operation, the belts
will seat themselves in the sheave grooves.
After that, the drive must be adjusted to take
up the slack. Slipping belts will result in
lowered capacity. Squealing or smoking belts
are sometimes a clue to the slipping of belts.
Keep belts clean and free from oil. Stop drive

to clean belts. DO NOT attempt to clean belts
while the drive is operating. Clean oily belts
with a cloth dampened with soap and water.
Never install new belts on the same drive with
used belts. DO NOT use sheaves with
chipped or worn grooves. For hazardous
WARNING! DO NOT operate without guards in
place. locations, check to see if an antistatic belt
should be used. When purchasing
The driver and pump shafts must be parallel, replacement belts, the same size and type
and the belts at right angles to these shafts. should be ordered as furnished originally.
Page 2 – 7
POWER TAKE-OFF DRIVE SYSTEMS Unless properly designed, guarded, and
maintained, all drive systems are dangerous.
When mounting a pump on a vehicle with a
PTO drive, always check with the • DO be careful near rotating PTO drive
manufacturer of the PTO equipment to systems. Contacting a PTO drive system
determine the alignment required for proper may cause serious injury or death.
operation of the PTO. The mount for the pump
must be rigid. The pump must be mounted the • DO install and maintain proper guard(s) for
way it was designed to be mounted. Pumps PTO drive systems.
with feet must be mounted by the feet. DO
NOT use the pump ports to mount a pump • DO NOT operate PTO drive systems
that has feet. It is acceptable to mount a foot without proper guards in place.
mounted pump in the three, nine, or twelve
o'clock position as well as the standard six • DO NOT work on or adjust a pump driven
o'clock position as long as proper shaft by a PTO drive system while it is operating
alignment is maintained. or has a chance of the driver becoming
energized except as specified in the
section titled, DIRECTION OF ROTATION
AND RELIEF VALVES.
• DO NOT work on a PTO drive system

while it may become energized.
Make sure there is no chance of the driver • DO NOT wear loose or dangling clothing
becoming energized while aligning the power or jewelry near the equipment. It could
take-off shafting. Getting caught in a power become caught and possible cause
take-off drive system will cause serious serious injury or death.
injury or death. Proper guarding must be
provided for all power take-off drive systems. GUARDING PTO DRIVE SHAFTS
PTO drive systems can be dangerous and

when used, additional safety precautions,
including guarding, may be required and must
be provided by the drive system installer.
Roper Pump Company has no responsibility
for recommending or providing proper
guarding or other safety measures in any
particular application.
The installation of proper guards for the power

take-off and its associated equipment is the
WARNING! DO NOT operate without guards in responsibility of the drive system designer and
place. the installer who know the particular product
Serious injuries and deaths have resulted from application and the user's exposure to danger.
persons becoming caught in power take-off The ultimate responsibility for the safe
(PTO) drive systems. Loose or dangling application and installation is the user's.
clothing and slippery or unsure footing are
SPECIAL PRECAUTIONS FOR HYDRAULIC
factors in many PTO accidents. DO NOT work
DRIVES
on or adjust a pump driven by a PTO drive
system while it is operating or has a chance of Avoid contact with high pressure fluids.
the driver becoming energized except as Check all hydraulic hoses.
specified in the section titled, DIRECTION OF
ROTATION and RELIEF VALVES.
Page 2 – 8
Hydraulic hoses can fail due to physical 2.6 ADDITIONAL
damage, kinks, age, and exposure. Check
hoses regularly. Replace damaged hoses. IMPORTANT WARNINGS AND
INFORMATION
• This manual contains general information
concerning the use, inspection, adjustment,
testing, and safety considerations of the
pump furnished. Other precautions and
safety measures may be appropriate
depending on the particular application and
installation and are the responsibility of the
product installer and user. Installers and
users of this pump must have sufficient
WARNING! AVOID CONTACT with high knowledge and training to apply sound
pressure fluids. safety and operating practices that may not
be mentioned in the manual, and the sale of
this pump is in reliance on such installer and
user knowledge and training.
• ROPER® pumps are general purpose
pumps for a wide range of uses; yet, they
are not designed nor intended for use with
Escaping fluid under pressure can every known substance. Maximum ratings
penetrate the skin causing serious injury. are shown in the section titled, MAXIMUM
Avoid the hazard by relieving pressure PUMP RATINGS. ROPER® sales
before disconnecting hydraulic or other brochures contain standard ratings.
lines. Tighten all connections before Ratings for SPECification number pumps
applying pressure. Search for leaks with a or standard pumps may be obtained by
piece of cardboard. Protect hands and contacting Roper Pump Company or an
body from high pressure fluids. authorized distributor.
If an accident occurs, see a doctor
• Review this manual to determine the
immediately. Any fluid injected into the
proper union of the pump into the total
skin must be surgically removed within a
plant or system operating programs.
few hours or gangrene may result. Doctors
unfamiliar with this type injury should • Roper Pump Company does not supply,
reference a knowledgeable source. recommend, or approve the systems in
which its pumps are or may be used.
Unless designed, built, and used properly,
systems may be unsafe or dangerous.
Installers and users should check and
comply with all applicable federal, state,
An overload or kickdown valve in a local, and other regulations and
hydraulic drive system is NOT a safe recommendations such as: NFPA, UL,
substitute for a pressure relief valve OSHA, API, etc.
correctly installed in the pump piping In particular, installers and users must check
system. the pumped liquid properties and take proper
precautions. Among other things, consider the
following:
• Decide the results of spillage or leakage
(all pumps or systems may fail sometime).
Page 2 – 9
__Explosion • Install a pressure relieving device in the
__Corrosion system discharge piping to protect the
equipment and crew from accident due to
__Chemical Burns too much pressure. NEVER place a
__High Pressure Spray shutoff valve between the pump and
system relief valve. Read Section 2.3,
__Toxic Exposure PREOPERATION CHECKS.
__Fire
• Spillage or overflow, from overfilling or
__Exposure to Extreme Temperatures putting too much pressure on any
__Environmental Impact component of a system incorporating this
pump, may result in an accident. Proper
__System Impact measures and precautions must be taken
__Other to avoid spillage or overflow from
overfilling or putting too much pressure on
• Are proper safeguards being used? any component of the system. This
__Temperature Controls includes the receiver and lines.
__Pressure Controls Prior to starting pump, read sections on

PREPARATION OF FOUNDATION;
__Leak Detectors
ALIGNING DRIVER AND PUMP;
__Shutoff Devices INSTALLATION OF PIPES; THREADED
PORT CONNECTIONS; and
__High or Low Pressure Safeguards
PREOPERATION CHECKS.
__Alarm Devices
__Overfill or Overflow Detection
2.7 INSTALLATION OF PIPES
__Driver Overload Controls
__Consider all possible methods and
• DO NOT connect raised face flanges to
series of failure.
the ports of a cast iron pump.
__Are any other methods needed to
control a hazard? • DO use flat faced flanges with cast iron
pumps.
__Regular scheduled inspection for the
wear and tear of parts. Piping must be installed and checked
carefully. Allow for any expansion or
• Identify all possible hazards. Decide upon contraction.
and install the required controls. Only the
Any external force or moment (torque or twist)
installer and user can fully understand the
applied on the pump ports by the piping will
product and system characteristics. The
cause stresses in the pump and its foundation.
ultimate responsibility for the safety of the
This may cause misalignment that could result
application and the system characteristics
in hot bearings, worn couplings, or excessive
is with the installer and user.
vibration. Such forces or moments may be
• Particularly note the chance of fire and caused by improperly aligned piping or by
burns from flammable or hot liquid spillage thermal expansion of the piping when
from burst hoses and take proper pumping hot or cold fluids. The piping should
precautions. be supported independently. Use flexible
piping connectors and insure that they are
• Properly guard all exposed rotating parts
properly anchored.
of the drive to the pump.
Page 2 – 10
If an expansion joint is installed in the piping 2.8 THREADED PORT
between the pump and the nearest point of
anchor in the piping, a force equal to the area CONNECTIONS
of the expansion joint (which may be
considerably larger than the normal pipe size) American National Standard Taper Pipe
times the pressure in the pipe will be Threads (NPT) are standard for pipe plugs
transmitted directly to the pump. Pipe and threaded ports of the pump ports. British
couplings that DO NOT provide an axially rigid Standard Pipe Threads (BSP) are available on
connection have the same effect. This request for most sizes.
reaction force can be so large that it would be
impractical to design suitable components to To produce a pressure tight joint, a thread
withstand the force. If an expansion joint or sealant must be used. TFE tape is generally
nonrigid coupling is used, install a pipe anchor not recommended where cast iron is used as
between it and the pump. If properly installed, one or more parts of the joint. The use of TFE
this will eliminate the forces mentioned above. tape for installing cast iron fillings may cause
damage to the pump or fittings.
The pump port size does not necessarily
establish the correct pipe size. Piping must be The following is a partial list of sealants that
sized and arranged to provide ample inlet may be used when making up joints on the
pressure at the pump and to insure that the pump:
discharge pressure will be at least as low as
• PST Pipe Sealant No. 567 − Loctite Crop.
the rated pressure of the pump. If the fluid to
be pumped is viscous, or the piping long, or • Rectorseal No. 5 − The Rectorseal Corp.
the suction lift or static discharge head
somewhat high, piping one or two sizes larger • Leak Lock − Highside Chemical, Inc.
may be required. Friction losses should be
carefully calculated (see Hydraulic Institute Follow the sealant manufacturer's instructions
Engineering Data Book or similar authority for when making up a joint.
friction loss data) and compared to the pump
ratings before the installation is made. Where
valves are used in the piping system, gate,
ball, or butterfly valves are preferable to globe
or angle valves. 90° long radius elbows or 45°
elbows are preferable to standard short radius
elbows. NEVER place a valve between the
pump and system relief valve.
Page 2 – 11
2.9 CHECKING PUMP PERFORMANCE
A summary of the causes of common malfunctions.
PROBLEM POSSIBLE CAUSES

Pump rotating in wrong direction.
Pump not primed.
Inlet lift too high. Check this with gauge at pump inlet.
Clogged inlet line.
NO LIQUID DELIVERED
Inlet pipe not submerged.
Air leaks in inlet line.
Faulty pressure relief device in system.
Pump Worn.
Excessive pressure.
Nonlubricating liquid.
Pump runs dry.
RAPID WEAR
Incompatibility of liquid and pump materials.
Pipe strain on pump. See Section 2.7, Installation of Pipes.
Excessive abrasives in liquid.
Starved Pump.
Air or gases in liquid.
EXCESSIVE NOISE Pump speed too high.
Relief valve chatter. Check pressure setting.
Improper mounting. Check alignment thoroughly.
See Section 2.4, Preparation of Foundation
and Section 2.5, Aligning Driver and Pump.
Speed too high.
Liquid more viscous than previously anticipated.
Operating pressure higher than specified. Check this with
gauge at pump discharge.
PUMP TAKES TOO
Discharge line obstructed.
MUCH POWER
Mechanical defect, such as bent shaft.
Pipe strain on pump. See Section 2.7, Installation of Pipes.
Pressure relief device not operating properly.
Air leaks through mechanical seal.
Speed too slow.
Excessive lift at inlet. Check this with gauge at pump inlet.
Viscosity of liquid too high for size and length of inlet pipe.
INSUFFICIENT LIQUID
Foot valve, if used, too small, stuck, or not working properly.
DELIVERED
Foot valve or end of inlet pipe not immersed deeply enough in
liquid.
Excessive clearance in pump caused by wear or corrosion.
Faulty pressure relief device.
Page 2 – 12
2.10 REPLACEMENT PARTS
Repair parts can be ordered from your nearest authorized distributor. For the location of a
distributor near you, contact Roper Pump Company. DO NOT order repair parts by their key
number. Order by ROPER® part number only and include the nameplate data for aid in
identification. Repair parts lists depicting ROPER® part numbers are available for most pumps.
• Roper Pump Company assumes no responsibility for parts other than those supplied by Roper
Pump Company. The use of substitutes may result in poor performance or in an accident
causing physical damage or injury to personnel.
• WARNING! Only use genuine ROPER® gaskets. Gasket thickness determines proper
clearances. Always check quantity of gaskets removed and replace with exact quantity. Proper
material must be used based on application.
SERVICE NOTES
Page 2 – 13
2.11 INDEX
Aligning Shafts
Belts and Sheaves, 2 - 7

Flexible Coupling, 2 - 5 through 2 - 7
Power Take-Off, 2 - 8
Pump and Driver, 2 - 5 through 2 - 8
Foundation, 2 - 4 through 2 - 5
Guarding Power Take-Off Shafts, 2 - 8
Installation of Pipes, 2 - 10 through 2 - 11
Pipe Installation, 2 - 10 through 2 - 11

Pipe Threads - Threaded Port Connections, 2 - 11
Preoperation Checks, 2 - 3 through 2 - 4
Problems and Causes, 2 - 12
Replacement Parts, 2 - 13
Safety Precautions, 2 - 2 through 2 - 3, 2 - 9 through 2 - 10
Threaded Port Connections, 2 - 11
Page 2 – 14
Section 3.0
TABLE OF CONTENTS
Section Page
3.1 Safety Signal Words and Symbols ................................................. 3 - 1
3.2 Recommended Tool List ................................................................. 3 - 1
3.3 Truck Mounting................................................................................ 3 - 1
3.4 Direction of Rotation ....................................................................... 3 - 3
3.5 High Drive to Low Drive .................................................................. 3 - 4
3.6 Instructions for Draining Pump ...................................................... 3 - 5
3.7 Instructions for Pump Disassembly............................................... 3 - 5
3.8 Bearing Removal and Installation .................................................. 3 - 6
3.9 Instructions for Pump Assembly.................................................... 3 - 7
3.10 Pump Sectional Drawing................................................................. 3 - 8
3.11 Parts List .......................................................................................... 3 - 9
3.12 Shaft Sealing .................................................................................. 3 - 11
3.13 Lubrication ..................................................................................... 3 - 11
3.14 Common Maintenance Questions ................................................ 3 - 12
3.15 Index ...............................................................................................3 – 13
Page 3 – i
3.1 SAFETY SIGNAL 3.3 TRUCK MOUNTING
WORDS AND SYMBOLS
The mounting pads for truck mounted pumps
SAFETY SIGNAL WORDS must be rigid and properly aligned with the
driver. When PTO drives are used, always
The safety signal words CAUTION!, check with the manufacturer of the PTO
WARNING!, DANGER!, and TOXIC! Have equipment to determine the alignment
specific meanings in this manual. required for proper operation of the PTO and
the type of guarding that must be used. See
CAUTION! Is used to identify hazards that Section 2.5, ALIGNING DRIVER AND PUMP.
may cause damage to property or equipment.
The GHB, HB, H, BHB, and BH pumps are
WARNING! Is used to identify hazards that designed to be mounted by the feet. These
may cause personal injury. pumps may be mounted with the feet in the
three, nine, or twelve o'clock position as
DANGER! Identifies the most serious hazards. well as the standard six o'clock position.
DANGER! Is used to identify hazards that will
cause personal injury or death.
TOXIC! Identifies hazards that involve

materials that may cause death by contact,
ingestion, or inhalation. TOXIC! Will always be
used with the safety signal word DANGER!
3.2 RECOMMENDED TOOL

LIST
NOTE: Tools not furnished with pump.
Tools for all Pumps:

(1) Safety Glasses
(1) 3/4" Combination Wrench
(1) Pliers
(1) 18" Pipe Wrench
Additional Tools for Pumps with

Flanges:
Page 3 – 1
MOUNTING POSITIONS
Page 3 – 2
3.4 DIRECTION OF ROTATION
DIRECTION OF ROTATION FOR HIGH DRIVE AND LOW DRIVE PUMP CONFIGURATIONS
FIGURE 3.4.1
Page 3 – 3
3.5 HIGH DRIVE TO LOW 5. Switch drive gear and shaft assembly
DRIVE (71) and idler gear/shaft (73) position in
case (1).
Prior to operating pump, make sure that the 6. Position appropriate number of case
shaft rotation and pipe connections are in gaskets (5) on case (1) (oil or grease
accordance with the appropriate illustrations may be used to hold gaskets in place).
(Figure 3.4.1). In order to change the rotation
and/or piping orientation, it may be 7. Rotate backplate (20) assembly 180°.
necessary to remove the piping from the
8. Slide backplate (20) assembly with drive
pump or the pump from the mounting.
gear/shaft (72) assembly into position
(Fittings (3) and flange gaskets (2), when
and secure.
provided, can be removed from pump.)
REVERSE ROTATION, SAME DRIVE
Whenever changing rotation, inspect all parts SHAFT AND CASE ARRANGEMENT
before reassembly. Replace all worn parts
and install new gaskets in appropriate 9. To reverse flow of liquid through pump
numbers as removed. ports, reverse rotation of drive gear and
shaft (72), maintain the original positions
1. Remove coupling or universal joint and of the drive gear/shaft and case (1).
drive key (70) from drive shaft (72). CHANGE PORT AND DRIVE SHAFT
LOCATION, SAME ROTATION
Remove all burrs and sharp edges from
drive shaft and keyway. 10. To change the port to the opposite side
and maintain same pump rotation,
2. To reverse pump rotation and keep
change drive gear and shaft (72) from
piping arrangement the same, drive shaft
high drive to low drive or vice versa.
(72) position must be changed. Follow
steps 3 - 10. 11. Remove ten hex head cap screws (22) and
To reverse pump rotation and leave drive two nuts (85) securing backplate (20) to
shaft (72) in same position; liquid flow case (1) and separate backplate assembly
through pump will be reversed. Follow from case assembly. The drive gear and
steps 11 - 12. shaft (72) will pull out with backplate
assembly.
REVERSE ROTATION, SAME PIPING
ARRANGEMENT 12. Switch drive gear and shaft (72) and idler
gear/shaft (73) positions in case (1).
3. To reverse pump rotation and keep
piping arrangement the same, it is 13. Rotate backplate (20) assembly 180° and
necessary to change from high drive to remount on case (1).
low drive or low drive to high drive.
4. Remove ten hex head cap screws (22)
and two nuts (85) securing backplate (20)
to case (1) and separate backplate
assembly from case assembly. The drive
gear and shaft assembly (71) will pull out
with backplate assembly.
Page 3 – 4
3.6 INSTRUCTIONS FOR 3. Rotate drive shaft very slowly by hand.
Each time that flow from drain increases,
DRAINING PUMP stop turning shaft until flow stops; then
resume until flow increases again. Be
Refer to Section 3.10, PUMP SECTIONAL sure to rotate shaft several complete
DRAWING. revolutions in each direction until all flow
from drain has stopped.
4. Reinstall and tighten pipe plug (8A).
3.7 INSTRUCTIONS FOR

PUMP DISASSEMBLY
• WARNING! Relieve all internal fluid and
air pressure inside the pump before
attempting to drain the pump. Refer to Section 3.10, PUMP SECTIONAL
DRAWING.
• WARNING! Take necessary precautions
to prevent the pump from becoming 1. Read section 2.0 on SAFETY
energized while draining the pump. PRECAUTIONS and ADDITIONAL
IMPORTANT WARNINGS AND
• WARNING! Take necessary precautions INFORMATION before starting to
to prevent injury or physical damage that disassemble pump. While disassembling
could be caused by any loss of the pump, always inspect disassembled
product being pumped while draining the parts and adjacent parts to see if further
pump. disassembly is needed. Replace worn or
damaged parts as required. Read
The extent to which a pump can be drained Section 2.0, REPLACEMENT PARTS.
is dependent upon the product being
pumped. Low viscosity products such as 2. If you do not know which pump
solvents will drain quickly and easily. High arrangement you have, collect nameplate
viscosity products such as molasses and tar data and refer to Section 1.0,
will drain very slowly. Also, the draining of NAMEPLATE DATA, to determine what
high viscosity products will be less complete. you have. Consult a Roper Pump
Company or an authorized distributor if
Regardless of the product pumped, the areas you have any questions.
at the blind end of the bearing bores and the
mechanical seal chamber will not drain. 3. When cleaning or lubricating, use only
cleaning solutions and lubricants that are
FOR PUMPS EQUIPPED WITH DRAIN compatible with products being pumped
PLUGS; and with pump elastomers.
1. Refer to Section 2.0 and read sections on 4. Turn off pump and lock out energy
SAFETY PRECAUTIONS and source to driver. DO NOT proceed further
ADDITIONAL IMPORTANT WARNINGS with disassembly of pump it there is the
AND INFORMATION before starting slightest possibility that driver may be
draining procedure. started.
2. There are two pipe plugs (8A) in the 5. Close inlet and discharge valves.
faceplate (45). Remove one that is in
lowest position. 6. Remove guard and disconnect coupling
between driver and pump.
Page 3 – 5
7. Drain inlet and discharge lines. Dis- 2. Place backplate or faceplate face down
connect lines from pump inlet and on press.
discharge.
3. Using proper size arbor press bearings
8. Follow the procedure in Section 3.6, out.
INSTRUCTIONS FOR DRAINING PUMP.
9. Remove ten hex head cap screws (22) BEARING INSTALLATION

and two nuts (85) securing faceplate (20)
to case (1). 1. Remove all burrs and raised edges from
bores for bearings.
10. By screwing two long 3/8 - 16 thread bolts
in jack holes, remove faceplate (45). 2. Place faceplate or backplate on a press
base with milled face upward. Support
11. Remove case gaskets (5). endplate so that milled face is
perpendicular (square) with press ram.
12. Remove idler gear/shaft (73).
3. Position endplate so that one bearing
13. Remove packing nut (87) from end of
bore is located directly under press ram.
backplate (20).
14. Remove drive gear/shaft (72). 4. Lubricate endplate bores with a light oil
that is compatible with product to be
15. Remove ten hex head cap screws (22) pumped.
and two nuts (85) securing backplate (20)
to case (1). 5. Place end of new bearing at entrance of
bore in endplate, taking care to align
16. By screwing two long 3/8 - 16 thread grooves in bearing with the grooves in
bolts in jack holes, remove backplate(20). face of endplate.
17. Remove case gaskets (5) from opposite 6. Press bearing into endplate bore. It is
side of case (1). best to use a stepped arbor with a few
thousandths of an inch clearance
18. Remove four dowel pins (4) from case
between arbor and bore of bearing. Be
(1), backplate (20), and faceplate (45).
sure to press bearings in until they are
19. Visually inspect all parts. Replace all flush to .005 of an inch [.127 mm] below
worn or damaged parts before milled face of endplate.
reassembling pump. It is recommended
that new gaskets (2, 5, if applicable) be 7. Repeat procedure for second bearing.
installed each time pump is
disassembled and reassembled. 8. Using a three square file, file shallow
grooves in ends of bearings to connect
grooves inside bearings with groove on
3.8 BEARING REMOVAL milled face of endplate. If your bearings
AND INSTALLATION or endplates DO NOT have grooves, omit
this step.
BEARING REMOVAL
1. Remove NPT plugs (8B) from ends of

bearing areas in faceplate (45) and
backplate (20).
Page 3 – 6
3.9 INSTRUCTIONS FOR 4. Place drive gear/shaft (72) and idler
gear/shaft (73) into case bore.
PUMP ASSEMBLY
5. Place appropriate number of case
Refer to Section 3.10, PUMP SECTIONAL gaskets (5) on backplate side of case.
DRAWING. Slide backplate over shafts and up to
case. Drive in two dowels (4). Secure
Refer to Section 3.4, DIRECTION OF backplate to case with ten hex head cap
ROTATION, to assure proper configuration screws and two nuts.
for pump rotation, port location, and relief
valve position prior to assembling pump. 6. Install three packing rings (91) in packing
nut (87) bore. Stagger joints on each
1. Refer to Section 2.0 and read instructions packing ring 180° apart. Rings must not
on REPLACEMENT PARTS, be tamped or seated.
THREADED PORT CONNECTIONS,
SHAFT SEALING, and SAFETY 7. Slide packing nut (87) with rings over end
PRECAUTIONS before assembling of drive shaft.
pump. Visually inspect all parts during
assembly. Replace all worn or damaged 8. Screw packing nut (87) on backplate (20)
parts. Although they may appear finger tight. Tighten 1/2 to 3/4 of one
reusable, it is recommended that new round then loosen to finger tight.
gaskets (5) and packing rings (91) be
installed when pump is being 9. Screw hex head cap screw (10) into
reassembled. backplate adjacent to packing nut (87).
• WARNING! Only use genuine 10. Attach lockwire (9) to packing nut and
ROPER® gaskets. Gasket thickness hex head cap screw (10). Be sure to
determines proper clearances. wrap lockwire in a clockwise direction
Always check quantity of gaskets facing drive shaft end.
removed and replace with exact
quantity. Proper material must be
used based on application.
2. When cleaning or lubricating, only use

products that are compatible with product
being pumped and elastomers within
pump. Clean and lubricate parts with
bearing grease.
3. Place appropriate number of case

gaskets (5) on faceplate side of case.
Align faceplate on two finger tight hex
head cap screws (22) at top and bottom
of faceplate. Drive in two dowels (4).
Secure faceplate to case with ten hex
head cap screws (22) and two nuts (85).
Page 3 – 7
3.10 PUMP SECTIONAL DRAWING
FIGURE 3.10.1
Page 3 – 8
3.11 PARTS LIST
1. Case Assembly 21. Stud
2. Flange Gasket 22. Hex Head Cap Screw
3. Flange 25. Lube Fitting
4. Dowel Pin 45. Faceplate Assembly
5. Case Gasket 70. Drive Key
6. Hex Head Cap Screw 72. Drive Gear, Shaft, & Key
8A. Pipe Plug (small) 73. Idler Gear & Shaft
8B. Pipe Plug (large) 85. Nut
9. Lockwire 87. Packing Nut
10. Hex Head Cap Screw 91. Packing Rings
20. Backplate Assembly
Page 3 – 9
3.12 SHAFT SEALING Note: The wire should be wrapped in a
clockwise direction from the packing nut to
STANDARD COMPRESSION PACKING the hex head cap screw.
After the pump is started, note the stuffing
One type of shaft sealing used in these box. If the packing leakage exceeds ten
pumps is formed ring packing with or drops per minute, stop the pump and adjust
without a lantern ring. When using a packed the gland nut. The gland nut should be
box pump, use formed packing rings. DO adjusted evenly in 1/6 to 1/3 turn (1 to 2
NOT use a one piece spiral wrap of flats on the nut) increments. Start the pump
packing. Packing rings are available in a and allow it to operate for several minutes.
wide selection of materials for various Again, visually examine the stuffing box for
applications and temperatures. Previous excessive leakage. Repeat the above
experience with the pumped fluid is the best procedure until the stuffing box leakage is
guide in selecting the proper packing ring between five to ten drops per minute.
material for your particular application.
DO NOT over-tighten the packing. Slight
CARE OF PACKING leakage is a necessary requirement for
proper packing operation. Leakage of five to
ten drops per minute when the pump is
operating is desirable, as it will preserve the
packing and avoid scoring of the shaft.
Over-tight packing may score shafts,
increase torque requirements of the pump,
damage couplings and drivers, and
DO NOT work on or adjust packing while
generate excessive heat.
the pump is running.
The pump should be stopped and the
If truck mounted, disengage the PTO or
packing gland adjusted whenever leakage
hydraulic drive and shut off the engine.
exceeds ten drops per minute. The
If motor driven, TURN OFF motor and condition of the packing should be checked
lock out the energy source. at regular intervals, the frequency
depending on the type of service.
CLOSE VALVES on the inlet and
Experience will dictate how frequently the
discharge while working on the pump.
inspections should be made.
It is generally not recommended to reuse old
packing rings. When installing packing, use 3.13 LUBRICATION
formed packing rings. DO NOT use a one
piece spiral wrap of packing. Before installing Pumps are fitted with lube fittings to all four
packing, carefully clean the stuffing box and bearings. Lubricate the bearing on a regular
shaft. basis with any good quality bearing grease
Packing rings should be installed one ring at that is compatible with the product being
a time, with the joints of adjacent rings pumped.
staggered approximately 180°.
The packing gland nut should be tightened
with a wrench to seat the packing firmly in
the stuffing box and against the shaft. DO
NOT over-tighten the packing. The gland
nut should then be backed off until finger-
tight. Connect the lock wire from the
packing nut to the hex head cap screw
adjacent to the packing nut and twist ends
together.
Page 3 – 10
3.14 COMMON If the pump is used exclusively in an
abrasive application or high viscosity
MAINTENANCE QUESTIONS application, you may be able to extend the
life of the gears or case. If a case with
Question: straight through ports is worn on the inlet
At what point do I need to overhaul my side only, the case can be turned around
pump? and used again.
Answer: Question:
As with all rotating equipment, your pump What do I look for to determine excessive
will eventually wear to a point where the wear?
pump's performance is diminished. The
pump's performance is dependent upon the • Gears
application. For instance, a very worn pump The gears are serviceable if there is no
may work at an acceptable level in an degradation of the teeth or end faces.
application involving a high viscosity (thick) Check for uniform wear. There should be no
liquid when combined with low discharge burrs or gouges on any of the gear's
pressure. This same pump would most surfaces.
likely be unsatisfactory in a low viscosity, • Endplates
high pressure application. The best answer Excessive wear is usually the result of
to the above question is the following: You pumping products containing abrasives. If
need to overhaul your pump when you feel the endplates are damaged in the area that
that the performance has dropped to an the ends of gears rub, they should be
unacceptable level for your application. replaced. If a bearing has turned or spun in
If you have set up your own test procedure the bore, the endplate must be replaced.
to check your used pumps, it will be helpful
• Cases
to test at least one new pump of each size
Excessive case wear is usually the result of
to use as a benchmark for setting your own
worn bearings or shafts allowing gears to
acceptance levels.
contact the case bores. Minor rubbing of the
Question: case bore is normal.
What parts will I need to replace to get my
• Bearings
pump back to “like-new” condition?
If bearings appear worn, the bearings
Answer: should be replaced. See Section 3.8 for
As a general rule, replace all gaskets and proper bearing removal and installation.
packing seals at each servicing regardless
of their apparent condition. These parts are • Shafts
Replace the shaft if it is scored in the
usually less expensive than the labor costs
packing, seal, or bearing area.
and downtime incurred if the pump has to
be serviced a second time to stop a leak. • Packing
The parts subject to wear should be Replace packing if it cannot be properly
examined for obvious wear and corrosion. adjusted to control leakage as described in
This includes bearings, shafts, gears, Section 3.12, SHAFT SEALING. It is normal
cases, and endplates. Measurements and necessary for packing to drip slightly.
should be made and compared to the Never rebuild a pump with used packing.
dimensions shown in Section 3.9. Replace
any parts that are worn beyond the limit
shown.
Page 3 – 11
Question: Question:
Do I need special tools to disassemble and At what point should I buy a new pump?
reassemble my pump?
Answer:
Answer: A new pump should be purchased when the
The only special tools required are for old pump cannot be economically repaired.
removal and installation of the bearings. A
list of all tools required can be found in Question:
Section 3.2, TOOL LIST. Are there service centers where I can get
my pump repaired?
Question:
Is it okay to reface worn endplates? Answer:
Most Roper Pump Company distributors are
Answer: able to repair pumps. Consult the factory to
No. Roper Pump Company does not find your nearest distributor. Also, Roper
recommend this procedure. Refacing Pump Company has a repair department.
reduces the face flange thickness and Any pump repaired at the factory is rebuilt to
increases the possibility of interference like-new condition and carries a new pump
between the internal parts. warranty. Pumps may be returned to the
Question: factory by an authorized ROPER® pump
How long can my 5600 Series pump run distributor.
dry?
Answer:
One minute is a practical maximum for
running a pump dry. Anything longer could
cause the pump to overheat resulting in
possible pump damage or failure.
Page 3 – 12
3.15 INDEX
A M
Assembly Instructions Maintenance Questions, 3 - 12 through 3 - 13
All, 3 - 6 through 3 - 7 P
B Packing, 3 - 10
Bearing R
Removal, 3 - 6 Rotation
Installation, 3 - 6
Direction of Rotation, 3 - 3
D Reversing, 3 - 3, 3 - 4
Disassembly Instructions T
All, 3 - 5 through 3 - 6 Tools, 3 - 1
Draining Pump, 3 - 5 Truck Mounting, 3 - 1, 3 - 2
L
Lubrication, 3 - 11
Page 3 – 13
TERMS & CONDITIONS AND LIMITED WARRANTY
This agreement (this “Agreement”), consisting of these Terms and Conditions, and the associated Order Acknowledgement is binding upon Roper Pump
Company, hereinafter “SELLER,” and the customer, hereinafter “BUYER.” By placing an order for a product with the Seller, the Buyer agrees to these
Terms and Conditions of sale and acknowledges that the person placing the order has the authority to enter into the Order Acknowledgement on Buyer’s
behalf.
LEGAL EFFECT: Except as expressly otherwise agreed to in writing by an PAYMENTS: Standard terms for customers who qualify for credit net 30. A
authorized representative of Seller, the following terms and conditions shall monthly service charge of 1.5% may be charged on amounts owed by
apply to and form a part of any Order Acknowledgement. Seller may Buyer to Seller that have not been paid within by the due date, subject to
suspend its performance of any Order Acknowledgement if Buyer defaults the maximum amount permitted by law.
in the performance of its duties under the Order Acknowledgement or
under any other agreement between the Buyer and Seller. TAXES: Buyer assumes exclusive liability for any and all taxes, tariffs,
fees, duties, withholdings or like charges, whether domestic or foreign, now
ACCEPTANCE: The sale of goods and services is expressly conditional imposed or hereafter becoming effective (“Taxes”) related to the goods and
on Buyer’s acceptance of Seller’s terms and conditions as stated herein. its purchases from Seller, including without limitation, federal, provincial,
Provided that Seller’s terms and conditions have not been previously state and local taxes, value-added taxes, goods and services taxes, stamp,
accepted by Buyer, Buyer’s receipt of goods or services shipped under this documentary, excise or property taxes, duties and other governmental
Agreement constitutes acceptance of these terms and conditions. No charges.
additional, different or conflicting provisions proposed by Buyer are
acceptable to Seller and are hereby specifically rejected, Seller being TITLE AND LIEN RIGHTS: The equipment will remain personal property,
unwilling to sell goods on any terms conflicting with, limiting or modifying regardless of how it is installed or affixed to any realty or structure. After
the terms hereof. Buyer shall not sell, transfer or otherwise provide any delivery to Buyer, Seller will have all such rights, including security
goods to another for resale without the prior, written authorization of Seller.
interests and liens, in the equipment as lawfully may be conferred upon
Seller reserves the right to sell and to authorize other entities to sell such
Seller by contract under any applicable provision of law. Buyer agrees to
goods through all means and channels of distribution and in competition cooperate fully with Seller in the filing of any financing statements,
with Buyer. Buyer acknowledges that it has no authority to bind or contract including Uniform Commercial Code (UCC) filings or other documents
in the name or for the account of Seller, to create any liability against Seller
necessary to perfect such interests and liens. If Buyer defaults in its
or to exert any direction or control over Seller’s personnel. obligations under the Order Acknowledgement before the price (including
any notes given therefore) of the equipment has been fully paid in cash,
CHANGES: This Agreement and the associated Order Acknowledgement Seller may take any and all actions permitted by law to protect its interests
constitutes the entire agreement between Seller and Buyer with respect to including, where permissible, repossession of such equipment.
the subject matter thereof, and supersedes all prior oral or written
agreements. This Agreement and the associated Order Acknowledgement SHIPMENTS: All sales are Ex-Works Factory (as such term is defined by
may not be amended or modified, except by a further written agreement the International Chamber of Commerce as of the date hereof). Shipping
signed by an authorized representative of Seller. Seller reserves the right contracts made by Seller shall be to Buyer’s account. All claims for loss or
to make reasonable changes to an Order Acknowledgement, including damage after risk of loss has passed to Buyer shall be filed by Buyer with
changes as to packaging, testing, specifications, designs and delivery the carrier. Buyer shall be liable to Seller for the full price of the goods,
schedules. The terms and conditions of any purchase order or other irrespective of loss or damage in transit. Seller shall not be required to
instrument issued by Buyer or its agent in connection with this Agreement provide freight cost receipts to Buyer at the time of invoice. Buyer shall
and the associated Order Acknowledgement or any goods sold thereunder bear all risk and expense for delivery of goods, including without limitation,
that is in addition to or inconsistent with the terms and conditions of this shipping, loading, unloading, storage, freight, and insurance. Goods may
Agreement or the associated Order Acknowledgement are null and void be shipped to Buyer in whole or in part. Title to goods shall pass to Buyer
and shall not be binding on Seller. Buyer’s changes made after formation when delivered to the carrier or the Buyer, whichever occurs first, even if
of this Agreement that affect the schedule or requirements for services or the goods are shipped freight prepaid. Among other things, a signed
otherwise affect the scope of this Agreement shall be submitted in writing delivery receipt or bill of lading will constitute proof of delivery. The choice
by Buyer and shall become binding only if approved in writing by Seller’s of carrier is made solely at the discretion of Seller, and Seller makes no
cognizant representative. All charges and delays resulting from such representation as to the acceptability of a particular carrier. Except when
changes shall be solely determined by Seller and shall be binding upon Seller expressly agrees in writing, Seller does not guarantee shipment or
Buyer. delivery by a certain date or time, although Seller will strive to deliver
goods by the date that it may communicate to Buyer. Seller shall not be
TERMINATION, SUSPENSION, AND CANCELED ORDERS: Provided liable to Buyer, or any other person, for any loss or damage of any kind
that Seller receives adequate written notice from Buyer, Buyer may which results from delay in shipment, delivery, or failure to give notice of
terminate or suspend performance at Buyer’s convenience subject to all delay, whether or not such delay was caused by Seller or otherwise. Seller
reasonable charges, which charges shall be solely determined by Seller. reserves the right to backorder any goods and to ship from backorder in
Buyer cannot cancel or alter Orders without the Seller’s written consent. If such order as Seller determines.
Seller grants such consent, Buyer will reimburse Seller for all of Seller’s
losses and expense caused by such cancellation or alteration, including LIMITED WARRANTY: Seller warrants, to its original Buyer, that goods
without limitation all of Sellers additional costs caused by changes in manufactured by Seller are free from defects in material and workmanship
design or specifications, or by product revisions, and all incidental and for 12 months from date of shipment (except for specified products with
consequential damages incurred by Seller as a result of such cancellation warranties that supercede this limited warranty. Please consult factory for
or alteration. No goods may be returned to Seller except with Seller’s these products). The Buyer hereby acknowledges and agrees, though free
written consent. Title in a returned good will pass when Seller takes from defects in material and workmanship at the time of shipment, that the
possession of the returned goods. useful life of goods manufactured by Seller will vary depending upon the
Buyer’s frequency of use, application, and other factors, with regard to
CREDIT: The amount of credit offered by Seller to Buyer is contingent such goods. In that respect, notwithstanding any other provision to the
upon Seller’s opinion of Buyer’s capacity, ability, and willingness to contrary in the Agreement, these Terms and Conditions, or the Order
promptly pay for goods and services received under the terms of this Acknowledgement, the Seller specifically does not warrant the useful life of
Agreement. Provided that, in Seller’s opinion, there is a material adverse any product. If a failure to conform to specifications or a defect in materials
change in Buyer’s financial condition and/or Buyer has not, within the or workmanship is discovered within this period, Seller must promptly be
agreed time, fully paid for goods and services previously supplied under notified in writing within thirty (30) days, which notification, in any event
this and/or another Agreement(s) with Seller, Seller reserves the right to must be received no later than 12 months from the date of shipment.
revoke Buyer’s credit and/or suspend performance on this and/or other Within a reasonable time after such notification, Seller will correct any
orders for goods and services. failure to conform to specifications or any defect in materials or
workmanship, or in lieu of such repair, and at its sole option, shall replace
the equipment. THE ABOVE ARE THE BUYER’S EXCLUSIVE CONFIDENTIAL INFORMATION: During the term of this Agreement and
REMEDIES FOR BREACH OF WARRANTY. Seller does not warrant: (a) the associated Order Acknowledgement and for the longer of (a) three (3)
defects caused by failure to provide suitable installation environment for years following its termination and (b) for such Confidential Information of
the product, (b) damage caused by use of the product for purposes other Seller that is a Trade Secret of Seller as defined by applicable law, for the
than those for which it was purchased, (c) damage caused by disasters life of such Seller Trade Secret, Buyer agrees to receive and hold
such as fire, flood, wind, and lightning, (d) damage caused by unauthorized Confidential Information of Seller in trust and in strictest confidence and
attachments, or modification, (e) any other abuse or misuse by the Buyer, shall not use, reproduce, distribute, disclose or otherwise disseminate any
including improper installation; or (f) goods which have been damaged or Confidential Information except as necessary to perform its obligations
altered by Buyer or its customers. hereunder. Disclosures of the Confidential Information may be made only
to Buyer’s employees and agents who have a specific need to know and
Each good sold by Seller to Buyer shall be deemed to be without defect are subject to confidentiality restrictions at least as restrictive as those
and in conformity with its specifications and the terms of this Agreement contained herein. “Confidential Information” means confidential information
and the associated Order Acknowledgement even though reasonable relating to the business, products and services of Seller which is or has
variances may exist. As a result, Seller cannot and does not guarantee been disclosed to Buyer, and which has value to Seller and is not generally
that goods sold hereunder, whether in whole or in part, will exactly match in known to Seller’s competitors, including (without limitation), information
specification or otherwise, and Buyer acknowledges that reasonable regarding the specifications provided to Buyer by Seller and Seller’s
variance is permissible. Additionally, Seller shall have no liability if a good product plans, designs, costs, prices, finances, marketing plans, business
does not conform to any applicable state, county or local ordinance, as the opportunities, personnel, R&D activities and know-how.
conformity of a good to each state, county and local ordinance is the sole
responsibility of the Buyer. Seller reserves the right to change its goods CONTROLLING LAW: This Agreement and the associated Order
and the components of its goods without prior notice to Buyer, although in Acknowledgement entered into hereunder shall be governed and
circumstances where an order from Buyer has been accepted by Seller, construed in accordance with the laws of the State of Georgia and of the
Seller will use commercially reasonable efforts to ensure that such change United States of America without reference to any conflicts of law
will not affect performance of the good in a materially adverse manner. principles; the parties submit themselves to the jurisdiction of the federal
and state courts located in Jackson County, Georgia, which shall have
EXCEPT AS SET FORTH ABOVE AND TO THE MAXIMUM EXTENT exclusive jurisdiction of any disputes arising hereunder, and the parties
PERMITTED BY LAW, SELLER MAKES NO OTHER WARRANTIES waive any objection to venue therein. The United Nations Convention on
FOR A PRODUCT OR UNDER THIS AGREEMENT OR ANY ORDER Contracts for the International Sale of Goods, the Uniform Law on the
ACKNOWLEDGEMENT AND HEREBY DISCLAIMS ALL OTHER Formation of Contracts for the International Sale of Goods, and any
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED applicable international discovery and service of process conventions shall
TO THE WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE OR not be applicable. In the event legal action is undertaken by Seller to
USE, AND INCLUDING THE WARRANTY OF MERCHANTABILITY. IN collect any amounts due to Seller by Buyer hereunder and if Seller prevails
NO CASE SHALL SELLER BE LIABLE FOR ANY SPECIAL, in such action, then Buyer shall reimburse Seller for its reasonable attorney
INCIDENTAL, OR CONSEQUENTIAL DAMAGES BASED UPON ANY fees and costs incurred in conjunction with such action, which amount shall
LEGAL THEORY, INCLUDING BUT NOT LIMITED TO LOSS OF not exceed the maximum amount allowed by law of the forum in which
PROFITS, LOSS OF SAVINGS OR REVENUE, LOSS OF USE OF THE such action is brought.
PRODUCT OR ANY ASSOCIATED EQUIPMENT, COST OF CAPITAL,
COST OF ANY SUBSTITUTE EQUIPMENT, FACILITIES OR SERVICES, ASSIGNMENT: Neither this Agreement nor any associated Order
DOWNTIME, THE CLAIMS OF THIRD PARTIES INCLUDING Acknowledgement may be assigned by the Buyer, or its contents
CUSTOMERS, INJURY TO PROPERTY AND, UNLESS PRECLUDED publicized by the Buyer, without the written consent of Seller. Seller shall
UNDER APPLICABLE STATE LAW, BODILY AND PERSONAL INJURY. have the right to assign, transfer or sublicense all or any part of this
Agreement or any associated Order Acknowledgement to another at any
INDEMNITY; LIABILITY LIMITATION: Buyer hereby agrees to indemnify, time and without the consent of Buyer.
reimburse in full, defend and hold harmless Seller, its subsidiaries,
affiliates, officers, directors, personnel and agents from and against any MISCELLANEOUS: The various provisions of this Agreement and any
and all liability, claims, suits, actions, losses, costs or expenses including associated Order Acknowledgement are severable, and any determination
(without limitation) reasonable attorneys’ fees relating to or arising out of of invalidity or unenforceability of any one provision hereof shall no bearing
any claim or demand (a) for any Taxes or related penalties and interest, (b) on the continuing force and effect of the remaining provisions hereof. This
due to Buyer’s breach of the Order Acknowledgement; (c) that Buyer’s Agreement and any associated Order Acknowledgement and the terms
customers or a third party may make against Seller based upon or arising and conditions contained herein constitute the entire understanding of the
from damage due to the acts and/or omissions of Buyer or due to the parties with respect to the purchase and sale of the goods, and any prior
installation of the goods; (d) for infringement or misappropriation of a third agreements, with respect thereto, whether written or oral, are superseded
party’s intellectual property rights based upon Seller’s incorporation of any hereby. This Agreement and any associated Order Acknowledgement
designs, formulas or specifications in any goods where such designs, shall be binding on the parties and their respective successors and any
formulas or specifications have been specifically ordered or requested by permitted assigns.
Buyer. To the maximum extent allowable under applicable law and
excluding those liabilities that by law Seller cannot limit or disclaim, (i) ELECTRONIC DATA INTERCHANGE: The parties may execute a Order
Seller’s aggregate liability arising from or relating to this Order Acknowledgement by transmitting and receiving the data contained in the
Acknowledgement or goods, regardless of the cause of action asserted, is Order Acknowledgement electronically rather than in paper form. To
limited to the amount paid by Buyer to Seller for the applicable goods and provide the legal validity and enforceability of such Order
(ii) Seller shall not be liable for any special, incidental, consequential, Acknowledgement, the parties further agree that the data transmitted
indirect, or punitive damages, including without limitation, lost revenues, herein will be considered “in writing” and to have been “signed.” The
loss of use of the goods, loss resulting from improper storage, processing, parties agree not to contest the validity or enforceability of a Order
padding/cushion, delay in delivery or shipment or errors in shipment or Acknowledgement because of the electronic origination, transmission,
labeling, loss of data, or the cost of any substitute goods or related storage or handling of such Order Acknowledgement. Any computer
equipment, even if Seller has been advised of the possibility of such printout of the data contained in the Order Acknowledgement will be
damages. considered an “original” when maintained in the ordinary course of
business and will be admissible as between the parties to the same extent
EXPORT RESTRICTIONS: Buyer shall not export or re-export goods in and under the same conditions as other business records maintained in
violation of any applicable laws or regulations of the United States or the documentary form. The parties agree to properly use those security
country in which Buyer obtained them. procedures which are reasonably sufficient to ensure that a transmission of
the data contained in a Order Acknowledgement is authorized and to
protect its business records and data from improper sources.
Additional copies of the installation and operation manual may be obtained by contacting a Roper
Pump Company distributor or:
Roper Pump Company

PO Box 269
Commerce, Georgia 30529 USA
Telephone: (706) 335-5551

TeleFAX: (706) 335-5490
Your Roper Pump Company distributor is:
PART NO. G12-405

ITEM PART NUMBER DESCRIPTION SHIFTER FRONT/
NO. QTY.
54 NM 502.1.1 SHIFTER ROD 1 57
55 NM 502.2.1 SHIFTER HOUSING 1 53 NM 502 SHIFTER ASSEMBLY 1
60
56 NM 502.3 PISTON MOUNT 1 52 76-66-19 SHIFTING FORK 1
57 NM 502.4 PISTON COVER 1 51 70465-6 SHIFTING RING 1
61
58 NM 502.5 PISTON 1 50 1-1/4"-18 TPI SHAFT NUT 1
59 NM 502.6.1 CYLINDER 1 61 49 1-1/4" FLAT WASHER 1
60 2-224 O-RING 2 48 1-3/4 FLAT WASHER 2
61 4180840601625 U PACKING 2 58 47 1227-D-940-S SHAFT NUT 2
62 5/8"-11NC-1.5 SET SCREW 1 59 46 1/4"-20NCx1 HEX BOLT 20
63 5/8"-11NC 5/8-NC JAM NUT 1 45 3/8"-16 NCx1.75 SOCKET HEAD CAP SCREW 12
64 1/2" X 1.5" SPRING 1 60 44 3/8" LOCK WASHER 12
65 1/2" BEARING BALL 1 43 1/2"-13NCx1.75 SOCKET HEAD CAP SCREW 12
42 1/2" LOCK WASHER 12
56 41 1/4" LOCK WASHER 26
11 20 29 36 4 24 6 40 1/4"-20NCx1.25 SOCKET HEAD CAP SCREW 6
46 41
44 54 39 5/16" - 18 NC x 1.5 HEX BOLT 4
38 5/16"-18NCx5 HEX BOLT 4
45
37 5/16"-18 NC-D-N HEX NUT 4
36 STD COVER TOP COVER 1
55 35 SQUARE KEY 5/8 SQUARE KEY 5/8" 1
34 417349 SEAL 1
34
29 33 415146 SEAL 2
63 32 5100-156 RETAINING RING-EXTERNAL 1
31 N5000-500 RETAINING RING-INTERNAL 2
21
30 5100-237 RETAINING RING -EXTERNAL 1
49
29 N5000-433 RETAINING RING-INTERNAL 2
50 62 28 N5000-354 RETAINIGN RING-INTERNAL 1
30
27 330281 THRUST RING 1
10 64 26 NB-F004 BEARING 1
25 NB-J004 BEARING 1
65 24 BEARING BEARING 1
18 44
23 NB-F006 BEARING 1
45 22 NB-F004 BEARING 1
21 NB-F003 BEARING 1
52 22 12 19 NB-FOO4 BEARING 1
14
18 6-1-1731 COMPANION FLANGE 1
17 6.5-1-741 COMPANION FLANGE 2
19 NM 508
26 16 SPACER 1
15 NM 505 SPACER 1
14 NM 504 SPACER 1
33 13 NM 503 SPACER 1
47 12 NM 501 SPACER 1
25
11 NM 406 SEAL CARRIER 1
48
10 NH 405 END CAP 1
2
9 NH 403 SEAL CARRIER 1
5 8 NH 402 BEARING HOUSING 1
47
7 NH 401 BEARING HOUSING 1
48 6 NS 203 SECONDARY OUTPUT SHAFT 1
17
5 NS 201 LOWER OUTPUT SHAFT 1
17 4 NG 101 OUTPUT GEAR 1
3 NG 102 INPUT GEAR 1
2 NS 202 INPUT SHAFT 1
7 42 43 13 8 43 42 9 40 41 1 NC 301 GEAR CASE 1
ITEM PART NUMBER DESCRIPTION QTY.
NO.
31 32
NAMCO www.namco.ca
Machine & Gear Works LTD.
9168-35 AVE.Edmonton, Ab.Canada PH: 780-463-5602
27 24 3 28 23 1 DATE NAME TITLE:
PROPRIETARY AND DRAWN JAN/28/05 M.M
M85
CONFIDENTIAL
This document is the property CHECKED M.N. CUSTOMER: NAMCO DWG. NO. REV.
of NAMCO MACHINE & GEAR
WORKS Ltd. FILE NO. M85-RR-450 M85
Do not reproduce,copy or ENG. APPR
disclose except with the prior DRAWING SIZE: 11" X 8.5" SHEET OF
written consent of NAMCO. MFG. APPR
21 22 12 1 25 26 6 9 21 27 13 15 2 17 16 6 18
4 11 10 21 22 5 7 27 21 8 16 3 24 23
SECTION A-A 28 1" NPT 1" NPT DRAIN PLUG WITH 1

MAGNET
27 3/8"-16NCx1.75 HEX BOLT 12
26 1/2"-13NCx1.75 HEX BOLT 8
24 7/16"-14NCx1.25 HEX BOLT 8
22 3/8"-16NCx0.75 HEX BOLT 57
20 NAMCO PLATE NAMCO LOGO 3
19 CH960808 GASKET 3
18 CH960330 GASKET 1
17 415146 SEAL "NATIONAL OIL SEAL" 1
15 SQUARE KEY SQUARE KEY 3/4 2
14 NM 537 SPACER 1
13 NM 536 COMPANION FLANGE 1
12 NM 535 PUMP ADAPTOR 1
11 NM 534 TAPER LOCK BUSHING 1
19
21 10 NH 441 COVER 1
22 9 NH 440 COVER 1
20 8 NH 439 COVER 1
5 1 IN PITCH -114 LINKS TRIPLE CHAIN 1
4 NG 120 OUTPUT SPROCKET 1
3 NG 119 INPUT SPROCKET 1
2 NS 223 SHAFT 1
1 NC 308 CASE 1
ITEM NO. PART NUMBER DESCRIPTION QTY.

NAMCO www.namco.ca
Machine & Gear Works LTD.

9168-35 AVE.Edmonton, Ab.Canada PH: 780-463-5602
DATE NAME TITLE:
PROPRIETARY AND CONFIDENTIAL DRAWN JAN/25/05 M.M CHAIN DRIVE
CUSTOMER:
This document is the property
of NAMCO MACHINE & GEAR
CHECKED M.N. NAMCO DWG. NO. REV.
WORKS Ltd. CC-400

Do not reproduce,copy or
ENG. APPR FILE NO. CC-400 A
disclose except with the prior DRAWING SIZE:
written consent of NAMCO. MFG. APPR SHEET OF
11" X 8.5"
Flow Control Division
Vogt Valves
Forged Check Valves
Class 1500 (PN 260)
Conventional Port
3705 PSI @ 100°F (255.5 BAR @ 38°C)
For other ratings see pgs. 112-115 ■ Round Bolted Bonnet
■ Spiral Wound Gasket
A105 Body/Bonnet ■ Horizontal Type
SERIES NUMBER ■ Piston Check
CLASS 1500 (PN 260)
■ Integral Hard Faced Seat

15593 Trim: 13% Cr. ■ ASME B16.34
Seat: HF
CHECK
15593FHF Trim: 13% Cr.

15593
Disc/Seat: HF
Flanged Ends: 1/4" R.F.

Bold face numerals are in inches and pounds.
Dimensions Blue numerals are in millimeters and kilograms.
Size NPS 1/2 3/4 1 1-1/2 2

DN 15 20 25 40 50
A-End-to-End 8.50 9.00 10.00 12.00 14.50
216 229 254 305 368
B 3.06 3.06 4.41 5.03 6.12
78 78 112 128 155
C 4.75 5.12 5.88 7.00 8.50
114 130 149 178 216
D-Seat Diameter .50 .50 .75 1.12 1.38
12.7 12.7 19.1 28.4 35.1
Weight 17.0 21.0 36.0 37.5 81.4
7.7 9.5 16.3 17.0 37.0
Valve flanges conform to ASME Standard B16.5 and end-to-end For Cv factors see page 123, Valve Matrix NN.
dimensions conform to ASME Standard B16.10.
Refer to pages 116-120 for full materials description.
105
A LGUNOS D E N UESTROS P RODUCTOS INDOIL
INFORMACIÓN TÉCNICA CERTIFICACIONES DE MATERIALES Y ENSAYOS
Descripción del producto: Válvula Tapón Balanceado

Válvula Tapón Balanceado Modelo: SR 5M
Serie Nro: _ _ _ _
Modelos: SR-5M ; SR-10M; SR- Tamaño: 2”
15M Conexiones: Roscadas 2” API LP
2” a 3” Máxima Presión de Trabajo: 5000 PSI
Tipo de Servicio: STD. Acido
Temperatura: -29º C a 80º C
Materiales Utilizados
Cuerpo: Acero al carbono Forjado
Tapón: Acero al carbono, con recubrimiento superficial
duro.
Segmentos Asiento: Acero al Carbono microfundido
con
tratamiento de endurecimiento superficial y
antioxidante.
Pruebas Realizadas
Ensayo Hidrostático de Cuerpo:
Presión de prueba: 10000 PSI
Ensayo Hidrostático de cierre:
Lado A Presión de prueba: 5000 PSI
Lado B Presión de prueba: 5000 PSI
MANTENIMIENTO RUTINARIO RECOMENDADO

1. Engrasar las válvulas después de cada uso con
grasa aprobada por Indoil para válvulas tapón:
- Entre 0º C y 120º C utilice grasa y lubricante Indoil
para válvulas tapón, Nro. 5
- Entre –29º C y 10º C utilice grasa y lubricante Indoil
VÁLVULAS Y EQUIPOS para válvulas tapón, Nro. 6
NOTA: Se podrá utilizar cualquier otra grasa
PARA LA INDUSTRIA DEL compatible, de reconocida calidad.
GAS Y EL PETROLEO a. Engrasar las válvulas en posición abierta hasta
que la grasa pueda ser vista a través del agujero
de pasaje.
b. Ciclar la válvula, abriéndola y cerrándola e
inyectar mas grasa manteniéndola en posición
abierta.
c. Si la válvula se halla instalada, inyectar una
moderada cantidad de grasa hasta llegar a la
presión máxima de engrase, luego ciclar la
válvula y reengrasar.
NOTA: Las presiones máximas en las
INDUSTRIA ARGENTINA engrasadoras durante el engrase van desde 6000 a
20000 PSI.
2. Reengrase las válvulas inmediatamente después de
que por las mismas hayan circulado solventes.
3. Recircule, lavando las válvulas, con agua dulce
limpia luego de cada uso para desplazar cualquier
residuo de cemento ó ácidos que hayan permanecido
en el interior de las válvulas.
INDOIL T e l / F a x (011) 4 6 6 0 - 4 3 2 8 [email protected] p24

Pressure, Level & Temperature Transmitters & Transducers
WECO® “HAMMER” UNION PRESSURE TRANSMITTER

Model 170, 270, 370, 570
Designed specifically for use with either WECO® 2” 1502 or 2” 2002 Wing Union Fittings for the high
pressure /vibration applications such as Cementing, Fracturing, Mud Pressure Measurement & Acidizing.
FEATURES:
• Designed to reduce “clamping effects” of Wing Union
• 0-5000 thru 0-20,000 psi
• Corrosion resistant materials
• High Accuracy
• 0-5 VDC, 4-20 mA, CANbus outputs
• Hazardous Locations Approvals
• 350°F version available
OIL AND GAS

• 100% Shunt Cal
GROUND
SCREW
HOUSING
304 SST
Ø2.22
4.75
SENSOR
BODY
1.75
Ø3.69 Ø3.35
2” #1502 CONFIGURATION 2” #2002/2202 CONFIGURATION

(SHOWN WITH “CA” CONNECTOR) (SHOWN WITH “CF” CONNECTOR)
Some options will affect dimensions. Consult factory if important.
WIRING CODE
PIN 170/270 370 570
A/1 + EXC. + EXC./SIGNAL + EXC.
B/2 - EXC. - EXC./SIGNAL - EXC.
C/3 + SIGNAL NC SIG/J1939
D/4 - SIGNAL CASE GROUND SIG/J1939
E/5 + SHUNT/CAL + SHUNT/CAL NC
F/6 - SHUNT/CAL - SHUNT/CAL NC
GP:50 reserves the right to make product improvements and amendments to the product specifications stated throughout this brochure
without prior notification. Please contact the factory on all critical dimensions and specifications for verification.
A5SL-70.00 Rev D
2770 Long Road, Grand Island, NY 14072 USA
Tel. (716) 773-9300 Fax (716) 773-5019 E-mail:[email protected] website:www.gp50.com
Pressure, Level & Temperature Transmitters & Transducers
Specifications reflect standard product, improved performance/mechanical options available. Modifications may alter
specs, consult factory for more information.
Accuracy (Static Error Band- Non-linearity, Hysterisis, Non-repeatability)
≤0.25% FSO (RSS)
Zero Balance (Model 170) (Model 270) (Model 370) (Model 570)
0.0 mV/V ±1% FSO @ 10 Vdc 0.0 V ±1% FSO @ 24 Vdc 4.0 mA ±1% FSO @ 24 Vdc CANbus J1939 @ 12Vdc
Full Scale Output (Model 170) (Model 270) (Model 370) (Model 570)
3 mV/V 5 Vdc 16mA J1939
Temperature Limits
Compensated -40ºF to 180ºF (-40°C to 80°C)
Operating -50ºF to 190ºF (-45°C to 85°C)
Temperature Compensation
Zero Less than ±1.0% FSO/100ºF
Span Less than ±1.0% FSO/100ºF
Electricals (Model 170) (Model 270) (Model 370) (Model 570)
Excitation Voltage 16 Vdc max 9-36 Vdc 9-36 Vdc* 6-18 Vdc
Input Current 45 mA 8 mA 23 mA max 40 mA
Output Current N/A 10 mA 23 mA max N/A
Load Impedance >10K ohms > 5K ohms N/A N/A
Shunt Calibration 100% FSO ±0.2% by exciting Pins E and F N/A
*10-28 Vdc for GI/AI/I approvals
Mechanicals
Proof Pressure 1.5 times pressure range
Burst Pressure 3.0 times pressure range
Materials of Construction
Sensor (See options below)
Housing 300 Series SST
Connections
Pressure WECO® 2” 1502 or WECO® 2” 2002/2202
Electrical Bendix PTØ2E-10-6P
Identification Etched on housing
ORDERING GUIDE:
Ordering: Specify model, and pressure range and indicate modifications or accessories required.
Use the following codes to identify desired item.
OPTIONS/ELECTRICAL
MODEL APPROVAL PROCESS CONNECTION RANGE
CONNECTIONS
● ● ● ● ●/●/●
Example: 370-A-R-Z-CA
MODEL ELECTRICAL CONNECTION

170 3 mV/V CA Bendix 6-pin PTØ2E-10-6P (SST) (Standard and I/AI/GI)
270 0 - 5 Vdc CF 1/2” NPT(M) with 18” 18 AWG MTW cable (N/AN/GN standard)
370 4 - 20 mA DK Glenair 4-pin GC379-2-14S-2P
570 CANbus J1939 DO Jupiter RECM 10TPN04-16
APPROVAL DM MS3102E 14S-2P
I FM/CSA Intrinsic Safety - 370 DP 4-Pin Brad Harrison (IR4ØØ6A2ØA12Ø1)
AI ATEX/IEC Intrinsic Safety - 370
AN ATEX Zone 2 OPTIONS
GI ATEX/IEC/FM/CSA Intrinsic Safety - 370 GB Alternate electrical output
EC CE Marking - 370 GC Special calibration run
N FM/CSA Div/Zone 2 GE Improved temperature comp. (± 0.5% FSO/100° F for zero/span)
PROCESS CONNECTION GG Alternate shunt calibration signal, designate value on sales order
A WECO® 2” 1502 Inconel X750 ME 80% Shunt Calibration
B WECO® 2” 2002 Inconel X750 ** MR Alternate wiring
NB 100% Powered Shunt (std on 370)
C * WECO® 2” 2202, Inconel 718 ** NG Removable carrying handle
D * 2” 1502, Inconel 718 NH Dual welded handle
G * 2” 1502 SST NC 100% Unpowered Shunt Calibration (std on 170/270)
H * WECO® 2” 2202/2002 SST ** QX Extended 350° F process temperature (-45°F to 185°F electronics)
* Material meets NACE MR0175 Guidelines QY Remove shunt cal.
** Non-Detachable
PRESSURE RANGE
SZ Non-standard range, if applicable
RV 5,000 psi Consult factory for more options, such as carrying handle, optional
RW 6,000 psi materials, electrical connectors and replacement fasteners
RX 7,500 psi
RZ 10,000 psi Consult WECO® manufacturer for published presssure maximums.
SB 15,000 psi WECO® is a Federally Registerd Trademark with FMC Technologies
SD 20,000 psi
2770 Long Road, Grand Island, NY 14072 USA

Tel. (716) 773-9300 Fax (716) 773-5019 E-mail:[email protected] website:www.gp50.com
1
1.000 PSI
!
"
"
# "
2.000 PSI
$ !
%
&
"
De ¼” a 10”
2
6.000 PSI 10.000 PSI
15.000 PSI BUTT WELD
PARA SOLDAR
3
4
5
6
Tubería de acero al carbono – accesorios ranurados 09.04-SPAL
Mover® Unión de Expansión
Tipo 150
El Victaulic Mover ® Estilo 150 es una unión de expansión de tipo deslizable, el cual permite
un movimiento longitudinal axial de hasta 3”/80 mm. Las uniones de expansión Victaulic Mover
permiten un fácil ajuste antes de la instalación para acomodar la expansión, la contracción
ó ambas. Están diseñadas para el servicio hasta +230°F/+110°C y para presiones de trabajo
de hasta 350 psi/2400 kPa; dependiendo del tipo de acoplamiento utilizado en la instalación.
El estilo 150 es suministrado con extremos ranurados para la instalación con los acoplamientos
rígidos Zero-Flex® Estilo 07 ó con extremos planos para instalarlos con los acoplamientos
Roust-A-Bout ® Estilo 99.
Vea información sobre el diseño de la instalación en 09.06 y 26.02.
Especificaciones de materiales Bastidor: De hierro dúctil conforme a ASTM A-536, clase 65-45-12. De hierro dúctil conforme
a ASTM A-395, clase 65-45-15, disponible a pedido especial.
Recubrimiento del bastidor: Esmalte anaranjado. Para informarse de otras modalidades,

comuníquese con Victaulic.
Cuerpo, extremo: Acero al carbono, Schedule 40, conforme a ASTM A-53, Tipo E o S, Clase B.
Corredera: Schedule 40, tubería sin costura de acero estirado al frío, conforme a AISI 1015 o 1018.
Recubrimiento de Cuerpo/Extremo: Esmalte negro. Para informarse de otros, comuníquese con

Victaulic.
Recubrimiento de corredera: Sulfuro de polifenileno modificado con politetrafluoretileno (PPS/PTFE).
Clase de empaquetadura: (especifique su selección*)
• Clase “E” EPDM

EPDM (código de color verde). Rango de temperatura de –30°F a +230°F/–34°C a +110°C.
Recomendado para servicios de agua fria y caliente dentro del rango de temperatura
especificado, además una gran variedad de ácidos diluidos, aire sin aceite y muchos servicios
químicos. Clasificación UL de acuerdo con ANSI/NSF 61 para servicio de agua potable fría
a 30°C y caliente a +82°C. NO RECOMENDADA PARA SERVICIOS DE PETRÓLEO.
• Nitrilo Clase “T”

Nitrilo (código de color anaranjado). Rango de temperatura de –20°F a +180°F/–29°C to +82°C.
Recomendado para derivados del petróleo, aire con vapores de aceite, aceites de vegetales
y minerales dentro del rango de temperatura especificado. No recomendado para servicios
de agua caliente sobre +150°F/+66°C o de aire seco caliente sobre +140°F/+60°C.
* Los servicios de la lista son únicamente Recomendaciones Generales de Servicio. Cabe hacer
notar que hay servicios para los cuales no se recomiendan estas empaquetaduras. Siempre
debería consultar las recomendaciones de servicio de empaquetaduras específicas y una lista
de servicios no recomendados en la Guía de Selección de Empaquetaduras Victaulic más reciente.
Pernos/Tuercas: Cabezas de acero al carbono enchapado con tratamiento térmico conforme a los
requerimientos físicos y químicos de ASTM A-449 y los requerimientos físicos de ASTM A-183.
Obra/Propietario Contratista Ingeniero

No. de sistema________________________ Enviado por_ _________________________ Secc. Especif.__________ Párrafo_ _______
Ubicación____________________________ Fecha_ ______________________________ Aprobado_ ___________________________
Fecha_ ______________________________
www.victaulic.com
Victaulic es una marca registrada de Victaulic Company. © 2006 victaulic company. Todos los derechos reservados. Impreso en EE.UU.
REV_C 09.04-SPAL_
Tubería de acero al carbono – accesorios ranurados 09.04-SPAL
Mover® Unión de Expansión
Tipo 150
Dimensiones
Presión Movimiento
máxima Máximo Peso aprox.
Tamaño de trabajo Disponible Dimensiones – pulg./mm c/u
Diámetro
Y Tamaño Exterior Longitud Z
nominal Actual
Pulgadas Pulgadas psi Pulgadas Altura Ancho Lbs.
Mm Mm kPa Mm X Y Mínimo Máximo Kg
2 2.375 350 3 3.38 5.50 11.88 14.88 15.9
X 50 60,3 2410 76,2 86 139 302 378 7,2
3.000 350 3 4.38 6.75 12.13 15.13 38.0
76,1 mm
76,1 2410 76,2 111 171 308 384 17,2
3 3.500 350 3 4.75 7.25 12.13 15.13 25.6
Z max. 80 88,9 2410 76,2 121 184 308 384 11,6
Z min. 4 4.500 350 3 6.25 9.00 14.13 17.13 39.6
100 114,3 2410 76,2 159 229 359 435 18,0
5.50 350 3 6.25 9.00 14.13 17.13 56.0
139,7 mm
139,7 2410 76,2 159 229 359 435 25,4
5 5.563 350 3 7.12 10.75 14.13 17.13 55.0
125 141,3 2410 76,2 181 273 359 435 24,9
6.50 350 3 8.63 12.00 16.00 19.00 75.0
165,1 mm
165,1 2410 76,2 219 305 406 483 34,0
6 6.625 350 3 8.63 12.00 16.00 19.00 75.0
150 168,3 2410 76,2 219 305 406 483 34,0
Comuniquese con Victaulic para solicitar detalles.
Garantía Consulte la sección Garantía de la Lista de Precios actual o póngase en contacto con Victaulic para
solicitar detalles.
Nota Este producto debe ser fabricado por Victaulic o según las especificaciones de Victaulic. Todos
los productos deben instalarse de acuerdo con las últimas instrucciones de instalación / montaje
de Victaulic. Victaulic se reserva el derecho de cambiar las especificaciones, el diseño y el equipo
estándar del producto sin aviso y sin incurrir en obligaciones.
Instalación Siempre se deberá consultar el Manual de Instalación en Campo I-100 de Victaulic correspondiente
al producto que esté instalando. Con cada envio, se incluyen manuales de los productos de Victaulic
con información completa de instalación y montaje. Están disponibles en formato PDF en la pagina
de web www.victaulic.com.
WCAS-6UPRAU
Para obtener la información de contacto completa, visite www.victaulic.com

09.04-SPAL 1652 rev C Actualizado al 8/2006
Victaulic es una marca registrada de Victaulic Company. © 2006 victaulic company. Todos los derechos reservados. Impreso en EE.UU.
09.04-SPAL
GENEBRE S.A. · C/ Pedrosa A, 46-48 · EDIFICIO GENEBRE
Tel. +34 93 298 80 00/01 · Fax +34 93 298 80 06
08908 L’HOSPITALET DE LLOBREGAT Barcelona (Spain)
e-mail: [email protected]
internet: http://www.genebre.es
ARTICULO: 2109
Válvula de mariposa tipo wafer.
Butterfly valve wafer type.
Características Features
1. Válvula de mariposa tipo wafer. 1. Butterfly valve wafer type.
2. Cuerpo de fundición GG-20 para montaje 2.GG-20 Iron body, allows installation in ANSI
entre bridas ANSI 150 y DIN PN 10/16. 150 and DIN PN 10/16 pipe flange.
3. Elastómero de EPDM. 3. EPDM body seat.
4. Disco de Acero Inoxidable 316 (CF8M). 4.Butterfly made in AISI 316 ( CF8M ).
5. Brida montaje actuadores según ISO 5211 – 5.Actuator mounting plate according ISO 5211 –
DIN 3337. DIN 3337.
6. Longitud entre caras según UNE EN 558-1 6. Face to face according UNE EN 558-1 Serie 20
Serie 20 (DIN 3202 K1). ( DIN 3202 K1).
7. Pintado con pintura Epoxi. 7. Epoxi painted.
8. Máxima temperatura de trabajo 100 ºC. 8.Max. Working Temperature 100 ºC.
Nº Denominación/Name Material Acabado Superficial/Surface Treatment

1 Cuerpo / Body Fundición GG-20 / cast iron GG-20 Pintado Epoxi / Epoxi Painted
2 Eje / Stem Acero Inox AISI 420 / SS 420 ------
3 Pivote / Pivot Acero Inox AISI 420 / SS 420 ------
4 Disco / Disc Acero Inox AISI 316 / SS 316 Granallado / Shot Blasting
5 Tapón / Cap Acero Inox AISI 420 / SS 420 ------
6 Elastómero / Seat EPDM ------
7 Casquillo / Bush PTFE ------
8 Estopada / Stem packing PTFE ------
9 Tórica / O’ ring NBR ------
10 Arandela / Washer Bronze ------
11 Seguro / Stop Ring Acero / Steel ------
GENEBRE S.A. FECHA DE REVISIÓN: 09/06/2004 18:08 NUMERO DE REVISIÓN: 2

Tel. +34 93 298 80 00/01 · Fax +34 93 298 80 06
DIMENSIONES GENERALES / GENERAL DIMENSIONS
Ref Medida/ Dimensiones/Dimensions (mm) Peso/

Size DN PN L ∅E H L M Weight
(Kg)
2109 09 2" 50 16 43 200 75 90 270 4.20
2109 10 2 ½" 65 16 46 200 85 90 270 4.80
2109 11 3" 80 16 46 200 100 90 270 5.55
2109 12 4” 100 16 52 220 120 90 270 6.80
2109 13 5” 125 16 56 250 125 90 270 8.75
2109 14 6” 150 16 56 250 150 125 300 11.15
2109 16 8” 200 16 60 300 150 125 300 16.60
2109 18 10” 250 16 68 330 200 125 300 23.45
2109 20 12” 300 16 78 360 250 150 300 33.80
2109 22 14” 350 10 78 390 260 150 *** 61.00
2109 24 16” 400 10 102 420 300 175 *** 82.00
2109 26 18” 450 10 114 445 330 175 *** 136.00
2109 28 20” 500 10 121 480 370 175 *** 163.00
*** Nota: A partir de 14” (DN 350) operación mediante reductor manual.
*** Note: From 14” included , handling by gear operator.
Dimensiones de brida superior / Top flange dimensions:
Top flange dimensions

Art DN F S D H Torque / par
(ISO 5211) mm mm mm N.m
2109 09 50 F07 11 14 30 12
2109 10 65 F07 11 14 30 20
2109 11 80 F07 11 14 30 27
2109 12 100 F07 14 18 30 39
2109 13 125 F07 14 18 30 58
2109 14 150 F07-F10 17 22 30 90
2109 16 200 F07-F10 17 22 30 120
2109 18 250 F10 22 28 40 180
2109 20 300 F10-F12 22 28 40 340
2109 22 350 F12 22 28 45 640
2109 24 400 F14 27 36 45 805
2109 26 450 F14 27 36 45 1100
2109 28 500 F14 36 48 45 1500

Tel. +34 93 298 80 00/01 · Fax +34 93 298 80 06
Perdidas de Carga ( Cv ) según posición del disco / Head losses according disc position:
Posición del Disco (grados) / Disc Position (degrees)

DN 90º 80º 70º 60º 50º 40º 30º 20º 10º
50 144 114 84 61 43 27 16 7 1
65 282 223 163 107 67 43 24 11 1.5
80 461 364 267 154 96 61 35 15 2
100 841 701 496 274 171 109 62 27 3
125 1376 1146 775 428 268 170 98 43 5
150 1850 1542 1025 567 354 225 129 56 6
200 3316 2842 1862 1081 680 421 241 102 12
250 5430 4525 2948 1710 1076 667 382 162 19
300 8077 6731 4393 2563 1594 1005 555 235 27
350 10538 8874 5939 3384 2149 1320 756 299 34
400 13966 11761 7867 4483 2847 1749 1001 397 45
450 17214 14496 10065 5736 3643 2237 1281 507 58
500 22339 18812 12535 7144 4536 2786 1595 632 72
Medidas de Precaución para instalación / Precautions measures for Installation:

1. No instale la válvula en posición totalmente cerrada / Do not assemble the butterfly valve in total
closed position.
2. Verifique el buen paralelismo de las bridas / Check the good parallelism of the flanges.
3. No coloque otras juntas entre las bridas / Do not insert others gasket between flange and valve.

Float Actuated Oil Level 0710176
Revised 03-07
Swichgage® instrument Catalog Section 15
L100 For Small Engines and Pumps

■ See Oil Level and Condition
Without Shutting Down
■ Shutdown or Alarm on Low Lube Level
■ Adjustable Limit Switch for Alarm

and/or Shutdown
■ Save on Reduced Downtime
L120
and Repair Costs
■ Simple Installation **
L127/L128
Description Specifications ■ L127 and L128

These float actuated Oil Level Swichgage instru- ■ Maximum Pressure Rating (all models): Case: TROGAMID® Nylon
ments are a combination oil level sight gage and 30 psi (207 kPa) [2.07 bar] Float: Brass
adjustable, low and/or high limit switch. The Rating: 2 A @ 30 VAC/DC
■ L100 and L100W Wire: 16 AWG x 48 in. (1.5 mm2 x 1.2 m)
limit switches are normally open during opera-
Case: Die cast aluminum Mounting Bolts:
tion–yet close if the level drops (or rises) to
Float: Brass • L127: 1/4-20 NC x 2 in. (4 required)
where the float contacts the limit screw. The con- Rating: 2 A @ 30 VAC/DC
tact completes a circuit to ground a magneto or
• L128: 3/8-16 NC x 3/4 in. (2 required)
Vent Fitting: 1/4 in. (6 mm) tube x 1/8 NPT
trip a Murphy magnetic switch. The magnetic Inlet Fitting: Hex Nipple 1/4 NPT
switch can be used to activate alarms and/or Hardware (shipped loose) Warranty
shutdown. Models are also available without L100: A limited warranty on materials and workmanship
limit switches. is given with this FW Murphy product. A copy of
• Copper Tubing: 1/4 x 48 in. dia. the warranty may be viewed or printed by going to
(6 mm x 1.2 m) www.fwmurphy.com/support/warranty.htm
Application • Reducer Bushing: 1/2 NPT x 1/4 NPT
The level instruments described above can be • Close Nipple: 1/2 NPT
used on a variety of crankcases, pump gearcases, • Tee: 1/2 NPT, black pipe †
Models available with high and low options. See How to
or oil reservoirs–primarily on small engines and • Wire: 16 AWG x 24 in. (1.5 mm2 x 610 Order on reverse side
pumps. The following list displays the model mm) **Products covered by this bulletin comply with EMC
and its typical application: L100W: Council directive 89/336/EEC regarding electromagnetic
compatibility except as noted.
L100†: Small engines and pumps with • Vent Tube: 1/4 x 3-3/8 in. (6 x 86 mm)
non-vented crankcase. • Reducer Bushing: 3/4 NPT x 1/4 NPT
L100W†: Small engines and pumps with • Close Nipple: 3/4 NPT
vented crankcase. • Tee: 3/4 NPT, black pipe
L120: Machined surface on crankcase such as
• Wire: 16 AWG x 24 in. (1.5 mm2 x 610
Witte, National-Oilwell/Garland.
mm)
L127: Machined surface on crankcase, specifi- ■ L120
cally, Fairbanks-Morse ZC Series and Case: Cast Aluminum
Bell Engines. Float: Brass
L128: Machined surface on crankcase, specifical- Rating: 2 A @ 30 VAC/DC
ly, Arrow and Continental Emsco/Climax. Mounting Bolts: 1/4-20 UNC–2A (4 req'd)
0710176 page 1 of 2
Typical Wiring Diagram Dimensions
Below is a typical wiring diagram for a level 2-1/8 in.
L100 and L100W (54 mm)
Swichgage instrument. A Swichgage instru-
ment can be connected to a Murphy magnetic Shipping Dimensions:
switch or magneto. Switch Contact Rating is • L100: 5-1/4 x 5-1/4 x 5-1/2 in.
2 A @ 30 VAC/DC resistive. (133 x 133 x 140 mm)
• L100W: 4-3/4 x 4-3/4 x 3-1/4 in. 3-1/8 in.
(79 mm)
Murphy
magnetic
(121 x 121 x 83 mm) CL
27/32 in.
Float Magneto
switch Shipping Weight: (21 mm)
• L100: 2 lbs. (0.91 kg)
OR
• L100W: 2 lbs. (0.91 kg)
How to Order L120 2-1/8 in.

(54 mm) 2-7/32 in.
Specify base model designator and options in (56 mm)
sequence shown below. Example: L100-HL. 3-3/8 in.
(86 mm)
____ - ____ 4-5/16 in. 2-7/32 in.
(110 mm) (56 mm)
Option
Blank: Low contact.
LF: Less fittings and hardware.
Mounting Holes 4 places,
5/16 in. (8 mm) diameter
Shipping Weight: 1 lb 8 oz (0.68 kg) Shipping Dimensions: 4-3/4 x 4-3/4 x 3-1/4 in. (121 x 121 x 83 mm)
Base Model (refer to “Application” section) L127 and L128 2-1/2 in.* L128 Mounting Dimensions
L100: Sight gage with low limit switch. (64 mm)
2-15/64 in. Mounting** 47/64 in.
L100W: Same as L100 except fittings. (57 mm) holes 4 places 2 in.**
(51 mm) (19 mm)
L120: Sight gage with low limit switch. 5/16 in. (8 mm) 3/8 in.
diameter (10 mm) 17/32 in.
L127: Sight gage with low limit switch. (13 mm)
Oil inlet
L128: Sight gage with low limit switch. holes
2-3/4 in. 2-15/64 in.
(70 mm) (57 mm)
Mounting 1-17/32 in.

holes 2 places (39 mm)
* Applies to L128 only 5/16 in. (8 mm)
** Applies to L127 only
Shipping Weight: Shipping Dimensions (L127 and L128):
• L127: 8 oz (0.23 kg) 4-3/4 x 4-3/4 x 3-1/4 in. (121 x 121 x 83 mm)
• L128: 10 oz (0.36 kg)
FW MURPHY CONTROL SYSTEMS & SERVICES DIVISION COMPUTRONIC CONTROLS, LTD

P.O. Box 470248 P.O. Box 1819 41 - 43 Railway Terrace Nechells
Tulsa, Oklahoma 74147 USA Rosenberg, Texas 77471 USA Birmingham B7 5NG UK
+1 918 317 4100 Fax: +1 918 317 4266 Phone: +1 281 633 4500 Fax: +1 281 633 4588 Phone: +44 121 327 8500 Fax: +44 121 327 8501
E-mail: [email protected] E-mail: [email protected] E-mail: [email protected]
INDUSTRIAL PANEL DIVISION FRANK W. MURPHY, LTD Web site: www.computroniccontrols.com
Fax: +1 918 317 4124 Church Rd Laverstock FW MURPHY INSTRUMENTS (HANGZHOU) CO. LTD
E-mail: [email protected] Salisbury SP1 1QZ UK 77 23rd Street
MURPHY POWER IGNITION Phone: +44 172 241 0055 Fax: +44 172 241 0088 Hangzhou Economic & Technological Development Area
Web site: www.murphy-pi.com E-mail: [email protected] Hangzhou, Zhejiang 310018 China
Web site: www.fwmurphy.co.uk Phone: +86 571 8788 6060 Fax: +86 571 8684 8878
www.fwmurphy.com Printed in U.S.A.
0710176 page 2 of 2
C-Accesorios
de Izaje
Sucker Rod Hooks
Frontlock Hook
All O’Bannon Sucker Rod Hooks are designed Steel alloy castings are heat treated A
for maximum safety and ease of operation. for optimum strength and hardness.
The double-latch locking mechanism is strong Capacity ratings are determined by B C
D
enough to ward off steel beams, yet as easy tensile strength testing. The load
to open as your hand. Half concealed in the rating applied to each tool is based
E
shank of the hook is a lever, which releases the upon API Specification 8C.
latch only when the hook is gripped to engage F
J H
or disengage the elevator bail. A guard, cast
K
as an integral part of the shank, protects this
L
release lever.
I
The main bearings in all Frontlock Hooks are

M
heavy-duty ball thrust type, fully enclosed to
keep out dirt. It is easily lubricated by means
of a shielded grease zerk fitting.
Fig. IX
O’Bannon Frontlock Hooks
Catalog Number
Frontlock Hook A
Item Qty. Description
Regular Type Spring Type
FH11EGH FH12GH
Fig. IX Fig. X
A 1 Bail FH2D FH2C

B 1 Cap FH17 FH17 B
C 1 Pin FH10 FH10 C
D
D 1 Nut FH7 FH7
E 1 Fitting, Zerk FH18 FH18
F 1 Bearing FH6AH FH6AH E
G 1 Spring Compression --- FH14
H 1 Pin, Lever FH8P FH8P
F
I 1 Pin, Latch FH8P FH8P
G
J 1 Shank FH1AG FH1BG
K 1 Lever FH4 FH4
L 1 Spring, Lever FH5 FH5
M 1 Latch FH3 FH3
Regular Type Frontlock Hook

Repair Kit
--- 1 Repair kit includes 1 (each) Cap, Pin, FHERP-1 ---
Nut, Bearing, Lever Pin, Latch Pin,
Lever, Lever Spring and Latch. J H
Spring Type Frontlock Hook
Repair Kit K
Repair kit includes 1 (each) Cap, Pin,
--- 1 Nut, Bearing, Compression Spring, --- FHERP-2 L
Lever Pin, Latch Pin, Lever, Lever
Spring and Latch.
Specifications Regular Type Spring Type I

Load Rating 25 Tons 25 Tons
Weight 32 lbs. 48 lbs. M
Overall Length 23” 31-1/2”
Net Length 19” 27-1/2”
Spring Travel --- 2-1/2”
Diameter Bail Opening 3-1/2” 3-1/2”
Hook Opening 2” 2”
Fig. X
CYE
INGENIERIA S.A.
Av. San Martín 4172 - C1417DSO Capital Federal
Telefax: (54-11) 4523-8033 Líneas rotativas / e-mail: [email protected]
ESLINGAS DE CABLE DE ACERO

Cargas límite de trabajo para cables de acero 180 Kg./m2. Alma textil
Factor de seguridad: 5
10º 30º 60º 90º 120º 150º
Diámetro Carga
del de 1 2 3 4 5 6 7 8 9
Cable rotura CONFIGURACION
mm. Kgs. Kgs. Kgs. Kgs. Kgs. Kgs. Kgs. Kgs. Kgs. Kgs.
6 1999 400 300 800 800 772 693 566 400 206
8 3907 781 586 1563 1563 1508 1354 1105 781 403
9.5 5504 1101 826 2202 2202 2125 1907 1557 1101 568
6 x 19 F
11 7375 1475 1106 2950 2950 2847 2556 2087 1475 761
13 10302 2060 1545 4121 4121 3977 3570 2915 2060 1063
14 11934 2387 1790 4774 4774 4607 4136 3376 2387 1232
16 15606 3121 2341 6242 6242 6024 5408 4415 3121 1611
19 21522 4304 3228 8609 8609 8307 7459 6089 4304 2222
22 28866 5773 4330 11546 11546 11142 10004 8167 5773 2980
26 40290 8058 6044 16116 16116 15552 13963 11399 8058 4159 6 x 36 WS
28 46716 9343 7007 18686 18686 18032 16190 13217 9343 4822 ó
32 60996 12199 9149 24398 24398 23544 21139 17257 12199 6296 6 x 41 WS
35 72930 14586 10940 29172 29172 28151 25275 20633 14586 7528
38 85986 17197 12898 34394 34394 33191 29799 24327 17197 8875
CABLES Y ACCESORIOS DE ACERO INOXIDABLE
Algunos ejemplos de eslingas:

S1-O-O S1-GU-O S1-GU-O/GA S1-O/GA - O-GA S4-GU/AP-GU/GA S1-O-O/GAC S2-GU/A - GU/-GA
CYE
INGENIERIA S.A.
GUARDACABOS PARA CABLES
Diám. Largo Ancho Espesor Peso embal.

Ancho Largo Total Interior Interior aprox. x paquetes
del 100 pcs de
cable
a L I C S
mm. mm. Pulg. mm. mm. mm. mm. kg.
8 8 2 51 35 22 4 6 600
10 10 21/2 64 47 30 4 7 400
12 12 3 76 57 35 5 14 300
14 14 3 1/2 89 65 45 6 22 150
16 16 4 102 76 50 6 24 150
18 18 4 1/2 114 86 53 8 4 75
20 20 5 127 94 60 9 65 75
22 22 5 1/2 140 107 65 10 93 40
24 24 6 152 114 70 10 102 40
28 28 7 178 130 80 10.5 135 25
32 32 8 203 157 100 10.5 162 20
36 36 9 229 177 115 12 363 -
40 40 10 254 198 120 12 376 -
44 44 11 279 214 130 15 608 -
50 50 12 305 215 140 20 960 -
56 56 14 356 245 160 20 1400 -
64 64 16 407 275 180 20 1700 -
GUARDACABOS PARA SOGAS
Largo Largo Ancho Peso aprox.

Ancho Exterior Interior Interior Espesor por cada
100 pcs.
a B L C s
mm. mm. mm. mm. mm. kg.
8 43 27 16 1 1.08
10 50 30 19 1.5 1.70
12 55 36 22 1.75 3
14 60 41 24 2 3.50
16 66 43 26 2.5 8
18 77 47 30 3 12.6
20 91 58 35 3 16
22 100 67 38 3 24
25 115 71 45 3 25
30 140 91 55 3 43
35 140 91 55 3 45
38 140 91 55 4 45
CYE
INGENIERIA S.A.
GRAMPAS PRENSACABLES FORJADOS

U.S. Fed. Spec. FF-C-450
Diám. Diám. Largo Ancho Largo Largo Ancho Altura Peso
del caballete caballete Interior de la de la de la de la aprox x.
cable rosca base base base cada 100
pcs.
A B C D F H I
mm. mm. mm. mm. mm. mm. mm. mm. kg.
1/8 5 24 12 11 24 21 10 2
3/16 6 31 15 13 29 24 13 4
1/4 8 34 19 13 37 30 17 8
5/16 10 45 22 19 43 33 18 14
3/8 11 49 26 19 49 42 25 19
7/16 12 60 30 25 58 46 26 31
1/2 13 61 30 26 58 48 27 34
9/16 14 72 33 32 63 52 31 36
5/8 14 74 33 32 64 52 33 45
3/4 16 86 38 37 72 57 37 68
7/8 19 98 45 40 80 62 40 108
1 19 108 48 46 88 67 44 113
1 1/8 19 117 51 51 91 72 48 140
1 1/4 22 130 59 54 105 79 56 207
1 3/8 22 140 60 59 108 79 58 234
1 1/2 22 147 66 60 112 86 64 266
1 5/8 22 161 70 67 121 92 67 329
1 3/4 29 175 78 74 134 97 78 441
2 32 195 86 78 152 113 87 603
2 1/4 32 208 98 81 162 116 100 707
2 1/2 32 227 105 87 168 119 113 806
2 3/4 32 243 112 91 174 127 124 1000
3 38 271 121 104 194 135 136 1440
GRAMPAS PRENSACABLES COMUNES
Diám. Diám. Largo Ancho Largo Largo Ancho Altura Peso

del caballete Interior de la de la de la de la aprox x.
cable rosca base base base cada 100
pcs.
mm. A B C D F H I kg.
3 4 20 9 12 21 10 10 14
5 5 24 11 13 23 11 10 15
6 5 28 13 15 26 12 11 21
8 6 34 16 19 30 15 15 41
10 8 42 19 22 34 18 17 68
11 8 44 20 22 36 19 18 72
13 10 55 24 30 42 23 21 130
14 10 57 25 30 44 23 22 135
16 12 63 29 33 50 26 26 210
19 12 75 32 38 54 29 30 280
22 14 85 37 44 61 33 34 400
26 14 95 41 45 65 35 37 440
CYE
INGENIERIA S.A.
TENSORES DE CAJA ABIERTA
Medida L1 L2 e e1 C D A Peso Carga

aprox. x de
DyL mm. mm. mm. mm. mm. mm. mm. 100 pcs. trabajo
M6 x 100 mm 83 80 50 50 8 20 9 11 100
M8 x 125 mm 93 84 62.5 62.5 10.5 22 10 20 200
M10 x 150 mm 123 105 75 75 13 31 14 28 300
M12 x 200 mm 130 110 100 100 16 35 16 43 500
M16 x 250 mm 167 143 125 125 19 47 22 100 1000
M20 x 200 mm 198 165 150 150 21 52 24 160 1500
M22 x 330 mm 223 185 165 165 24 60 28 220 2200
M24 x 350 mm 245 208 175 175 26 65 28 280 3000
Tipo A: Ojo y horquilla
Tipo B: Ojo y ojo
Tipo C: Horquilla y horquilla
Tipo D: Gancho y gancho
Tipo E: Horquilla y gancho
Tipo F: Gancho y ojo

D-Registradores
Technical Note – Load Pins TN1003
Load Measuring Pin in Double Shear
Load measuring pins are designed for many diverse applications as direct replacements for clevis
or pivot pins. They have many advantages over other load sensors in that they do not normally
require any change to the mechanical structure being monitored. Load pins are typically used in
rope, chain and brake anchors, sheaves,
shackles, bearing blocks and pivots. FORCE
General Description
A load measuring pin senses the force
applied across it, via strain gauges installed
within a small bore through the centre of the
pin. Two grooves are machined into the outer
circumference of the pin to define the shear
planes, which are located between the forces
being measured.
Internally bonded strain gauges
Environmental Protection
As the instrumented area of the load pin is totally contained within a small central bore, the load
pin sensor is inherently waterproof. Manufactured from special stainless steels, fitted with welded
or `O' ring sealed end caps and with special attention to the signal cable glanding, a very high
operating reliability can be guaranteed even for load pins operating underwater.
LCM Systems Ltd

Unit 15, Newport Business Park, Barry Way, Newport, Isle of Wight, PO30 5GY, UK
Tel: +44 (0)1983 249264 Fax: +44 (0)1983 249266
email: [email protected]
www.lcmsystems.co.uk
Typical locations
If a pin exists within a defined load path or can be
fitted to experience a force, then an LCM Load Pin
can be installed to monitor that load. The sketches
below show typical locations for load pins.
Load pin locking systems

A load-measuring pin needs to be securely locked into
position in order to fix its orientation with respect to its
associated assembly. This needs to be fixed, both in the
axial and rotation modes, to ensure that accurate and
repeatable results are obtained from the system.
A standard load pin is designed to sense the force in one direction only. A force at right angles to
that force will produce a zero output from the sensor.
Load Pin Locking Systems
LCM Systems Ltd

Tel: +44 (0)1983 249264 Fax: +44 (0)1983 249266
Cable and connector arrangements
The signal cable can normally exit from the load pin to suit the installation and space
requirements. Emphasis should be placed on the protection of the cabling system from accidental
damage during installation and use. A plug and socket breakdown can be incorporated at the load
pin if required. Extra protection can be provided over the standard polyurethane sheathed cable in
the form of hydraulic hose. This provides excellent protection with the advantage of associated
fittings being readily available.
Cable & Connector Systems
Standard and custom load pin sizes

The following table shows the LCM range of standard load
pins within the range of 2.5 to 50 tonnes. Most pins, however,
do not match these exact dimensions and are therefore
custom designed to suit a specific location and application.
There is no extra cost for the design of a custom pin.
Standard Load Pin Sizes

Type/Ref ØD L1 L2 L3 L4 Rating (tonne)
LMP-25-70 25.00 100 70 45 43 2.5
LMP-30-75 30.00 105 75 50 48 3.5
LMP-40-95 40.00 125 95 63 60 6.5
LMP-50-114 50.00 150 114 75 72 15
LMP-63-152 63.00 195 152 89 85 25
LMP-75-175 75.00 225 178 102 98 50
LCM Systems Ltd

Tel: +44 (0)1983 249264 Fax: +44 (0)1983 249266
Load Rating
Special high strength steels are used in the manufacture of all LCM load pins to optimize on the
load bearing capabilities of any one design of pin. There is always, however, a compromise
between output signal and ultimate strength of any load pin design. For a load pin in double shear,
the graph below indicates optimum load ratings for given pin diameters.
Load Pin in Double Shear
If a pin is being designed into an assembly without restrictions in size for a given load rating, then
the design should be aimed at the optimum curve as shown. However, many load pins are
designed to retrofit existing structures and will not always fall into the ideal range.
The high side of the graph indicates a load pin that will give an output of 2.5 to 3.5 mV/V for a
given load but with some degree of compromise on the ultimate safety factor of that pin.
The lower end of the graph will produce a load pin, which has either a low output at its rated load
or has to be machined with excessive shear notches to create enough signal. At the very low end
we would normally propose a bushed load pin - details available on request.
LCM Systems Ltd
Tel: +44 (0)1983 249264 Fax: +44 (0)1983 249266
Installation Notes
Various factors influence the performance of a load pin when it is put into service. The majority of
load pins are designed to fit existing structures so that each design is dependant on the size and
constraints of that structure. If a pin is subjected to a high load, in relation to its diameter (see load
rating graph) then it will not perform as well as a pin that is designed to fall within the optimum or
low range of that graph.
A rigid support structure is required to minimize the bending forces imparted on to the pin. The pin
works by sensing the shear and any bending stresses within the pin will degrade its overall
accuracy. The fit of the pin within its mating holes is important in the overall performance of the
load pin. For an “optimum” range pin, an H7, g6 fit would normally be recommended, however this
is not always achievable in the field and some slight loss of repeatability and linearity can normally
be tolerated at the expense of an `easy to fit' requirement.
Bearing stresses, and overall proportions of the pin are always taken into consideration with the
design of a new pin. We will always endeavour to optimize the performance of any pin (within its
service structure) given the restraints placed upon it. The key consideration in the performance of
any load pin is that if there is no change in the geometry of the pin, the loading structure or loading
conditions, throughout the range of the pin (0 -100%), then a high performance can be expected.
Even minimal bending of the structure, changes in bearing areas or bending of the load pin (if
highly loaded) will have an effect on performance however repeatability is unlikely to be affected.
Calibration
Load pins are normally calibrated in half or full blocks in a traceable compression test machine.
When a load pin is supplied as the sensing member of a shackle, we would normally calibrate the
total shackle assembly in tension.
We endeavour to match the loading conditions that would be experienced in service but it would
be unrealistic to totally simulate the on-site structure for every load pin manufactured. It is for this
reason that for optimum system accuracy, a calibration in the final assembly is recommended.
LCM Systems Ltd

Tel: +44 (0)1983 249264 Fax: +44 (0)1983 249266
Indirectly Applied Load
A load pin can be installed within a sheave
system to monitor the resultant force applied
to that sheave. The load applied to the wire
and the wrap angle that the wire makes with
the sheave determines the resultant force.
The following graph indicates the load on the
sheave/pin versus wire load
tension.
Varying Force Angle

If the angle of force, as applied to the standard load
pin, varies in service, either by changes in wrap
angle or by some other exterior factor then there will
be a loss in output of that pin as shown in the graph
over. It will be noted that up to +/-8 degrees of
loading variation can be accommodated before a
loss of 1% in signal output is recorded
LCM Systems Ltd

Tel: +44 (0)1983 249264 Fax: +44 (0)1983 249266
0%
1%
2%
3%
4%
0° 2° 4° 6° 8° 10° 12° 14° 16° 18°
X/Y Load Pin

Where a high degree of angular variation will be encountered
an X/Y load pin can normally be offered. This will provide two
outputs, as described by the following graph, which can be
read simultaneously to compute the true resultant force
applied to that pin. The direction of force, as applied to the pin,
can also be computed from polarity and magnitude of the X
and Y signals.
LCM Systems Ltd

Tel: +44 (0)1983 249264 Fax: +44 (0)1983 249266
The angular orientation of the load pin, in its associated mechanical assembly, will depend on the
angular window of operation of that pin. This needs to be defined in order to optimize the installation
and results from that pin.
LCM Systems Ltd

Tel: +44 (0)1983 249264 Fax: +44 (0)1983 249266
Instruction Manual May 2008
sitrans
PROBE LU (HART)
Safety Guidelines: Warning notices must be observed to ensure personal safety as well as that of
others, and to protect the product and the connected equipment. These warning notices are
accompanied by a clarification of the level of caution to be observed.
Qualified Personnel: This device/system may only be set up and operated in conjunction with this
manual. Qualified personnel are only authorized to install and operate this equipment in accordance with
established safety practices and standards.
Unit Repair and Excluded Liability:
• The user is responsible for all changes and repairs made to the device by the user or the user’s
agent.
• All new components are to be provided by Siemens Milltronics Process Instruments Inc.
• Restrict repair to faulty components only.
• Do not reuse faulty components.
Warning: This product can only function properly and safely if it is correctly transported, stored,
installed, set up, operated, and maintained.
This product is intended for use in industrial areas. Operation of this equipment in a residential area
may cause interference to several frequency based communications.
Note: Always use product in accordance with specifications.
Copyright Siemens Milltronics Process Disclaimer of Liability

Instruments Inc. 2008. All Rights Reserved
This document is available in bound version and in While we have verified the contents of this
electronic version. We encourage users to purchase manual for agreement with the
authorized bound manuals, or to view electronic versions instrumentation described, variations
as designed and authored by Siemens Milltronics Process remain possible. Thus we cannot
Instruments Inc. Siemens Milltronics Process Instruments guarantee full agreement. The contents of
Inc. will not be responsible for the contents of partial or this manual are regularly reviewed and
whole reproductions of either bound or electronic corrections are included in subsequent
versions. editions. We welcome all suggestions for
improvement.
Technical data subject to change.
MILLTRONICS®is a registered trademark of Siemens Milltronics Process Instruments Inc.
Contact SMPI Technical Publications European Authorized Representative

at the following address:
Technical Publications Siemens AG
Siemens Milltronics Process Instruments Inc. Industry Sector
1954 Technology Drive, P.O. Box 4225 76181 Karlsruhe
Peterborough, Ontario, Canada, K9J 7B1 Deutschland
• For a selection of Siemens Milltronics level measurement manuals, go to:

www. siemens.com/processautomation. Under Process Instrumentation, select Level
Measurement and then go to the manual archive listed under the product family.
• For a selection of Siemens Milltronics weighing manuals, go to:
www. siemens.com/processautomation. Under Weighing Technology, select Continuous
Weighing Systems and then go to the manual archive listed under the product family.
© Siemens Milltronics Process Instruments Inc. 2008

Table of Contents
Table of Contents
Table of Contents .................................................................................................................i
mmmmm
Safety Notes ..................................................................................................................1
Safety marking symbols ..............................................................................................................1
The Manual ...............................................................................................................................................1
Application Examples ...................................................................................................................2
Abbreviations and Identifications .............................................................................................2
SITRANS Probe LU (Ultrasonic) ....................................................................................... 4
Applications ....................................................................................................................................4
Level, volume or flow ................................................................................................................. 4
SITRANS Probe LU System Implementation ..........................................................................5
Programming ..................................................................................................................................5
SITRANS Probe LU Approvals and Certificates ....................................................................5
Specifications ...................................................................................................................... 6
SITRANS Probe LU ............................................................................................................................... 6
Power............................................................................................................................................. 6
Performance................................................................................................................................. 6
Interface ........................................................................................................................................ 7
Programmer (infrared keypad) ................................................................................................ 7
Mechanical................................................................................................................................... 7
Environmental .............................................................................................................................. 8
Process.......................................................................................................................................... 8
Approvals (verify against device nameplate)....................................................................... 9
Installation ......................................................................................................................... 11
Mounting Instructions ..........................................................................................................................12
SITRANS Probe LU Dimensions ..............................................................................................13
Flange Adaptor (optional) ..........................................................................................................13
Wiring .................................................................................................................................. 14
Power .............................................................................................................................................14
Connecting the SITRANS Probe LU ......................................................................................14
Operating the SITRANS Probe LU .................................................................................. 16
RUN Mode ..............................................................................................................................................16
Display ......................................................................................................................................... 16
PROGRAM Mode ..................................................................................................................................17
Programming ................................................................................................................................17
Display ......................................................................................................................................... 17
i
Low temperature effects on RUN/PROGRAM modes .......................................................18
Security ..........................................................................................................................................19
Starting PROGRAM mode .........................................................................................................19
Table of Contents
Handheld programmer ...............................................................................................................19

Activating SITRANS Probe LU ...........................................................................................................19
mmmmm
Accessing a parameter ..............................................................................................................20

Changing a Parameter Value ....................................................................................................20
Master Reset (P999) ...................................................................................................................21
Using Units or Percent (%) ........................................................................................................21
Setup Steps (outline) ............................................................................................................................21
Setup Instructions .......................................................................................................................22
Additional Settings ................................................................................................................................27
Parameter Reference ......................................................................................................28
Helpful Hints ............................................................................................................................... 28
To access a parameter and change a value (primary index): ....................................... 28
To access a secondary index and change a value: ......................................................... 29
Quick Start (P001 to P010)................................................................................................................. 30
Volume (or Flow) P050 to P055 ........................................................................................................ 33
Lock (P069)............................................................................................................................................ 41
Failsafe (P070 to P073) ....................................................................................................................... 41
mA Output (P201 to P215).................................................................................................................. 42
Installation Records (P300 to P346) ................................................................................................ 45
Range Calibration (P650 to P654) .................................................................................................... 47
Temperature Compensation (P660 to P664) ................................................................................. 50
Rate (P700 and P701).......................................................................................................................... 51
Measurement Verification (P709 to P713)..................................................................................... 52
P752 HART address............................................................................................................................ 54
Communications (P799) ..................................................................................................................... 55
Echo Processing (P800 to P825) ...................................................................................................... 55
Algorithm (P820) .................................................................................................................................. 58
TVT (Time Varying Threshold) Adjustment Parameters (P830 to P839) ................................ 59
Diagnostic Tests (P900 to P924) ...................................................................................................... 62
Measurement ...................................................................................................................................... 63
ii
Appendix B: Programming Chart ...................................................................................67
Appendix C: HART Communications .............................................................................71
Table of Contents
HART Electronic Device Description (EDD) ...................................................................................71
HART Communicator 275/375: ..................................................................................................72
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SIMATIC Process Device Manager (PDM): ....................................................................................75
Maintenance settings (accessible via PDM only) ..............................................................75
HART Version .........................................................................................................................................76
Burst mode ....................................................................................................................................76
Multidrop Configuration ............................................................................................................76
Appendix D: Troubleshooting .........................................................................................77
Communication Troubleshooting ......................................................................................................77
Generally: .......................................................................................................................................77
Specifically: ...................................................................................................................................77
General Fault Code ...............................................................................................................................78
Operation Troubleshooting .................................................................................................................81
Appendix E: Maintenance ...............................................................................................82
Unit Repair and Excluded Liability ....................................................................................................82
Appendix F: Technical References ................................................................................83
Principles of operation .........................................................................................................................83
Blanking Distance .................................................................................................................................83
TVT (Time Varying Threshold) curves ..............................................................................................83
Auto False-Echo Suppression ..................................................................................................83
Open Channel Monitoring (OCM) ......................................................................................................85
Failsafe .....................................................................................................................................................85
Chemical compatibility .........................................................................................................................86
Startup Behavior ...................................................................................................................................86
Appendix G: Hazardous area installations ..................................................................87
Wiring Details .........................................................................................................................................87
Intrinsically Safe Model .............................................................................................................87
FM/CSA ..........................................................................................................................................88
EU Equivalency .......................................................................................................................... 88
Loop Voltage versus Loop Resistance ...................................................................................89
IS Safety Barrier Selection .......................................................................................................89
How to select a passive barrier for SITRANS Probe LU ................................................. 89
PLC Input Modules.................................................................................................................... 90
Passive Shunt Diode Barriers ............................................................................................... 90
Active barriers (repeating barriers)...................................................................................... 90
iii
Product Nameplate ...............................................................................................................................91
Intrinsically safe connection drawing (FM) ....................................................................................92
FM Class 1, Div. 2 connection drawing ...........................................................................................93
Table of Contents
Intrinsically safe connection drawing (CSA) ..................................................................................94

Instructions specific to hazardous area installations ..................................................................95
mmmmm
(Reference European ATEX Directive 94/9/EC, Annex II, 1/0/6) .......................................95

Appendix H: Firmware Revision History ......................................................................97
Glossary ..............................................................................................................................99
Index .................................................................................................................................. 103
Appendix A: Alphabetical Parameter List .................................................................. 105
iv
Safety Notes1
Special attention must be paid to warnings and notes highlighted from the rest of the text
by grey boxes.
WARNING: relates to a caution symbol on the product, and means

that failure to observe the necessary precautions can result in death,
serious injury, and/or considerable material damage.
WARNING1: means that failure to observe the necessary
precautions can result in death, serious injury, and/or considerable
material damage
Note: means important information about the product or that part of the operating
SITRANS Probe LU
manual.
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Safety marking symbols
In manual: On product: Description
(Label on product: yellow background.) WARNING: refer
to accompanying documents (manual) for details.
The Manual
Notes:
• Please follow the installation and operating procedures for a quick, trouble-free
installation and to ensure the maximum accuracy and reliability of your
SITRANS Probe LU.
• This product is intended for use in industrial areas. Operation of this equipment in a
residential area may cause interference to several frequency based communications.
• This manual applies to the SITRANS Probe LU (HART) only.
This manual will help you set up your SITRANS Probe LU for optimum performance. We
always welcome suggestions and comments about manual content, design, and
accessibility. Please direct your comments to [email protected].
For other Siemens level measurement manuals, go to:
www.siemens.com/level and look under Level Measurement..
1.
This warning symbol is used when there is no corresponding caution symbol on the
product.
7ML19985HT02 SITRANS Probe LU (HART) – INSTRUCTION MANUAL Page 1

Application Examples
The application examples used in this manual illustrate typical installations using
SITRANS Probe LU. Because there is often a range of ways to approach an application,
other configurations may also apply.
In all examples, substitute your own application details. If the examples do not apply to
your application, check the applicable parameter reference for the available options.
If you require more information, please contact your Siemens representative. For a complete list
of Siemens representatives, please go to:
www.siemens.com/processautomation.
Abbreviations and Identifications

SITRANS Probe LU
Short
Long Form Description Units
mmmmm
form
Conformitè Europèene /
CE / FM /
Factory Mutual / Canadian safety approval
CSA
Standards Association
Ci Internal capacitance
D/A Digital to analog
ETFE Ethylene-tetrafluoroethylene
Highway Addressable
HART
Remote Transducer
Ii Input current mA
Io Output current mA
IS Intrinsically Safe safety approval
Li Internal inductance mH
LRV Lower Range Value value for process empty level 4 mA1
below which no PV is
LSL Lower Sensor Limit
anticipated
µs microsecond 10-6 Second
PBT Polybutylene Terephthalate
Pressure Equipment
PED safety approval
Directive
PVDF Polyvinylidene fluoride
Page 2 SITRANS Probe LU (HART) – INSTRUCTION MANUAL 7ML19985HT02

Short
Long Form Description Units
form
ppm parts per million
PV Primary Variable measured value
SELV Safety extra low voltage
SV Secondary Variable equivalent value
TVT Time Varying Threshold sensitivity threshold
Ui Input voltage V
Uo Output voltage V
20 mA1
SITRANS Probe LU
URV Upper Range Value value for process full level
above which no PV is
USL Upper Sensor Limit
anticipated
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1. 100% is most commonly set to 20 mA, and 0% to 4 mA: however, the settings
can be reversed.

SITRANS Probe LU (Ultrasonic)
SITRANS Probe LU is a 2-wire loop-powered ultrasonic transmitter for level, volume, and
flow monitoring of liquids in storage vessels and simple process vessels, as well as in
open channels.
The transducer is available as ETFE (ethylene-tetrafluoroethylene) or PVDF
(polyvinylidene fluoride) to suit the chemical conditions of your application. For
applications with varying material and process temperatures, the Probe LU incorporates
an internal temperature sensor to compensate for temperature changes.
SITRANS Probe LU uses field-proven Sonic Intelligence ® signal processing.
SITRANS Probe LU
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Applications
Level, volume or flow
SITRANS Probe LU is designed to measure levels of liquids in a variety of applications:
• storage type vessels
• simple process vessels with some surface agitation
• liquids
• slurries
• open channels
Volume
By using the volume parameters (P050 to P055) you can obtain the measurement as
volume instead of level.
Flow
If you have an open channel system (a Parshall flume, v-notch weir or other open channel
device), you can obtain flow values instead of level. By using the universal linear function
of parameter P051, and entering values for Head and Flow in the breakpoint parameters
P054 and 055, you can use SITRANS Probe LU to convert head levels into flow rates.

SITRANS Probe LU System Implementation
SITRANS Probe LU supports the HART communications protocol and SIMATIC® PDM
software.1 2
Typical PLC/mA configuration with HART
active PLC
SITRANS Probe LU
power supply1 R2 = 250 Ω
handheld programmer
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HART modem
SITRANS
Probe LU HART
communicator
Programming
SITRANS Probe LU carries out its level measurement function according to the set of
built-in parameters. Parameter changes can be made via the handheld programmer, via a
PC using SIMATIC PDM, or via a HART Handheld Communicator.
SITRANS Probe LU Approvals and Certificates

Note: Please see Approvals on page 9 for an approvals listing.
1. Depending on the system design, the power supply may be separate from the PLC, or
integral to it.
2. A 250 Ohm resistor may be required if the loop resistance is less than 250 Ohms.

Specifications
Note: Siemens makes every attempt to ensure the accuracy of these specifications
but reserves the right to change them at any time.
SITRANS Probe LU
Power
Nominal 24 V DC at For other configurations, see the chart Loop Voltage
max. 550 Ohm. versus Loop Resistance on page 89.
• Maximum 30 V DC
• 4 to 20 mA
• Max startup current see Startup Behavior on page 86
Performance1
Reference operating conditions according to IEC 60770-1
• ambient temperature +15 to +25 oC
• humidity 45 to 75% relative humidity
Specifications
• ambient pressure 860 to 1060 mbar

mmmmm
Measurement Accuracy (measured in accordance with IEC 60770-1)

• non-linearity (accuracy) greater of 6 mm (.24”) or 0.15% of span (including
hysteresis and non-repeatability)
• non-repeatability 3 mm (0.19”) [included in non-linearity specification]
• deadband (resolution) 3 mm (0.19”) [included in non-linearity specification]
• hysteresis error 0 mm
Analog Output Accuracy (measured in accordance with IEC 60770-1)

• non-linearity (accuracy) 0.125% of span (including hysteresis and repeatability)
• non-repeatability 0.025% of span (included in non-linearity specification)
• deadband (resolution) 0.0375% of span [included in non-linearity
specification]
• hysteresis error 0%
Frequency 54 KHz
Measurement range2 6 m (20 ft) model: 0.25 m to 6 m (10" to 20 ft) liquid
12 m (40 ft) model: 0.25 m to 12 m (10" to 40 ft) liquid
1.
Reference conditions.
2. Reference point for measurement is the transducer face.

Blanking distance2 0.25 m (0.82 ft)
Update time at 4mA ≤5s
Beam angle 10o at –3 dB boundary
Temperature compensation built in to compensate over temperature range
Memory non-volatile EEPROM,
no battery required
Interface
• HART standard, integral to analog output
• configuration Siemens SIMATIC PDM (PC), or HART handheld
communicator, or Siemens infrared handheld
programmer
• analog output 4–20 mA ± 0.02 mA accuracy
• display (local) multi-segment alphanumeric liquid crystal with Bar
graph (representing level)
Programmer (infrared keypad)

Siemens Infrared IS (Intrinsically Safe) Handheld Programmer: for all locations, including
hazardous.
• approval ATEX II 1 G EEx ia IIC T4, SIRA 01ATEX2147

FM/CSA Class I, Div. 1, Groups A, B, C, D
Specifications
• ambient temperature −20 to +40 °C (−5 to +104 °F)
• interface proprietary infrared pulse signal
mmmmm
• power 3V lithium battery (non-replaceable)
• weight 150 g (0.3 lb)
• color black
Mechanical
Process Connections
• threaded connection 2” NPT, BSP, or G (EN ISO 228-1) / PF2 (JIS B 0202)
• flange connections 3" (80 mm) universal flange
• other connections FMS 200 mounting bracket, or customer-supplied
mount
Transducer (2 options)
• ETFE (ethylene-tetrafluoroethylene), or
• PVDF (polyvinylidene fluoride)

Enclosure
• body construction PBT (polybutylene terephthalate)
• lid construction hard-coated PEI (polyether imide)
• cable inlet 2 x M20x1.5 conduit gland, or 2 x 1/2" NPT thread
• ingress protection Type 4X / NEMA 4X, Type 6 / NEMA 6, IP67, IP68 (see
note below)
Notes:
• Please check the ambient and operating temperatures under Environmental on page
8, and Process on page 8; also check Approvals (verify against device nameplate) on
page 9, for the specific configuration you are about to use or install.
• The use of approved watertight conduit hubs/glands is required for Type 4X /
NEMA 4X, Type 6 / NEMA 6, IP67, IP68 (outdoor application).
Weight
Standard model 2.1 kg (4.6 lb.)
Environmental
• location indoor/outdoor
• altitude 5000 m (16,404 ft) max.
• ambient temperature −40 to +80 °C (−40 to +176 °F)
• relative humidity suitable for outdoor
(Type 4X / NEMA 4X, Type 6 / NEMA 6, IP67, IP68
Specifications
enclosure)
• installation category I
mmmmm
• pollution degree 4
• pressure rating 0.5 bar g/7.25 psi g
Process
• temperature
(at flange or threads) −40 to +85 °C (−40 to +185 °F)
• pressure (vessel) 0.5 bar g/7.25 psi g

Approvals (verify against device nameplate)
• General CSAUS/C, FM, CE, C-TICK
• Hazardous Intrinsically Safe: (Europe) ATEX II 1 G EEx ia IIC T4

(US/Canada) FM/CSA: (barrier required)1
Class I, Div. 1, Groups A, B, C, D
Class II, Div. 1, Groups E, F, G
Class III T4
(Australia) ANZEx Ex ia IIC T4

(Tamb = –40 to +80 °C) IP67, IP68
(International) IECEx TSA 04.0020X Ex ia IIC T4
Non-incendive (US) FM2:

Class I, Div. 2, Groups A,B, C, D T5
• Marine Lloyd’s Register of Shipping

ABS Type Approval
Note: The use of approved watertight conduit hubs/glands is required for Type 4X /
NEMA 4X, Type 6 / NEMA 6, IP67, IP68 (outdoor application).
Specifications
mmmmm
1. See Intrinsically safe connection drawing (FM) on page 92 or Intrinsically safe connection
drawing (CSA) on page 94.
2. See FM Class 1, Div. 2 connection drawing on page 93.

Specifications Notes
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Installation
WARNINGS:
• SITRANS Probe LU is to be used only in the manner outlined in this
manual, otherwise protection provided by the equipment may be
impaired.
• Installation shall only be performed by qualified personnel and in
accordance with local governing regulations.
Notes:
• Refer to the device nameplate for information on approvals.
• This product is susceptible to electrostatic shock. Follow proper grounding
procedures.
• Ideally, mount SITRANS Probe LU so that the face of the transducer is at least 300
mm (1 ft) above the highest anticipated level.
Mounting Location
Recommendations:
• Ambient temperature within –40 to 80 oC (–40 to 176 oF).

• Easy access for viewing the display and programming via the handheld programmer.
• An environment suitable to the housing rating and materials of construction.
• Keep the sound path perpendicular to the material surface.
.
ambient temperature
surrounding enclosure
–40 to 80 oC (–40 to 176 oF) flange adaptor (option) Installation
mmmmm
customer-supplied
flange
process temperature
–40 to 85 oC (–40 to 185oF)

Precautions:
• Avoid proximity to high voltage or current wiring, high voltage or current contacts,
and to variable frequency motor speed controllers.
• Avoid interference to the sound path from obstructions or from the fill path
Fill
The sound path should be:

pipe
• perpendicular to the
monitored surface
• clear of rough walls, rungs
seams, rungs, or
other obstructions. seams
• clear of the fill path
10°
Mounting Instructions
Note:
• Ideally, mount SITRANS Probe LU so that the face of the transducer is at least 300
mm (1 ft) above the highest anticipated level.
SITRANS Probe LU is available in three thread types: 2" NPT, 2" BSP, or PF2/G.
1. Before inserting SITRANS Probe LU into its mounting connection, ensure that the
threads are of the same type to avoid damaging them.
2. Simply screw SITRANS Probe LU into the process connection and hand tighten.
Installation
mmmmm

SITRANS Probe LU Dimensions
.
139.7 mm
(5.50")
130.1 mm hinged lid

(5.12")
198.9 mm
(7.83") electronics
mounting
21 mm thread
(0.83") transducer
51.1 mm (2.01")
54.0 mm (2.13")
Flange Adaptor (optional)

SITRANS Probe LU can be fitted with the optional 3" (80 mm) flange adaptor for mating to
3" ANSI, DIN 65PN10 and JIS 10K3B flanges.
SITRANS Probe LU
Installation
mmmmm
"A" "A"
Optional flange
adaptor
VIEW "A"-"A"

Wiring
Power1
WARNINGS:
DC terminals shall be supplied from an SELV1 source in
accordance with IEC-1010-1 Annex H.
All field wiring must have insulation suitable for rated voltages.
Connecting the SITRANS Probe LU

Notes:
• Use shielded, twisted pair cable (wire gauge AWG 22 to AWG 14/ 0.34 mm2 to
2.08 mm2).
• Separate cables and conduits may be required to conform to standard
instrumentation wiring practices, or electrical codes.
• The non-metallic enclosure does not provide a continuous ground path between
conduit connections: use grounding-type bushings and jumpers.
• For Intrinsically Safe setups, see page 87 for detailed information.
• For a Class 1, Div. 2 (FM) configuration, see the connection drawing on page 93.
cover screws
terminals for loop
current
cable
watertight
gland
threaded
connection
1. Strip the cable jacket for approximately 70 mm (2.75") from the end of the cable, and
thread the wires through the gland2.
Wirng
mmmmm
1. Safety Extra Low Voltage

2.
If cable is routed through conduit, use only approved suitable-size hubs for
waterproof applications.

2. Connect the wires to the terminals as shown below: the polarity is identified on the
terminal block.
3. Tighten the gland to form a good seal.

4. Close the cover and tighten screws: please do not overtighten screws.
Recommended torque is 1.1 to 1.7 N-m (10 to 15 in-lb).
Wiring
mmmmm

Operating the SITRANS Probe LU
SITRANS Probe LU has two modes of operation: RUN and PROGRAM.
Operation
mmmmm
RUN Mode
SITRANS Probe LU automatically starts in RUN mode when power is applied, and detects
the material level. The primary reading displays the material level (in meters) referenced
from Empty (process empty level). This is the default start-up display mode.
System status is displayed on the LCD, or on a remote communications terminal.
Display
Normal operation Fail-safe operation
2 3 3
1
1 4
4
6 5
m 5 6 m
1 – Primary Reading (displays level, distance, or volume (or flow1), in either units or
percent)
2 – Secondary Reading (displays Parameter number for Auxiliary Reading2)
3 – Echo status indicator: Reliable Echo or Unreliable Echo
4 – Units or Percent
5 – Active bar graph represents material level
6 – Auxiliary Reading (depending on the parameter selected, it displays milliAmp value,
distance or confidence, with units where applicable)
If the echo confidence drops below the echo confidence threshold3, the failsafe timer
starts running. When the timer expires, the letters LOE alternate with the reading every
two seconds, and the Reliable Echo indicator is replaced by the Unreliable Echo indicator.
When a valid reading is received, the level reading display returns to normal operation.
1.
See P050 Vessel (or Channel) Shape on page 34, for details on displaying flow instead of
volume.
2.
Press to display the auxiliary reading field when in RUN mode.
3.
See P804 Confidence Threshold on page 56 for more detail.

Handheld Programmer: function keys in RUN mode
Certain functions can be accessed directly from RUN mode by using specific keys.
Key Run Mode
Operation
mmmmm
mA output value displayed in auxiliary reading field
Internal enclosure temperature displayed in auxiliary reading field (P343).
Parameter for auxiliary readings1

Displays the value representing Echo Confidence (P805).
Toggle between Units and % on reading display
Initiate and complete PROGRAM mode access
Measurement key displays distance in auxiliary reading field.
1.
Press plus three-digit parameter number, sets parameter to show in the auxiliary display.
PROGRAM Mode
Programming
Note: See Accessing a parameter, on page 20, for detailed instructions.
• Set parameters to suit your specific application.

• Activate PROGRAM mode at any time, to change parameter values and set
operating conditions.
• For local programming, use the Siemens handheld programmer.
• For programming from a distance, use either a PC running SIMATIC PDM, or a HART
handheld communicator.
Display
2 3 1 – Primary Reading (displays parameter value)
1 2 – Secondary Reading (displays parameter

number)
3 – Programming indicator
4 4 – Auxiliary Reading (displays parameter names

for parameters P001 to P010, if a language is
selected. It displays the index value for indexed
parameters, such as P054.)

Handheld Programmer: function keys in PROGRAM mode
Key Programming Mode
to Values
Operation
mmmmm
Decimal point
Negative value
CLEAR value
TOGGLE between Units and % on parameter value
End PROGRAM session and enable RUN mode
Update echo quality parameters
Parameter scroll-up
Parameter scroll-down
DISPLAY opens parameter fields
ENTER the displayed value
Low temperature effects on RUN/PROGRAM modes

If the internal temperature falls to –30 oC (–22 oF) or below, it will affect both RUN and
PROGRAM modes.
RUN mode will operate normally, with the following exceptions:
• handheld programmer operation is disabled
• the LCD displays only limited information: the bar graph and the reliable/
unreliable echo indicator
PROGRAM mode:
• handheld programmer operation is disabled

Security
The Lock parameter, P000, secures SITRANS Probe LU against changes via the handheld
programmer. To enable programming, set P000 to the Unlocked Value stored in P069. To
Operation
disable programming, enter a different value.
mmmmm
Note:
• A remote master can still change configuration, if P799 is set to allow this.
Starting PROGRAM mode

The handheld programmer gives you direct access to SITRANS Probe LU.
Handheld programmer
Note: For detailed instructions on using the handheld programmer, see the next page.
For direct access to SITRANS Probe LU, point the handheld programmer at the display
from a maximum distance of 600 mm (2 ft), and press the keys.
handheld programmer
display
Numeric and
600 mm
Auxiliary keys (2 ft)
Function
Keys
Activating SITRANS Probe LU

Note: Keep infrared devices such as laptops, cell phones, and PDAs, away from
SITRANS Probe LU to prevent inadvertent operation.
Power up the instrument. SITRANS Probe LU starts in RUN mode, and detects the
material level, displayed in meters, referenced from Empty (process empty level).

Accessing a parameter
Note:
• The following instructions apply when using the Handheld Programmer.
Operation
• Do not use the Handheld Programmer at the same time as SIMATIC PDM, or erratic
mmmmm
operation may result.

• You do not need to key in initial zeros when entering a parameter number: for
example, for P005, key in 5.
1. Press PROGRAM then DISPLAY to

PROGRAM Icon
activate PROGRAM mode.
Parameter Number
Parameter Value
2. Either use the ARROW keys to scroll to
a different parameter, or
3. Press DISPLAY to open the Parameter
current value
Number field.
4. Key in the desired parameter number followed by
ENTER .
For example: press .
The LCD displays the new parameter number and
value.
Changing a Parameter Value

Notes:
• Security must be disabled to enable programming: set P000 to the Unlocked Value
stored in P069. (For more details, see P069 Unlocked value on page 41.)
• Invalid entries will be rejected or limited.
• CLEAR can be used to clear the field
1. Use the ARROW keys to scroll to the parameter number, or press

DISPLAY and key in the parameter number followed by ENTER .
2. Key in the new value.
3. Press ENTER to set the value.
Parameter Reset to Factory Default

1. Scroll to the parameter or enter its address.
2. Press CLEAR then ENTER . The value returns to the default setting.

Master Reset (P999)
Note: Following a Master Reset, complete programming is required.
Operation
Resets all parameters to their factory settings, with the following exceptions:
mmmmm
• P000 and P069 are not reset.
• The learned TVT curve is not lost.
1. Press PROGRAM then DISPLAY to activate PROGRAM mode.
2. Press DISPLAY to open parameter fields.
3. Key in 999.
Press CLEAR then ENTER , to Clear All
and initiate reset. The LCD displays C.ALL.
4. Reset complete. (Reset takes several seconds

to complete.)
Using Units or Percent (%)

Many parameters can be viewed either as a percentage, or in measurement units (P005).
View the parameter, then press MODE to toggle between units and percentage.
Setup Steps (outline)

Set the Quick Start parameters between P001 and P010 (the main settings that apply to all
applications and make the system operational). Then set P837 and 838 to ignore false
echoes, and return to RUN mode.
1. Select a language option1, or numeric, for the auxiliary reading (P010).

2. Select the measurement mode: level, space, or distance (P001).
3. Set the response time to level changes (P003).
4. Select units of measurement: m, cm, mm, ft, or in. (P005).
5. Set process empty level (Empty: P006).
6. Set the range to be measured (Span: P007).
7. To ignore false echoes before the material echo, set Auto False-Echo Suppression
Distance P838.
8. Enable Auto False-Echo Suppression P837.
9. Return to RUN mode.
1. The language options are English, German, French, or Spanish. The parameter title appears in
the language selected, for the first 10 parameters.

Setup Instructions
Notes:
Operation
• In PROGRAM mode, you can use the ARROW keys to scroll to a

mmmmm
parameter number.
• The default parameter values are indicated by an asterisk (*) in the tables.
Using the handheld programmer, set each parameter value to suit your application. (For
detailed instructions on accessing a parameter and changing the value, see page20.)
1. Select a language (P010:

Language)
If a language is selected, parameter Parameter Auxiliary reading
titles for parameters P010 to P001 are P000 LOCK
displayed in the auxiliary reading field. P001 OPERATION
0 * Numeric/None P002 MATERIAL
1 English P003 MEAS RESP
Values 2 German P005 UNITS
3 French P006 EMPTY
4 Spanish P007 SPAN

P010 LANGUAGE
2. Select the measurement mode required for the application (P001:

Operation)
Level returns material level referenced from Empty (process empty level).
1 * The reading is returned in volumetric units if parameters 050 to 055 are
set to enable this.
Values
2 Space returns material level referenced from Span (process full level).
3 Distance returns material level referenced from the transducer face.
To measure how full the vessel is, select Level: the reading can be returned as level or as
volume (or flow – seeP050 on page 34 for details):
• for a level reading, ensure P050 is set to 0: the reading returns the distance from
process empty level (Empty) to the current level
• for a volume reading, select a vessel shape at P050, and set volume parameters
051 to 055 as required
To measure how much space remains in the vessel, select Space:
• Space returns a reading for the distance between current level and process full
level (Span)
To measure the distance from the transducer face to the current level, select Distance.

Level Space Distance
(P001 = 1) (P001 = 2) (P001 = 3)
transducer 0%
face (4 mA)
Operation
(20 mA) (4 mA)
Span 100% Span 0% Distance
mmmmm
Space
P007
P006
Level
Empty Empty
Empty 0% 100% 100%
(4 mA) (20 mA) (20 mA)
Notes:
• Setting P001 resets Span (P007), unless Span has previously been set to a different
value. Span is set to Empty distance minus 110% of Blanking1, unless Operation is set
to distance measurement (P001 = 3). In this case, Span is set to the same value as
Empty (P006).
• Changing P001 may reset Output Function (P201): this applies to HART only.
3. Set response time to maximum filling/emptying rate (P003:

Measurement Response)
Set P003 to a measurement response speed just faster than the maximum filling or
emptying rate (whichever is greater).
1 * slow 0.100 m/minute
Values
2 medium 1.000 m/minute
3 fast 10.000 m/minute
Slower settings provide higher accuracy; faster settings allow for more level fluctuation.
(For more detail on measurement response, see P003 Measurement Response, on
page 31.)
4. Select type of measurement units required (P005: Units)

1 * meters
2 centimeters
Values 3 millimeters
4 feet
5 inches
1.
Blanking distance is 0.25 m (10"). See Blanking Distance on page 83 for more details.

5. Set process empty level (P006: Empty)
Range 0.0000 to 6.00 m (20 ft) or

(depends on mode)l 0.0000 to 12 m (40 ft)
Operation
Values
maximum range:
mmmmm
Default
6.000 m (20 ft), or 12.000 m (40 ft)
Enter the distance from the transducer face to Level Setup

process empty level (Empty) using units sets in transducer
P005. Empty can be set to any distance: not face
necessarily the bottom of the vessel.
Span 100%
Note: P006 and P007 are interlinked: see
notes attached to P007.
P007
P006
Level
6. Set the range to be measured
Empty 0%
(P007: Span)
Range 0.0000 to 6.00 m (20 ft) or

Values (depends on model 0.0000 to 12 m (40 ft)
Default 5.725 m (18.78 ft), or 11.725 m (38.47 ft)
Enter the distance between Empty (process empty level) and Span (process full level), in
the units set in P005. Span can be set at any distance above the empty level.1
Notes:
• Setting P006 resets Span, if it has not previously been set to a different value.
• The default setting for Span is based on Operation (P001) and Empty (P006). Span is
set to Empty minus 110% of blanking distance1, unless Operation is set to distance
(P001 = 3). In this case, Span is set to Empty distance.
• Always prevent the monitored surface from approaching within 0.3 m (1 ft) of the
transducer face. This provides a 0.05 m (2") safety margin, as the minimum detectable
distance is 0.25 m (10").
1.

7. Minimize false reflections (P838: Auto False-Echo Suppression Distance)
If SITRANS Probe LU displays an incorrect full level, or if the reading fluctuates between
a false high level and a correct level, you can use the TVT (Time Varying Threshold)
shaper parameters P838 and P837 together to prevent false-echo1 detection. P837 and
Operation
P838 elevate the TVT in this region and de-sensitize the receiver from any ’base noise’
mmmmm
caused by internal transducer reflections, nozzle echoes, or other vessel false echoes.
Notes:
• This function works best when the vessel is empty or nearly empty: use it only if
there is a minimum distance of 2 meters from the transducer face to the material.
• Set P837 and P838 during start up, if possible.
• If the vessel contains an agitator, the agitator should be running.
Parameter Values
Range 0.0000 to 6.00 m (20 ft) or
P838 (depends on model 0.0000 to 12 m (40 ft)
Default 1.000 m (3.28 ft)
Use P838 in combination with P837. Determine the actual distance from the transducer
face to the material surface. Subtract 0.5 m from this distance and enter the result,
following the Setup Instructions for P837.
Display before Auto False Echo Suppression

(or when P837 = 0)
default TVT
true P839
echo Hover Level
Level (db)
false
echo
Distance (meters)
1. False echoes can be caused by obstructions within the beam path. For more detail, see TVT
adjustment parameters, page 59, and TVT curves, page 83.

8. Enable False-Echo Suppression (P837: Auto False-Echo Suppression1)
Use this feature to ignore false echoes before the material echo. Use P838 to set the Auto
TVT distance first.
Operation
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Parameter Values Description

0 * Off
P837 1 Use "learned" TVT
2 "Learn"
Setup Auto False-Echo Suppression:

a. Perform this function when the vessel is empty or nearly empty.
b. Determine actual distance from transducer face to material level.
c. Press PROGRAM , then DISPLAY .
d. Select P838 and key in [distance to material level minus 0.5 m].
e. Press ENTER .
f. Select P837.
g. Press 2 and then press ENTER . P 837 will automatically revert to 1 (use
Learned TVT) after a few seconds.
Display after Auto False Echo Suppression
TVT curve
material
(learned)
level
Level (db)
false
echo
Distance (meters)
9. Press PROGRAM to return to RUN mode.
1. False echoes can be caused by obstructions within the beam path. For more detail, see TVT
adjustment parameters, page 59, and TVT curves, page 83.

Additional Settings
• Convert readings to volume or flow (P050 to P055)
• Store unlocked value (P069)
Operation
• Set Failsafe timer conditions (P070 TO P073)
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• Control Analog Output (P201 to P215 and P911)
• Check installation records (P300 to P346)
• Calibrate transducer for unusual conditions (P650 to P654)
• Temperature Compensation (P660 to P664)
• Limit rate of change of reading (P700 and P701)
• Verify measurements (P709 to P713)
• Configure communications (P799)
• Control echo processing (P800 to P825)
• TVT curve adjustments - Auto False Echo Suppression (P830 to P839)
• Software diagnostic tests (P900 and P901)
• Adjust measurements (P911 to P924)
For a full list of available parameters, see Parameter Reference, starting on page 28.

Parameter Reference
Notes:
• Keep infrared devices such as laptops, cell phones, and PDAs, away from
SITRANS Probe LU to prevent inadvertent operation.
• Do not use the Handheld Programmer at the same time as SIMATIC PDM, or erratic
operation may result.
• Press PROGRAM then DISPLAY to access PROGRAM mode, and press
PROGRAM to return to RUN mode.
• CLEAR can be used to clear the field
• Default values (Factory settings) are indicated by an asterisk (*) in the parameter
Parameters
tables, unless explicitly described.

mmmmm
SITRANS Probe LU is configured through its parameters, and the application determines
the parameter values which are entered into the instrument.
Please check your value entries carefully before operating SITRANS Probe LU, to ensure
optimum performance.
Helpful Hints
• Primary index is an address: for example, P054.
• Secondary index is a sub-address that allows for multiple values on an indexed
point, and allows indexed values from more than one parameter to be linked, for
example, the breakpoints in P054 and P055. (See pages 36 and 39 for more details.)
To access a parameter and change a value (primary index):

Note: Initial zeros in a parameter number do not have to be entered: for example, for
P001, key in 1.
1. Press PROGRAM then DISPLAY to activate PROGRAM Mode.

2. Either use the ARROW keys to scroll to each parameter number, or
press DISPLAY again to access the parameter number field, and key in the
parameter number followed by ENTER .
3. Key in the new value.
4. Press ENTER .

To access a secondary index and change a value:
Notes:
• In a parameter with a secondary index, the ARROW keys control
whichever index was most recently changed.
• When you first access a parameter, the ARROW keys control the primary
index (parameter number).
• After the secondary index is changed, the ARROW keys control the secondary
index.
• When the primary index is changed, the ARROW keys revert to the primary index.
1. Select the parameter number, for example P054: the secondary index is displayed in
the auxiliary reading.
Parameters
2. Press DISPLAY twice1 (the auxiliary reading field goes blank).
mmmmm
3. Key in the address of the desired index, or use the ARROW keys to scroll to
the desired secondary index number, then press ENTER .
4. Key in the new index value and press ENTER .
5. Press DISPLAY twice, and use the ARROW keys or enter the parameter number
to select a different parameter.
P000 Lock
Notes:
• This lock only applies to the handheld programmer: it does not lock access through
communications.
• A remote master can change configuration if P799 is set to allow this.
Secures SITRANS Probe LU from parameter changes via the handheld programmer.
Unlocked Value (P069) * Unlocked: programming permitted1

Value
other Locked: programming not permitted
1.
The factory setting for P069 is 1954: after a new Unlocked value is entered and
accepted, the new value becomes the default setting.
To enable the programming lock:

1. Select P000.
2. Key in any value other than the Unlocked Value (P069).
3. Press ENTER to set the value: PROGRAM mode is now active for viewing only.
To disable the programming lock:
1. Select P000.
2. Key in the Unlocked Value (P069).
3. Press ENTER to set the value: PROGRAM mode is now active for programming.
1.
This focusses control on the secondary index.

Quick Start (P001 to P010)
P001 Operation
Note: Default values are indicated with an asterisk (*) in the parameter tables, unless
explicitly described.
Sets the type of measurement required for the application. (This affects the local LCD
only: the primary variable for HART is controlled by P201.)
To measure how full the vessel is, select Level. The reading can be returned as level or as
volume:
• for a level reading, ensure P050 is set to 0: the reading returns the distance from
Parameters
process empty level (Empty) to the current level

• for a volume reading, select a vessel shape at P050, and set volume parameters
mmmmm
051 to 055 as required

To measure how much space remains in the vessel, select Space:
• Space returns a reading for the distance between current level and process full
level (Span)
To measure the distance from the transducer face to the current level, select Distance.
0 Instrument out of service.
Level returns material level referenced from Empty (process empty level). The
1 * reading is returned in volumetric units if parameters 050 to 055 are set to enable
Values this.
2 Space returns material level referenced from Span (process full level).
3 Distance returns material level referenced from the transducer face.

(P001 = 1) (P001 = 2) (P001 = 3)
transducer 4 mA
face 0%
20 mA Span 4 mA
Span 100% 0% Distance
Space
P007
P006
Level
Empty 100% Empty 100%
Empty 0%
4 mA 20 mA 20 mA

1
Notes:
• Setting P001 resets Span (P007), unless Span has previously been set to a different
value. Span is set to Empty distance minus 110% of Blanking1 unless P001 is set to 3
(distance measurement). In this case Span is set to the same value as Empty (P006).
• Changing P001 may reset Output Function (P201).
P002 Material to be monitored

Note: For use only by Siemens service personnel.
P003 Measurement Response

Sets the rate of response to level changes.
Parameters
mmmmm
Related Failsafe Max.
Damping Echo
Para- Timer Measurement
P003 Filter Verification
meters P070 Response
P709 P711
(minutes) P700/P701
1 * slow 100.00 0.100 m/minute 10.000 s 2
Values 2 medium 10.00 1.000 m/minute 10.000 s 2
3 fast 1.00 10.000 m/minute 1.000 s 2
Note: Changing P003 resets the following parameters: P070, P700, P701, P709, and
P711.
Use a setting just faster than the maximum filling or emptying rate (whichever is greater).
Slower settings provide higher accuracy: faster settings allow for more level fluctuation.
• Echo Verification (P711): discriminates between agitator blades in motion (spurious
noise) and the target surface (true echo).
• Failsafe timer (P070): establishes the period from the time a loss of echo (LOE) starts
until the Failsafe default (P071) is triggered. P070 takes precedence over P003.
1.

P005 Units
Specifies measurement units used for dimensional values.
1 * meters
2 centimeters
Values 3 millimeters
4 feet
5 inches
P006 Empty (process empty level)

Sets the distance from the transducer face to the process empty level, in units selected at
P005.
Parameters
mmmmm
Range Level Setup

0.0000 to 6.00 m (20 ft) or
(depends transducer
0.0000 to 12 m (40 ft)
on model face
Values
Max. range:
Default 6.00 m (20 ft) or Span 100%
12 m (40 ft)
Enter the distance from the transducer face

to Empty (process empty level), using units P007
P006
set in P005. Empty can be set to any Level
distance: not necessarily the bottom of the
vessel Empty 0%
Notes:
• Default setting is maximum range.
• P006 and P007 are interlinked: see note
attached to P007.
P007 Span (process full level)

Sets the range to be measured (referenced from Empty) in units selected at P005.
Range 0.0000 to 6.00 m (20 ft) or

(depends on model 0.0000 to 12 m (40 ft)
Values 5.725 m (18.78 ft) or
Default 11.725 m (38.47 ft)
See note on next page for more details.
Enter the distance between Empty (process empty level) and Span (process full level), in
units set in P005. Span can be set at any distance above Empty level.1

Notes:
• Setting P006 will reset Span, if it has not previously been set to a different value.
• The default setting for Span is based on Operation (P001) and Empty (P006). Span is
set to Empty minus 110% of Blanking1 distance, unless Operation is set to Distance
(P001 = 3). In this case, Span is set to Empty distance.
• Always prevent the monitored surface from approaching within 0.3 m (1 ft) of the
transducer face. This provides a 0.05 m (2") safety margin, as the minimum
detectable distance is 0.25 m (10").
P010 Language
Selects the language used for the auxiliary reading on the display.
0 * Numeric / None
Parameters
1 English
mmmmm
Values 2 German
3 French
4 Spanish
If a language is selected, parameter titles for the Quick Start parameters are displayed.
(See the table on page 22 for the titles displayed.)
Volume (or Flow) P050 to P055

Set SITRANS Probe LU to calculate readings based on reservoir volume instead of level:
see P050 Vessel (or Channel) Shape on page 34 for details on displaying flowrate.
1. Operation must be set to Level (P001 = 1).

2. Select a vessel shape matching the monitored vessel (P050).
3. If required, add dimensions A or L (as shown in the chart on page 35), using P052
and P053,
or, if vessel shape 9 is selected, add level and volume breakpoints in P054 and P055.
4. Enter the value for the maximum vessel volume in P051.
5. Return to RUN mode: readings are now displayed in volumetric units. To select
PERCENT, press : the displayed volume reading will be a percentage of
Maximum Volume.
1.
Blanking distance is 0.25 m (10").

P050 Vessel (or Channel) Shape
Defines the vessel (or open channel) shape (see chart on next page) and allows
SITRANS Probe LU to calculate volume or flow instead of level. The default setting for
P050 is 0 (volume calculation not required).
Enter the value for the vessel shape matching the monitored vessel or reservoir (see
chart on page 35).
P051 Maximum Volume

For readings in volumetric units instead of percentage values, enter the vessel volume
corresponding to Span (P007). Any volumetric units can be chosen, because the volume
calculation is based on the maximum volume, and scaled according to the Vessel Shape
Parameters
(P050) value. If no value is entered, the default is 100, and the reading will be a
percentage value.
mmmmm
Range 0.0000 to 99999

Values
Default 100.0
P006 Empty
Related Parameters P007 Span
Enter the vessel volume corresponding to Span (P007).

1. Key in the value. (For example, if maximum volume = 3650 m3, key in 3650.)
2. Press ENTER .
If the value is too large for the LCD display, enter larger units.
Example:
If maximum volume = 267,500 gallons, key in 267.5 (thousands of gallons).).

P050 Value Vessel Shape Description Also required
0 * ---- no volume calculation required N/A
1 flat bottom P051
2 conical or pyramidal bottom P051, P052

A
Parameters
mmmmm
3 parabolic bottom P051, P052
A
4 spherical bottom P051, P052

A
5 angled bottom P051, P052

A
6 flat end cylinder P051
7 parabolic end cylinder P051, P052, P053

A L
P051
8 sphere
universal linear
9 P051, P054, P055
level/volume/flow breakpoints

P052 Vessel Dimension A
Dimension A as used for P050 Vessel Shapes 2, 3, 4, 5, or 7, in the chart on page 35.
Range 0.0000 to 99999 in units (P005)

Values Default 0.0
---- Display when P050 = 0
Related Parameters P050 Vessel Shape
Enter one of the following, using the units selected in P005:

• height of the vessel bottom if P050 = 2, 3, 4, or 5
• length of one end-section of the vessel if P050 = 7
P053 Vessel Dimension L

Parameters
mmmmm
Dimension L as used in P050 Vessel Shape 7, in the chart on page 35.

Values Default 0.0
---- Display when P050 = 0
Related Parameters P050 Vessel Shape
Enter the vessel length L (excluding both end sections) if P050 = 7. Use the units selected
in P005.
P054 Level or Head Breakpoints

P054 and 055 can be used to calculate either level and volume in a vessel, or head level
and flow rate in an open channel device. (For more information on Open Channel
Monitoring, please see Open Channel Monitoring (OCM) on page 85).
Level Breakpoints
When the vessel shape is too complex for any of the preconfigured shapes, you can
define the shape as a series of segments. In P054 you assign a level value to each
breakpoint. In P055 you assign a corresponding volume value to each breakpoint.
Primary Index P054

Secondary Index Breakpoint number
Values
Default 0.000
Related Parameters P055 Volume or Flow Breakpoints

Enter up to 32 level breakpoints, where the corresponding volume is known. The 100%
and 0% levels must be entered. The breakpoints can be ordered from top to bottom, or the
reverse.
1. First set P050 to 9.
2. Select P054. breakpoint
value field
3. The default breakpoint value appears, with
breakpoint
the breakpoint number in the auxiliary number
reading.
4. Press DISPLAY twice to focus control on the secondary index1 (the auxiliary
reading field goes blank).
5. Key in 1 and press ENTER .
6. Key in the level value for breakpoint 1, and press ENTER . (Use units defined in
Parameters
P005.)
mmmmm
7. Press the UP ARROW key to display 02 in the auxiliary reading.
8. Key in the level value for breakpoint 2, and press ENTER .
9. Repeat steps 7 and 8 until level values have been entered for all the required
breakpoints.
10. Press DISPLAY twice and use the UP ARROW key to go to P055.
Example:
Breakpoints Level value Breakpoint Level breakpoint Volume breakpoint
number (P054) (P055)
4 8m
1 0 0
2 1 200
3 2m
3 2 1200
2 1m
1 4 8 3200
0m
Note: Illustrated values for P054 and P055 are for example purposes only.
1.
For more details on secondary index operation, see page 29.

Head Breakpoints
When measuring flow in an open channel device, you can define the cross-section of the
channel as a series of segments. In P054 you assign a head value to each breakpoint. In
P055 you assign a corresponding flow value to each breakpoint.
Primary Index P054

Values
Default 0.000
Related Parameters P055 Flow Breakpoints
Enter up to 32 head breakpoints, where the corresponding flow is known. The 100% and
0% levels must be entered. The breakpoints can be ordered from top to bottom, or the
Parameters
reverse.
mmmmm
1. First set P050 to 9.

2. Select P054. breakpoint
value field
3. The default breakpoint value appears, with
breakpoint
the breakpoint number in the auxiliary number
reading.
6. Key in the head value for breakpoint 1, and press ENTER . (Use units defined in
P005.)
8. Key in the head value for breakpoint 2, and press ENTER .
9. Repeat steps 7 and 8 until head values have been entered for all the required
breakpoints.
10. Press DISPLAY twice and use the UP ARROW key to go to P055.
Example: v-notch weir:

flow characterization
Breakpoints Break Head Flow 4
4 -point (P054) (P055)
3
2 4 0.4 m 113.5 3
flow
1
3 0.3 m 55.3
2
2 0.2 m 20.07 1
1 2 3 4
1 0m 0 head
Note: Illustrated values for P054 and P055 are for example purposes only.
1.

P055 Volume or Flow Breakpoints
If you are measuring level and volume, follow the Volume Breakpoints instructions below.
If you are measuring head and flow, follow the Flow Breakpoints instructions on page 40.
Volume breakpoints
Each segment defined by the level breakpoints (P054) requires a corresponding volume,
so that SITRANS Probe LU can make the level-to-volume calculations.
Primary Index P055

Range 0.0000 to 99999 in units
Values
Default 0.0000
Parameters
Related Parameters P054 Level Breakpoints
mmmmm
Typical volume calculations:
Cone Cylinder
V = (1/3)πr2h V = πr2h
Enter a volume for each breakpoint defined in P054. (See illustrated example for P054 on
the previous page.)
1. P050 must be set to 9.
2. Select P055.
3. The empty breakpoint value field appears, with the breakpoint number in the
auxiliary reading field.
6. Key in the volume for breakpoint 1, and press ENTER . (Any volumetric units can
be used: see note to P051.)
8. Key in the volume for breakpoint 2, and press ENTER .
9. Repeat steps 7 and 8 until volume values have been entered for all the required
breakpoints.
10. Press DISPLAY twice and use the ARROW keys or enter the value for the next
desired parameter.
1.

Flow breakpoints
Each segment defined by the head breakpoints (P054) requires a corresponding flow
value, so that SITRANS Probe LU can make the head-to-flow calculations.
Primary Index P055

Range 0.0000 to 99999 in units
Values
Default 0.0000
Related Parameters P054 Head Breakpoints
Use the Flow Tables associated with your open channel device (Parshall flume, v-notch
weir, or other measuring device) to calculate the flow rate for each head breakpoint.
Parameters
Enter a flow value for each breakpoint defined in P054. (See illustrated example for Head
mmmmm
Breakpoints on page 38.)

1. P050 must be set to 9.
2. Select P055.
3. The empty breakpoint value field appears, with the breakpoint number in the
auxiliary reading field.
6. Key in the flow value for breakpoint 1, and press ENTER .
8. Key in the flow value for breakpoint 2, and press ENTER .
9. Repeat steps 7 and 8 until flow values have been entered for all the required
breakpoints.
desired parameter.
1.

Lock (P069)
P069 Unlocked value
Stores the value to enter in Lock (P000) to unlock programming. If P000 is locked, P069
will not display the Unlocked value.
Range 1 to 9999
Values Default 1954
---- Display when P000 is locked
Notes:
• Default setting for P000 is unlocked.
Parameters
• After a new value has been stored at P069, that value will be recalled after a master
reset (P999).
mmmmm
• Consult your Siemens representative, if you have forgotten the unlocked value.
Failsafe (P070 to P073)

P070 Failsafe Timer
Sets the time to elapse in minutes since the last valid reading, before Failsafe State
activates.
Range 0.0000 to720.00 min.

Values
Default 100.00 (based on P003)
Note: The last valid reading is maintained until the Failsafe timer expires. After the
timer expires, the reading is set based on P071.
P071 Failsafe Material Level

Allows you to select the material level to be reported when the Failsafe Timer expires.
(For more detail, see Failsafe on page 85.)
1 Use Maximum mA Limit (P213) as material level

2 Use Minimum mA Limit (P212) as material level
Values
3 * Level remains at last reading
4 User-selected value (defined in P073)
1. Enter the value corresponding to the level you want reported when the Failsafe
Timer expires.
2. Press ENTER .

P073 Failsafe level
Defines a user-defined level to report when the Failsafe timer expires.
Range 3.6000 mA to 22.600 mA

Values
Default 22.600 mA
Note: P071 must be set to User-selected value (4) to use this value.
mA Output (P201 to P215)

P201 mA Output Function
Parameters
Alters the mA output/measurement relationship, and allows the output to be set

mmmmm
independently from P001. If a HART master is connected, only the master can change the
value.
0 manual
1 * level
Values 2 space
3 distance
volume (only available if a tank shape has been selected at P050)
4 or flow (only available if 9 is selected at P050, and head level and flow
breakpoints are set at P054 and P055)
Notes:
• P201 is set independently from P001: set P001 first, as changing P001 will reset P201
to the same setting.
• P201 controls the primary value and the loop current for the HART common module
and should not be changed if using HART.
• Selection also affects the secondary, tertiary, and quaternary variables for HART.
• P201 must be set to 0 (manual) before you can modify P911. Remember to restore the
previous setting after using P911.
Independent mA Setpoint Parameters (P210 and P211)

P210 and P211 allow you to explicitly define the normal operating range. Use these
features to reference the minimum and/or maximum mA output to any point in the
measurement range.
For HART, 4 mA and 20 mA represent the upper and lower range limits for the primary
variable.

P201 (mA Function) Settings Response for P210 and P211
Key in the material level in Units (P005) or percent1 of Span
Level, Space, or Distance
(P007) as referenced from Empty (P006).
Key in the volume in Maximum Volume (P051) units or as a
Volume percent1 of Maximum Volume.
1. Ensure the % symbol is displayed before entering a % value.
P210 4 mA Setpoint (low output)
Note: P210 is used to set the 4 mA loop current for the HART common module.
Sets the process level corresponding to the 4 mA value. 4 mA always defaults to 0, and
P201 determines whether this is a Level, Space, Distance, or Volume (or flow)1
Parameters
measurement. Level and Space are measured as a percentage of Span; Distance is
mmmmm
measured as a percentage of Empty.
(P001 = 1) (P001 = 2) (P001 = 3)
transducer 4 mA
face 0%
20 mA Span 4 mA
Space
P007
P006
Level
Empty Empty
Empty 0% 100% 100%
4 mA 20 mA 20 mA
Range –99999 to 99999.

Values 0.000 m (set to 0% as defined by
Default
P201: mA Output Function)
Related Parameters P201: mA Output Function
Enter the reading that is to correspond to a 4 mA output. Use percent or units, depending
on the setting for P051.
1.
To display flowrate instead of volume, see P050 Vessel (or Channel) Shape on
page 34.

P211 20 mA Setpoint (high output)
Sets the process level corresponding to the 20 mA value. 20 mA always defaults to 100%,
and P201 determines whether this is a Level, Space, or Distance measurement. Level and
Space are measured as a percentage of Span: Distance is measured as a percentage of
Empty.
Range –99999 to 99999.

5.725 m (18.78 ft) or
Values Default
11.725 m (38.47 ft); set to 100% as
(depends on model)
defined by P201: mA Output Function.
Related Parameters P201: mA Output Function
Enter the reading that is to correspond to a 20 mA output, Use percent or units, depending
Parameters
on the setting for P051.

mmmmm
Note: P211 is used to set the 20 mA loop current for the HART common module.
mA Output Limit Parameters (P212 and P213)

P212 and P213 allow you to explicitly set a failsafe current outside the normal operating
range.
P212 Minimum mA limit

Prevents the mA output from dropping below this minimum level for a measurement
value. This does not restrict the Failsafe or manual settings.
Range 3.800 to 20.500 (mA)

Values
Default 3.800 (mA)
P213 Maximum mA limit

Prevents the mA output from rising above this maximum level for a measurement value.
This does not restrict the Failsafe or manual settings.
Range 3.800 to 20.500 (mA)

Values
Default 20.500 (mA)

P214 4 mA Output Trim
Note: This parameter is for use only by Siemens service personnel.
Calibrates the 4 mA output.
P215 20 mA Output Trim

Note: This parameter is for use only by Siemens service personnel.
Calibrates the 20 mA output.
Installation Records (P300 to P346)
Parameters
mmmmm
P300 Temperature, transducer maximum
Shows the highest temperature encountered (in degrees C), as measured by the
temperature sensor in the transducer (if applicable).
Primary Index Transducer

Range –50 to 150 oC (view only)
Values (view only)
Default –50 (oC)
Press CLEAR then ENTER , to reset the log after a short circuit on the transducer
wiring.
P341 RUN Time

Displays the number of uninterrupted 24 hour periods that the device has been operating.
Range 0 to 99999 (days)

Values (view only)
Default: 0
Related P342: Power-on Resets
P341 is updated once a day.

• If power is cycled before 24 hours have passed, the run time will not be updated.
• If an instrument is powered down on a regular basis, P341 will not have an
accurate value.

P342 Power-On Resets
The number of times power has been applied since the date of manufacture.
Display 0.0 to 99999

Values (view only)
Default: 0
Related P341 RUN Time
This parameter is updated every time the instrument is reset or is powered up.
P343 Internal Temperature

Parameters
WARNING: Internal temperature must not exceed 80 oC (176 oF).

mmmmm
Displays (in degrees C) either the current temperature on the circuit board, or the
maximum or minimum temperature recorded by the internal sensor. The high and low
values are maintained over a power cycle.
Primary Index P343

Value (view only) Range –50 oC to 150 oC
1 * Current temperature
Secondary Index 2 Maximum temperature
3 Minimum temperature
1. Select P343.
2. The primary reading displays a temperature, and the secondary index number is
visible in the auxiliary reading field.
3. Press DISPLAY twice to focus control on the secondary index.
4. Key in the index number required, and press ENTER .
5. The temperature value associated with the new secondary index appears.
desired parameter.

P346 Serial Number
Displays the serial number of the instrument. The numbers stored in Index 2, followed by
the numbers stored in Index 1, give you the complete serial number.
Index 2 Index 1
Values (view only) Range: 00000 to 99999 Range: 00000 to 99999
Example: 1503010 15 03 010
1. Select P346.
2. The primary reading displays one part of the serial number, with the secondary index
number visible in the auxiliary reading field.
3. Press DISPLAY twice to focus control on the secondary index.
Parameters
4. Key in the other index number and press ENTER .
mmmmm
5. The other part of the serial number, associated with the new secondary index,
appears.
desired parameter.
Range Calibration (P650 to P654)

There are two possible types of calibration:
• Offset Adjusts the measurement by a fixed amount

• Sound Velocity Adjusts speed of sound, and changes the measurement
calculations
Do Offset calibration at any steady level, unless a Sound Velocity calibration is also done.
If both calibrations are done, then do Offset at a known high level, and Sound Velocity at
a known low level.

P650 Offset Calibration
Calibrates Empty (P006) if the reported level is consistently high or low by a fixed amount
(stored in P652).
Values Range –99999 to 99999

• P006 Empty
Related • P652 Offset Correction
• P664 Temperature
Before using this feature, verify the following parameters are correct:
• Empty (P006)
• Temperature (P664)
Parameters
Offset Calibration
mmmmm
Begin with a steady level.
1. Press the measurement key to display the calculated reading.

2. Repeat step 1 at least five times, to verify repeatability.
3. Measure the actual reading (use tape measure).
4. Key in the actual value, and press ENTER .
The deviation between the entered Empty (P006) value and the calibrated Empty value is
stored in Offset Correction (P652).
P651 Sound Velocity Calibration

Calibrates the speed of sound constant.

• P653 Velocity
Related
• P654 Velocity at 20 oC
Use P651 under the following conditions:

• The acoustic beam atmosphere is other than air.
• The acoustic beam atmosphere temperature is unknown.
• The reading accuracy is acceptable only at higher material levels.
For best results, calibrate with the level at a known value close to empty.

Using Sound Velocity Calibration
Ensure a steady level at some low value (P653 and P654 adjusted accordingly).
1. Allow sufficient time for the vapor concentration to stabilize.
2. Press the measurement key to display the calculated reading.
3. Repeat step 2 at least five times to verify repeatability.
4. Measure the actual reading (use tape measure).
5. Enter the actual value.
6. Repeat this procedure if the atmosphere type, concentration, or temperature
conditions are different from when the last sound velocity calibration was
performed.
Note: In gases other than air, the temperature variation may not correspond with the
speed of sound variation. Use P660 and P661 to select a temperature source, and use a
Parameters
fixed temperature.
mmmmm
P652 Offset Correction
Stores the fixed offset value determined when an Offset Calibration is performed.

Related • P650 Offset Calibration
Alternatively, if the amount of Offset Correction required is known, enter the amount to be
added to the Reading before display.
P653 Velocity
Notes:
• P653 can only be accessed by entering the parameter number.
• The user cannot change the value of P653 directly, but can affect it via P654 or by
P660/P661.
Displays the value adjusted based on the Sound Velocity at 20 oC (P654) versus
Temperature (P664) characteristics of air.
Values (view only) Range 50.01 to 2001 m/s (164.1 to 6563 ft/s)
• P651 Sound Velocity Calibration
Related • P654 Sound Velocity at 20 oC
• P660/P661 Temperature setting
The units used depend on the setting for P005:

• m/s if P005 = 1, 2, or 3
• ft/s if P005 = 4 or 5.

P654 Sound Velocity at 20 oC
This value is used to automatically calculate Sound Velocity (P653).
Values Range 50.01 to 2001 m/s (164.1 to 6563 ft/s)

• P005 Units
Related • P651 Sound Velocity Calibration
• P653 Velocity
After performing a sound Velocity Calibration, check this value to verify the acoustic
beam atmosphere in air (344.1 m/s or 1129 ft/s).
Temperature Compensation (P660 to P664)

Parameters
mmmmm
P660 Temperature source

Determines the source of the temperature reading used for calculating speed of sound.
1 * Transducer (P664)
Values
2 Fixed temperature (P661)
Note: Maximum Temperature (P300) always uses the transducer as source: it is not
affected by P660.
P661 Temperature fixed

Defines the fixed temperature (in oC) used for calculating speed of sound if P660 is set to
2 (fixed temperature).
Range –40 to 85 oC
Values
Default 20 (oC)
Use this function when you want to manually override the temperature sensor with a
fixed temperature value.
• Set P660 to 2.
• Enter the fixed temperature value you want to use in place of the sensor
temperature.

P664 Temperature
Displays the temperature (in oC) read from the transducer.
Values Range –40 to 85 (oC)
Rate (P700 and P701)

These parameters determine how material level changes are reported.
P700 Maximum Fill Rate

Allows you to further adjust the SITRANS Probe LU response to increases in the actual
Parameters
material level (or an advance to a higher Failsafe Material Level, P071). P700 is
automatically updated whenever Measurement Response (P003) is altered.
mmmmm
Range 0.0000 to 99999 m / min.
Values
Default 0.100
Altered by P003 Measurement Response
P005 Units
Related
P007 Span
Enter a value slightly greater than the maximum vessel-filling rate, in Units (P005) or
percent of Span (P007) per minute.
P003 Value Meters/Minute

1 0.100
2 1.0000
3 10.000
P701 Maximum Empty Rate

Adjusts the SITRANS Probe LU response to decreases in the actual material level (or an
advance to a lower Failsafe Material Level, P071). P701 is automatically updated
whenever Measurement Response (P003) is altered.
Range 0.0000 to 99999 m / min.

Values
Default 0.100 (m)
P005 Units
Related P007 Span

Enter a value slightly greater than the vessel’s maximum emptying rate, in Units (P005) or
percent of Span (P007) per minute.
P003 Value Meters/Minute

1 0.100
2 1.0000
3 10.000
Measurement Verification (P709 to P713)

P709 Damping Filter
Stabilizes the reported level within the Echo Lock Window (P713) in the event of level
Parameters
fluctuations (for example, a rippling or splashing liquid surface). The value is in seconds,
mmmmm
and depends on the number of seconds it takes the device to reach 63% of a step value
change in reading.
Range 0 to 100.00 seconds (0 = off)

Values
Default 10.000 seconds
P007 Span
Related P713 Echo Lock Window
The value is automatically altered when Measurement Response Speed (P003) changes.
The higher the value entered, the greater the range of stabilized fluctuation.
P711 Echo Lock

Use this feature to select the measurement verification process.
0 Off
1 Maximum Verification
Values
2 * Material Agitator
3 Total Lock
P700 Maximum Fill Rate
P701 Maximum Empty Rate
Related P712 Echo Lock Sampling
P713 Echo Lock Window
P820 Algorithm

If a material agitator or mixer is used in the monitored vessel, set Echo Lock for Maximum
Verification or Material Agitator, to avoid agitator blade detection.
Note: Ensure the agitator is always running while SITRANS Probe LU is monitoring the
vessel, to avoid stationary blade detection.
• When Maximum Verification or Material Agitator is selected, a new measurement

outside the Echo Lock Window (P713) must meet the sampling criterion (P712).
• When Total Lock is selected, Echo Lock Window (P713) is pre-set to 0.
SITRANS Probe LU continuously searches for the best echo according to the algorithm
chosen (P820). If the selected echo is within the window, the window is then centered
about the echo. If not, the window widens with each successive shot until the selected
echo is within the window. The window then returns to its normal width.
When Echo Lock is Off, SITRANS Probe LU responds immediately to a new measurement,
Parameters
as restricted by the Maximum Fill / Empty Rate (P700 / P701). However, measurement
mmmmm
reliability is affected.
P712 Echo Lock Sampling

The sampling criterion sets the number of consecutive echoes that must appear above or
below the echo currently locked onto, before the measurements are validated as the new
reading. (Echo Lock P711 must be set to 1 or 2.)
Range 1:1 to 50:50

Format: x:y
Values
x = the number of above echoes
y = the number of below echoes
Related P711 Echo Lock
P711 default value Description P712 pre-set value

1 maximum verification 5: 5
2 * material agitator 5: 2
Example:
• Set P711 to 2 (material agitator)
• The preset values for P712 in this case are 5:2
• Result: a new reading will not be validated unless 5 consecutive measurements
higher or 2 consecutive measurements lower than the current reading occur.
Note: Resetting P711 returns P712 to the respective pre-set values.

P713 Echo Lock Window
Adjusts the size of the Echo Lock Window. This value is automatically altered when
Measurement Response (P003), Maximum Fill Rate (P700), or Maximum Empty Rate
(P701), are altered.
Range 0.000 to 9999

Values
Default 0.000
P005 Units
Related Parameters P711 Echo Lock
The Echo Lock Window is a ’distance window1, centered on the echo used to derive the
reading. When a new measurement falls within the window, the window is re-centered
Parameters
and the new reading calculated. Otherwise, the new measurement is verified by Echo
Lock (P711) before the reading is updated. The distance value of this parameter is given
mmmmm
for a temperature of 20 oC (68 oF).

When the value is 0, the window is automatically calculated after each measurement.
The value is fixed at 0 if Echo Lock (P711) is set to 3.
• For slower Measurement Response values (P003), the window is narrow.
• For faster P003 values the window becomes progressively wider.
Note: The echo lock window is stored as standard samples, but displayed in units
based on P005. Any value entered for P713 will be rounded to the nearest sample.
P752 HART address

Note: Accessible via the handheld programmer only by keying in P752.
Sets the device address or poll ID on a HART network. Any address other than 0 will
cause the output current to be a fixed value, and the current will not indicate the reading.
Values Range 0 to 15
1.
Units are those set in P005.

Communications (P799)
P799 Communications Control
Enables the read/write access to parameters via remote communications.
0 Read only
Values 1 * Read/write
2 Restricted access – read only except for P799 which is read/write
Notes:
• P799 controls the access if you are using a HART master.
• P000 controls the lock access if you are using the Siemens handheld programmer.
Parameters
mmmmm
Echo Processing (P800 to P825)
The following parameters are for authorized Siemens Service personnel or technicians
familiar with Siemens echo processing techniques. View the echo profile first, before
attempting to modify these parameters.
P800 Near Blanking 1

Defines the distance from the transducer face to be ignored by the transmitter/receiver.
0.000 to 6.000 m (20 ft) or

Range
0.000 to 12 m (40 ft)
Values (depends on model)
(units selected in P005)
Default 0.250 m (0.820 ft)
P006 Empty
Related P007 Span
P838 Auto False-Echo Suppression Distance
To extend the blanking beyond the minimum default, enter a value in the units selected in
P005.
1.
For more details, see Blanking Distance on page 83.

P801 Range Extension
Note: SITRANS Probe LU has an absolute maximum range of 7.2 m (23.6 ft). or 14.4 m
(47.24 ft), depending on the model.
Allows the material level to drop below Empty (process empty level), without generating
an LOE state.
Range 0 to 25 (% or units)
Values
Default 20.000 (% of Span)
P006 Empty
Related P007 Span
Parameters
Use this feature if the surface monitored can drop below Empty level (P006) in normal
operation. The value for P801 is added to Empty, and the sum can be greater than the
mmmmm
range of the transducer. Range Extension can be increased (in Units or percent of Span)
to a point where Empty plus Range Extension is greater than the distance from the
transducer face to the furthest surface to be monitored. (The distance below empty is not
blanked.)
• Enter the value as a percentage of P006.
• For vessels with conical or parabolic bottoms, increase the value for P801 to ensure
that an empty vessel reads Empty.
P804 Confidence Threshold

Determines which echoes are evaluated by software.
x:y
Format x = short (range 0 to 99)
Values y = long (range 0 to 99)
Default 10:5
Related Parameters P070 Failsafe Timer
P804 sets the minimum echo confidence that the echo must meet in order to prevent a
Loss of Echo condition and the expiration of the Failsafe timer (P070).
The short and long shot Confidence Thresholds are preset to 10 and 5 respectively. When
Echo Confidence (P805) exceeds the Confidence Threshold, the echo is evaluated by
Sonic Intelligence.
• Key in the value for the short shot, then press (decimal point).
• Key in the value for the long shot, then press ENTER .

P805 Echo Confidence
Measures echo reliability. It displays the echo confidence of the measurement echo from
the last shot. P804 defines the minimum criterion for echo confidence.
x:y
Format x = short (range 0 to 99)
Values (view only) y = long (range 0 to 99)
---- (Shot not used)
P804 Confidence Threshold
Related Parameters P830 TVT Type
Press the measurement key to get a new reading that will update confidence
values.
Parameters
Both short and long shot Echo Confidence values are displayed.
mmmmm
Display Description
x : -- short shot confidence value, (long shot not used)
-- : y long shot confidence value, (short shot not used)
x:y short and long shot confidence values (both used)
E transducer cable is open or short circuited
-- : -- no shots were processed for Sonic Intelligence evaluation
P806 Echo Strength

Displays the absolute strength (in dB above 1 µV rms) of the echo selected as the
measurement echo.
Values (view only) Display –20 to 99
Press the measurement key to get a new reading that will update echo strength.

P807 Noise
Displays the average and peak ambient noise of a noise profile (in dB above 1 µV rms)
as x.y. Noise level is a combination of transducer acoustic noise and receiving circuitry
noise.
x:y
Values (view only) Format x = average (range: –20 to 99)
y = peak (range: –20 to 99)
After a measurement, the values from the previous noise shot will be displayed. Press the
measurement key to get a new reading that will update the noise profile.
Algorithm (P820)
Parameters
mmmmm
P820 Algorithm
Selects the algorithm to be applied to the echo profile to extract the true echo.
3 Largest echo (L)

4 Reserved
Values
8 * best of Largest or First echo (bLF)
12 First echo (F)
For more clarification on the different options, please contact your local representative.
P825 Echo marker trigger

The point on the primary echo on which the measured value is based. The value is
entered in percent of echo height, which allows the Echo Lock Window to be set so that it
intersects the Echo Profile at the sharpest rising portion of the Echo Profile.
Range 5 to 90%
Values
Default 50 (%)

TVT (Time Varying Threshold) Adjustment Parameters
(P830 to P839)
First SITRANS Probe LU learns the echo profile. Then the learned profile, or part of the
learned profile, is used to screen out false echoes.1
The following parameters are for authorized Siemens Service personnel or technicians
familiar with Siemens echo processing techniques. View the echo profile first, before
attempting to modify these parameters.
P830 TVT Type

Selects the TVT Curve used.
Parameters
1 * TVT Short Curved
mmmmm
2 TVT Short Flat
3 TVT Long Flat

Values
4 TVT Long Smooth Front
5 TVT Long Smooth
6 TVT Slopes
Altered By • P002 Material
Related • P805 Echo Confidence
Select the TVT type which gives the highest confidence (P805) under all level conditions.
Use this parameter with caution, and do not use TVT Slopes with the F (First) or bLF (best
of Largest or First echo) Algorithm (P820).
P831 TVT Shaper

Note: This parameter is for use by Siemens Service personnel.
Turns the TVT Shaper ON or OFF.
1.
For more detail, see TVT (Time Varying Threshold) curves on page 83.

P832 TVT Shaper Adjust
Note: This parameter is for use by Siemens Service personnel.
Allows manual adjustment of the TVT curve.
P837 Auto False-Echo Suppression

Use P837 and P838 together, to set SITRANS Probe LU to ignore false echoes1. Use P838
to set the Auto TVT distance first.
Notes:
• This function works best when the vessel is empty or nearly empty: use it only if
there is a minimum distance of 2 meters from the transducer face to the material.
Parameters
• Set P837 and P838 during start up, if possible.

mmmmm
• If the vessel contains an agitator, the agitator should be running.
If SITRANS Probe LU displays a full level, or if the reading fluctuates between a false high
level and a correct level, set P837 to elevate the TVT in this region and to de-sensitize the
receiver from any ‘base noise’ caused by internal transducer reflections, nozzle echoes,
or other vessel false echoes. Set P838 and then P837 (detailed instructions follow P838).
0 * Off
Use ’learned’ TVT. (See ’learned TVT curve’ in Display
Values 1
after Auto False Echo Suppression on page 61.)
2 Learn
Display before Auto False Echo Suppression

(or when P837 = 0)
default TVT
true P839
echo Hover Level
Level (db)
false
echo
Distance (meters)
1.
For more detail, see TVT (Time Varying Threshold) curves on page 83.

Defines the range of Auto False-Echo Suppression (P837) to use for ignoring false
echoes. (Units are defined in P005.)
Maximum range:
Range
0.000 to 6.000 m (20 ft) or
Values (depends on model)
0.000 to 12 m (40 ft)
Default 1.000 m (3.28 ft)
Determine the actual distance from the transducer face to the material surface. Subtract
0.5 m from this distance, and enter the result.
Set Up:
Parameters
1. Perform this function when the vessel is empty or nearly empty.
2. Determine actual distance from transducer face to material level.
mmmmm
3. Select P838 and key in [distance to material level minus 0.5 m].
4. Press ENTER .
5. Select P837.
6. Press 2 and then press ENTER . P837 will revert to 1 (use Learned TVT)
automatically after a few seconds.
TVT curve
material
(learned)
level
Level (db)
false
echo
Distance (meters)

P839 TVT Hover Level
Defines (in percent) how high the TVT curve is placed above the profile, relative to the
largest echo. When SITRANS Probe LU is located in the center of the vessel, lower this
parameter to prevent multiple echo detections.
Range 0 to 100%
Values
Default 33 (%)
Diagnostic Tests (P900 to P924)

P900 Software Revision Number
Parameters
Displays the software revision level.

mmmmm
Values (view only) Range 0.00 to 99.99

1 Main code revision
2 Primary boot revision
Secondary index 3 Alternative boot revision
4 Hardware stack revision
Default Determined by the software revisions installed
1. Select P900.
2. The secondary index number is visible in the auxiliary reading field.
3. Press DISPLAY twice to focus control on the secondary index (the auxiliary
4. Key in the index number required, and press ENTER .
5. The software revision level associated with the new secondary index appears.
desired parameter.

P901 Memory Test
Press ENTER to activate the test.
IdLE Normal operation
PASS Memory test successful
Values (view only) F1 Fail RAM
F2 Fail EEPROM
F3 Fail FLASH
Measurement
P911 mA Output Value
Parameters
mmmmm
Access this parameter to display the current value of the mA output.
Range 3.6 to 22.6 (mA)

Values (HART)
Default 4 mA in HART fixed current mode
1. Set P201 to 0 (manual).

2. Enter a test value.
Note: P201 must be set to 0 to enable the test value to be entered at P911: be sure to
restore P201 to the previous setting after the test!
P912 Temperature
Displays the temperature in oC (as monitored by the connected transducer). This value is
not affected by Temperature Source (P660).
Values (view only) Range –40 to 85 (oC)

P920 Reading Measurement
P920 corresponds to the final reading after all programming is applied. It is a copy of one
of P921 to P924, depending on the setting for Operation (P001).
Operation P001 Source Parameter for P920

0 Off ––––
Related
1 Level P921 if P050 = 0, otherwise P924
parameters
2 Space P922
3 Distance P923
P920 Values –99999 to 99999 (dimensional units, if volume
Range:
(view only) has not been selected)
Parameters

(P001 = 1) (P001 = 2) (P001 = 3)
mmmmm
transducer 4 mA
face 0%
20 mA Span 4 mA
Space
P007
P006
Level
Empty Empty
Empty 0% 100% 100%
4 mA 20 mA 20 mA
P921 Material Measurement

Displays the distance between Empty /process empty level (P006) and the monitored
surface, in Units (P005) or percent of Span (P007).
Values (view only) Range –99999 to 99999
P922 Space Measurement

Displays the distance between the monitored surface and Span / process full level (P007).

P923 Distance Measurement
Displays the distance between the monitored surface and the transducer face.
P924 Volume (or Flow) Measurement

The calculated vessel capacity in Maximum Volume (P051) or percent of Maximum
Volume (volume calculation must be enabled at P050).
Range : –99999 to 99999

Values (view only) Display when volume calculation is not
----
enabled at P050 (P050 = 0)
Parameters
P051 Maximum Volume
Related Parameters
P050 Vessel (or Channel) Shape
mmmmm
P999 Master Reset
Note: Following a Master Reset, complete reprogramming is required.
Resets all parameters to their factory settings, with the following exceptions:
• P000 and P069 are not reset.
• The learned TVT curve is not lost.
Use this feature after upgrading software:
1. Select P999.
2. Press CLEAR then ENTER to Clear All and initiate reset.
3. Reset complete.
(Note: Reset takes several
seconds to complete.)

Parameters Notes
mmmmm

Appendix B: Programming Chart
Number Parameter Name Value
000 P000 Lock
001 P001 Operation
002 P002 Material to be monitored
003 P003 Measurement Response
005 P005 Units
006 P006 Empty (process empty level)
B: Programming Chart
007 P007 Span (process full level)
010 P010 Language
mmmmm
050 P050 Vessel (or Channel) Shape
051 P051 Maximum Volume
052 P052 Vessel Dimension A
053 P053 Vessel Dimension L
054 P054 Level or Head Breakpoints
055 P055 Volume or Flow Breakpoints
069 P069 Unlocked value
070 P070 Failsafe Timer
071 P071 Failsafe Material Level
073 P073 Failsafe level
201 P201 mA Output Function
210 P210 4 mA Setpoint (low output)
211 P211 20 mA Setpoint (high output)
212 P212 Minimum mA limit
213 P213 Maximum mA limit
214 P214 4 mA Output Trim
215 P215 20 mA Output Trim
300 P300 Temperature, transducer maximum
341 P341 RUN Time
342 P342 Power-On Resets
343 P343 Internal Temperature
650 P650 Offset Calibration
651 P651 Sound Velocity Calibration
652 P652 Offset Correction

653 P653 Velocity
654 P654 Sound Velocity at 20 oC
660 P660 Temperature source
661 P661 Temperature fixed
664 P664 Temperature
700 P700 Maximum Fill Rate
701 P701 Maximum Empty Rate
709 P709 Damping Filter
711 P711 Echo Lock

712 P712 Echo Lock Sampling
mmmmm
713 P713 Echo Lock Window

799 P799 Communications Control
800 P800 Near Blanking
801 P801 Range Extension
804 P804 Confidence Threshold
805 P805 Echo Confidence
806 P806 Echo Strength
807 P807 Noise
820 P820 Algorithm
825 P825 Echo marker trigger
830 P830 TVT Type
831 P831 TVT Shaper
832 P832 TVT Shaper Adjust
837 P837 Auto False-Echo Suppression
838 P838 Auto False-Echo Suppression Distance
839 P839 TVT Hover Level
900 P900 Software Revision Number
901 P901 Memory Test
911 P911 mA Output Value
912 P912 Temperature
920 P920 Reading Measurement
921 P921 Material Measurement
922 P922 Space Measurement

923 P923 Distance Measurement
924 P924 Volume (or Flow) Measurement
999 P999 Master Reset
mmmmm

mmmmm

Appendix C: HART Communications
Highway Addressable Remote Transducer, HART, is an industrial protocol that rides on
top of a 4-20 mA signal. It is an open standard, and full details about HART can be
obtained from the HART Communication Foundation at www.hartcomm.org
SITRANS Probe LU can be configured over the HART network using either the HART
Communicator, or a software package. There are a number of different software
packages available, and the SITRANS Probe LU should work well with any of them. The
recommended software package is the SIMATIC Process Device Manager (PDM) by
Siemens.
HART Electronic Device Description (EDD)

Note: SITRANS Probe LU (HART) cannot be configured using a generic EDD.
In order to configure a HART device, the configurator must have the HART Electronic
Device Description for the device in question. HART EDD’s are controlled by the HART
Communication Foundation.
C: HART Communications
Please contact your local Siemens representative concerning the availability of the HART
EDD for SITRANS Probe LU. Older versions of the library will have to be updated in order
to use all the features in the SITRANS Probe LU.
mmmmm

HART Communicator 275/375:
Chart 1
On Line PV
1. PV 1. PV is Level
2. Level 2. SV is Space
3. % Range 3. TV is Distance
4. AO 4. 4V is Volume
5. Device Setup
6. Refresh
Device Setup Quick Setup

1. Master Reset 1. Units
2. Quick Setup 2. Empty Wear Sensor Status
3. Display 3. Span 1. Run Time 1. Hardw/Firmw fail
4. Diagnostics 4. Language 2. number resets 2. Diagnostic warn
5. PV Exchange 5. Operation 3. Max Temp 3. Reading question
6. Device Data 6. Material 4. Int Temp 4. Simulation mode
7. Rate 7. Response
8. Review Status
Electronics Status
Display 1. Sensor status
1. RAM error
1. Level 2. Electronics status
2. ROM error
2. Space 3. Software status
3. FLASH error
3. Distance 4. Application status
4. Stack overflow
4. Volume
5. Error signal Self Test
1. Self Test Software Status
Diagnostics 1. Calib error
1. Wear 2. Temp out of range
2. Status Range Calibration
3. Self Test 1. Offset Application Status
4. Range Calibration 2. Velocity at 20 1. Loss of echo
5. trim analog output 3. Offset Calib 2. Failsafe

6. Simulate AO 4. Snd Vel Calib
PV Exchange Trim Analog Output

1. Read Analog Out 1. D/A trim
2. Select Analog Out 2. Scaled D/A trim
mmmmm
Simulate AO
1. 4 mA
2. 20 mA
3. Other
4. End
Device Data Units
1. Units 1. Units
2. Basic Setup
3. Detailed Setup
Basic Setup (See Chart 2 )
4. Output param
5. Device information
6. HART information Detailed setup (See Chart 3)
Rate
1. Max Fill Output param (See Chart 4)
2. Max Empty
Device information
1. Tag
Review 2. Descriptor
(all parameters)
3. Message
4. Final asmbly num
Manufacturer data
5. Last config
6. Manufacturer data 1. Serial No
2. Revision
HART information
1. Manufacturer
2. Model
3. HART Dev ID
4. Universal rev
5. Fld dev rev
6. Software rev
7. Hardware rev

Chart 2
Standard Setup
Basic Setup
1. URV
1. Master Reset 2. LRV
2. Standard Setup 3. Damping
3. Quick Setup
4. Sensor Temp Quick Setup
5. Volume 1. Units
6. Failsafe 2. Empty
3. Span
4. Language
5. Operation
6. Material
7. Response
Sensor Temp
1. Temp Source
2. Temp Fixed
3. Sensor Temp
4. Sensor Temp
Volume Shape
1. Shape no volume
2. Max Vol calculation
3. Dim A no volume calculation
4. Dim L flat level bottom
5. Bk LevVol Gr cone/pyramid bottom
parabol bottom
half sphere bottom
Failsafe flat sloped bottom
1. mA Function cylinder flat ends
2. FS Timer cylinder parabol end
sphere
3. FS default measure
4. FS Advance universal linear
5. FS level val
Bk LevVol Gr
Bk LevVol 1_32
mmmmm

Chart 3
Echo Lock Echo Lock
Detailed Setup Shaper V1_10
1. Echo Lock mat agitator
2. Sampling Up off 1. TVT breakpoint 1
1. Echo Lock max verific
3. Sampling Down 2. TVT breakpoint 2
2. Echo Select mat agitator
4. Window 3. TVT breakpoint 3
3. TVT Setup total lock
4. Echo Quality 4. TVT breakpoint 4
Echo Select algorithm 5. TVT breakpoint 5
1. Algorithm bLF 6. TVT breakpoint 6
2. Blanking L 7. TVT breakpoint 7
3. Rng Ext F 8. TVT breakpoint 8
4. Marker bLF
tF 9. TVT breakpoint 9
TVT breakpoint 10
Auto TVT
Shaper V1_20
off
TVT Setup off 1. TVT breakpoint 11
on 2. TVT breakpoint 12
1. Auto TVT learn
2. Range 3. TVT breakpoint 13
3. Hover P831-Mode 4. TVT breakpoint 14
4. P831-Mode off 5. TVT breakpoint 15
5. TVT Type off 6. TVT breakpoint 16
on 7. TVT breakpoint 17
6. Shaper Val
TVT type 8. TVT breakpoint 18
short curved 9. TVT breakpoint 19
Echo Quality short flat TVT breakpoint 20
long flat
1. Confidence short long smooth flat Shaper V21_30
2. Confidence long slopes
3. Strength Shaper Val 1. TVT breakpoint 21
4. Noise Average 2. TVT breakpoint 22
1. Shaper V1_10
5. Noise Peak 3. TVT breakpoint 23
2. Shaper V1_20
6. Threshold short 4. TVT breakpoint 24
3. Shaper V21_30
7. Threshold long 5. TVT breakpoint 25
4. Shaper V31_40
6. TVT breakpoint 26
TVT breakpoint 30
Shaper V31_40
mmmmm
TVT breakpoint 40

Chart 4
Output param Analog Output
1. Analog output 1. Read Analog Out FS default measurement

2. Apply values Apply values 2. mA Function
3. Local Display 1. 4 mA 3. FS default measure hold
4. HART output 2. 20 mA 4. Min mA hold
3. Exit 5. Max mA high
6. Low Setpoint low
7. High Setpoint select
Local Display
1. Write protect
2. Lock
3. Write Protect
4. unlock value
HART Output
1. Poll addr
2. Num req preams
3. Num resp preams
SIMATIC Process Device Manager (PDM):

This software package is designed to permit easy configuration, monitoring and
troubleshooting of HART devices. The HART DD for the SITRANS Probe LU was written
with SIMATIC PDM in mind and has been extensively tested with this software.
The Device Description for SIMATIC PDM may be downloaded from the product page of
our website at: https://pia.khe.siemens.com/index.asp?Nr=11157, under Downloads.
All parameters accessible via the HART Communicator are also accessible via PDM. In
mmmmm
addition, the Maintenance parameters listed below are accessible via PDM only.
Maintenance settings (accessible via PDM only)

Device Lifetime
Total Device Operating Time
Remaining Device Lifetime
Maintenance Required Limit
Maintenance Demanded Limit
Maintenance Alert Activation
Total Expected Device Life
Units
Maintenance Status
Acknowledge Status
Acknowledge

Sensor Lifetime
Total Sensor Operating Time
Remaining Sensor Lifetime
Total Expected Sensor Life
Units
Maintenance Status
Acknowledge Status
Acknowledge
Service Interval
Time Elapsed Since Last Service
Total Service Interval
Units
Maintenance Status
Acknowledge Status
Acknowledge
Calibration Interval
Time Elapsed Since Last Calibration

mmmmm
Total Calibration Interval

Units
Maintenance Status
Acknowledge Status
Acknowledge
HART Version
The SITRANS Probe LU (HART) conforms to HART rev. 5.
Burst mode
SITRANS Probe LU (HART) does not support burst mode.
Multidrop Configuration
SITRANS Probe LU (HART) does not support multidrop configuration.

Appendix D: Troubleshooting
Communication Troubleshooting
Generally:
1. Check the following:
• There is power at the unit
• The LCD shows the relevant data
• The device can be programmed using the handheld programmer
2. Verify that the wiring connections are correct.
Specifically:
If you try to set a SITRANS Probe LU parameter via remote communications, but the
parameter remains unchanged:
• Some parameters can only be changed when the device is not scanning. Try putting
the device in program mode using the operating mode function.
• Try setting the parameter from the keypad. (First make sure that the lock parameter
[P000] is set to the value stored in P069.)
• The communications control parameter P799 must be set to 1 to be able to write
parameters to SITRANS Probe LU.
D: Troubleshooting
mmmmm

General Fault Code
Note: Some faults cause the device to go to Failsafe mode (Fault 52). These are indicated
with an asterisk (*).
Code Meaning Corrective Action

S:0 * The device was unable to get a measurement Ensure installation details are
within the Failsafe Timer period. Possible correct. Ensure no antenna buildup.
causes: faulty installation, antenna buildup, Adjust process conditions to
foaming/other adverse process conditions, minimize foam or other adverse
invalid calibration range. conditions. Correct range
calibration. If fault persists, contact
your local Siemens representative.
S:2 * The device is operating in a low power Correct the power supply
condition that is outside its operating range. (resistance or voltage).
As a result, a valid measurement has not been
taken for the failsafe timer period, and the
device will be put into failsafe mode.
S:3 Device is nearing its lifetime limit according to Replacement is recommended.

the value set in Maintenance Required Limit.
S:4 Device is nearing its lifetime limit according to Replacement is recommended.

the value set in Maintenance Demanded Limit.
S:6 Sensor is nearing its lifetime limit according to Replacement is recommended.

the value set in Maintenance Required Limit.
S:7 Sensor is nearing its lifetime limit according to Replacement is recommended.

the value set in Maintenance Demanded Limit.
S:8 Service interval as defined in Maintenance Perform service.

Required Limit has expired.
D: Troubleshooting
S:9 Service interval as defined in Maintenance Perform service.

Demanded Limit has expired.
mmmmm
S:11 Internal temperature sensor failure. Repair required: contact your local
Siemens representative.

Code Meaning Corrective Action (cont’d)
S:12 Internal temperature of device has exceeded Relocate device and/or lower
specifications: it is operating outside its process temperature enough to
temperature range. cool device. Inspect for heat-
related damage and contact your
local Siemens representative if
repair is required.
S:17 Calibration interval as defined in Maintenance Perform calibration.

Required Limit has expired.
S:18 Calibration interval as defined in Maintenance Perform calibration.

Demanded Limit has expired.
S:28 * Internal device failure caused by a RAM Repair required: contact your local
memory error. Siemens representative.
S:29 * EEPROM damaged. Repair required: contact your local

S:31 * Flash error. Repair required: contact your local

S:33 * Factory calibration for the internal Repair required: contact your local
temperature sensor has been lost. Siemens representative.
S:34 * Factory calibration for the device has been Repair required: contact your local
lost. Siemens representative.
S:35 * Factory calibration for the device has been Repair required: contact your local
lost. Siemens representative.
S:36 * Unable to start microwave module. Reset power. If error persists,

contact your local Siemens
representative.
D: Troubleshooting
S:37 * Measurement hardware problem. Reset power. If error persists,
mmmmm
representative.
S:38 * Failure in the device electronics. Reset power. If fault persists,

representative: repair required.

S:39 * Transducer temperature sensor failure.. Reset power. If fault persists,
representative: repair required.
S:40 Transducer temperature too high. Relocate device and/or lower

process temperature enough to
cool device. Inspect for heat-
related damage and contact your
local Siemens representative if
repair is required.
S:41 Transducer temperature too low. Relocate device and/or raise

process temperature enough to
warm device. Inspect for damage
and contact your local Siemens
representative if repair is required.
S:42 Factory calibration for the transducer Repair required: contact your local
temperature sensor has been lost. Siemens representative.
S:43 * Factory calibration for the radar receiver has Repair required: contact your local
been lost. Siemens representative.
S:44 * Factory calibration for the echo slope has Repair required: contact your local
been lost. Siemens representative.
S:45 * No valid boot program detected: firmware Repair required: contact your local
corrupt. Siemens representative.
S:48 * User configuration is invalid. One or more of Reconfigure the unit. Ensure Span
parameters: Span, Volume breakpoints, and/or (P007) is not set to 0; check the
Auto False-Echo Suppression, are set to breakpoints (only required if P050 is
invalid values. set to 9); do a P999 reset.
D: Troubleshooting
S:49 * EEPROM corrupt. Repair required: contact your local

mmmmm


S:52 Failsafe is activated. Possible causes: 1) For 3) and 4) Correct configuration;

hardware failure; 2) memory failure; 3)Fault 48; ensure installation is correct; no
4) failsafe timer expired– possible causes: antenna buildup; adjust process
faulty installation, antenna buildup, foaming/ conditions to minimize foaming/
other adverse process conditions, invalid other adverse conditions; correct
calibration range. calibration range. If fault persists,
or for 1) and 2), contact your local
S:53 * Configuration lost: one or more parameter Restore user parameters using
settings have been lost. This may occur after SIMATIC PDM.
a firmware upgrade causes user parameters
to be reset.
Operation Troubleshooting
Operating symptoms and probable causes.1
Symptom Meaning Probable cause
• material or object in contact with transducer face
status symbol
• transducer face is too close to the fill point
flashes • transducer face is not perpendicular to the liquid
surface
Failsafe timer starts
• change in level too fast
running.
• measurement out of range
• foam on liquid surface
• high level of vibration in the mounting structure
• level inside the blanking zone
D: Troubleshooting
status symbol
does not flash,
and LOE
mmmmm
alternates The `Waiting' period

has expired.
with reading
Refer to P003 Measurement Response on page 31, or P070 Failsafe Timer on page 41, for
duration of `Waiting' periods.
1.
For details on blanking, see Blanking Distance on page 83.

Appendix E: Maintenance
SITRANS Probe LU requires no maintenance or cleaning.
Unit Repair and Excluded Liability

All changes and repairs must be done by qualified personnel, and applicable safety
regulations must be followed. Please note the following:
• The user is responsible for all changes and repairs made to the device.
• All new components must be provided by Siemens Process Instruments Inc.
• Restrict repair to faulty components only.
• Do not re-use faulty components.
E: Maintenance

Appendix F: Technical References
F: Technical References
mmmmm
Principles of operation
The transducer emits a series of ultrasonic pulses: each pulse is reflected as an echo
from the material and sensed by the transducer. The echo is processed by
SITRANS Probe LU, using Siemens ’ proven Sonic Intelligence techniques. Filtering is
applied to help discriminate between the true echo from the material, and false echoes
from acoustic and electrical noises and agitator blades in motion.
The time for the pulse to travel to the material and back is temperature compensated and
then converted into distance for display and mA output.
Blanking Distance
The crystal which produces the transmit pulse has to stop vibrating before it can receive
an echo. The blanking1 distance is the space in front of the transducer face where level
measurement is not possible, because within that distance, the echo would return before
the vibration had ceased.
The reference point for measuring blanking distance is the transducer face. The minimum
recommended blanking value is 0.25 m (10"), but this can be increased in order to extend
the blanking.
TVT (Time Varying Threshold) curves

A TVT curve describes a threshold below which any echoes will be ignored. The default
TVT curve is used, until P837 and P838 are used to create a new ’learned TVT curve’.
Auto False-Echo Suppression

False echoes can be caused by an obstruction in the beam path (pipes, ladders, chains,
and such). Such false echoes may rise above the default TVT curve.
P838 allows you to set a distance, and P837 then instructs the Probe LU to ’learn’ where
the obstructions/false echoes are within that distance. The new TVT curve is set above
the false echoes, screening them out.
1. Also referred to as "Near Blanking".

F: Technical References Display before Auto False Echo Suppression
(or when P837 = 0)
mmmmm
default TVT
true P839
echo Hover Level
Level (db)
false
echo
Distance (meters)
TVT curve
material
(learned)
level
Level (db)
false
echo
Distance (meters)

Open Channel Monitoring (OCM)
OCM converts a level reading (head) into a flow value using a linear algorithm.
SITRANS Probe LU can convert a head level measurement into a flow rate, using a thirty-
mmmmm
two breakpoint head-versus-flow characteristic curve. This chart is usually available
from the manufacturer of the v-notch weir, Parshall flume, or other open channel device.
Parameter P050 must be set to 9 (universal linear function), and breakpoints must be set
for head levels and corresponding flowrates at parameters P054 and P055. Once these
parameters are set, the mA output is scaled to represent the flowrate, and the RUN mode
display will show the flowrate
Example: Flow Characterization.
11
10
9
flow (P055)
8
7
6
5
4
3
2
1
1 2 3 4 5 6 7 8 9 10 11
head (P054)
The maximum and minimum points on the curve must be defined. Then program the
remaining breakpoints to closely match the flow curve of your open channel device.
Failsafe
The Failsafe function can be activated either if there is not a valid measurement, or by
one of the faults marked by an asterisk in the table General Fault Code on page 78. In
Failsafe mode, the device will output one of the four options determined by P071 (Failsafe
Material Level).
Failsafe Mode P071

1 = HI Use Maximum mA Limit (P213) as material level
2 = LO Use Minimum mA Limit (P212) as material level
3 = HOLd Level remains at last reading
4 = SEL User-selected value (defined in P073)

If an invalid measurement is generated by the application (for example, material level
outside threshold settings), the Failsafe timer (P070) will control the speed of the Failsafe
response. When the Failsafe timer expires, the device outputs the value selected in P071.
If a valid measurement is received before the timer expires, the timer will be reset.
If Failsafe mode is activated by a fault (see General Fault Code on page 78), the
mmmmm
instrument will go into Failsafe mode without delay.
Chemical compatibility
The plastic materials used in the construction of SITRANS Probe LU (ETFE, PBT, and
PVDF) are resistant to attack from most chemicals. For exposure to specific
environments, check with chemical compatibility charts before installing and operating
SITRANS Probe LU in your application.
Startup Behavior
Notes:
• SITRANS Probe LU (HART) is designed to start reliably with a power supply
capable of delivering at least 25 mA.
• When connected to a power supply with a current limit of < 25 mA, the Probe LU
may not start reliably.
Typical Startup Current
35
Loop Power Supply
30
without Current Limit
25
Current (mA)
20
Loop Power Supply with
15 25 mA Current Limit
10
0
0 2 4 6 8 10 12 14 16
Time (seconds)
No
withcurrent
currentlimit
limited power supply Current-limited
without current power
limited power supply

Appendix G: Hazardous area
installations
• Wiring details
• Instructions specific to hazardous area installations
Wiring Details
Intrinsically Safe Model
G: Hazardous Installation
FM (reference drawing 23650516: see page 92)
CSA (reference drawing 23650517: see page 94)
mmmmm
Under the entity evaluation concept, SITRANS Probe LU has the following
characteristics:
(input voltage) Ui = 30 V DC (max.)

(input current) Ii = 120 mA DC (max.)
(input power) Pi = 0.8 W
Definition:
The Entity Concept allows interconnection of intrinsically safe apparatus to associated
apparatus not specifically examined in such combination. The criteria for interconnection
is that the voltage and current which intrinsically safe apparatus can receive and remain
intrinsically safe, considering faults, must be equal to or greater than the output voltage
(Uo) and output current (Io) levels which can be delivered by the associated apparatus,
considering faults and applicable factors. In addition, the maximum unprotected
capacitance (Ci) and Inductance (Li) of the intrinsically safe apparatus, including
interconnecting wiring, must be equal to or less than the capacitance and inductance
which can be safely connected to associated apparatus.

FM/CSA
• Approved dust-tight and water-tight conduit seals are required for outdoor
NEMA 4X / type 4X / NEMA 6, IP67, IP68 locations.
• The maximum voltage of the non-intrinsically safe apparatus must not exceed 250 V rms.
• Recommended intrinsically safe barriers are listed on page 89.
Hazardous Area Non-hazardous Area
load EEx ia
4 – 20
Certified Barrier
mA
2
2
mmmmm
PLC (active)
Zone 0, 1, or 2
HART handheld
Communicator
EU Equivalency
Any zener diode safety barrier, certified by an EU approved certification body to
[ EEx ia ] IIC, its output voltage (Uo) not exceeding 30 V and its output current (Io) limited
by load resistance (Ro); such that Io = Uo / Ro, does not exceed 120 mA.

Loop Voltage versus Loop Resistance
Power Supply Requirements
1000
900 (30.0v,845 ohms)
800
L
RL=44.6*VL - 493.4
Loop Resistance - R
700
600
500
400
(17.8v, 300 ohms)
300
mmmmm
RL=272.7*VL - 4554.1 ALLOWABLE OPERATING
200 AREA
100
(16.7v, 0 ohms)
0
10.00 15.00 20.00 25.00 30.00
Loop Voltage-VL
(Source voltage)
IS Safety Barrier Selection

Selecting a suitable barrier or power supply requires knowledge about Intrinsic Safety
and the application. It is the responsibility of the installer to ensure that the intrinsically
safe installation complies with both the apparatus approval requirements and the
relevant national code of practice.
How to select a passive barrier for SITRANS Probe LU

1. Make sure that the barrier safety description is suitable for the SITRANS Probe LU
Intrinsically Safe (IS) input parameters.
2. Determine the maximum end-to-end resistance of the barrier (Re-e) from the data
sheet.
3. Determine other loop resistance (Rloop): for example, sense resistance, displays,
and/or PLC inputs.
4. Calculate Rworking = Re-e + Rloop.

5. Determine any non-linear voltage drops due to the barrier (Vbarrier) from the barrier
data sheet (for example, voltage drops due to diodes).
6. Calculate Vworking = Vsupply – Vbarrier.
7. Using Vworking and Rworking, confirm that operation is within the shaded area of
the graph Loop Voltage versus Loop Resistance on page 89.
Notes:
• The following list is not complete: there are many safety barriers on the market,
which will work with the SITRANS Probe LU.
• The barriers listed below have all been tested and are functionally compatible with
the SITRANS Probe LU.
• The barriers listed below are all HART compatible.
PLC Input Modules

mmmmm
Manufacturer Part Number

Siemens SM331 PCS7 HART Input Module
Passive Shunt Diode Barriers

Note: A well regulated supply voltage is required.

MTL 7787P+ (Dual channel)
Stahl 9001/01-280-100-10 (Single channel)
Stahl 9002/01-280-110-10 (Dual channel)
Active barriers (repeating barriers)

Siemens 7NG4122-1AA10
MTL 706
MTL 7206
Stahl 9001/51-280-110-14

Product Nameplate
SITRANS Probe LU
7ML1234-78910-ABC-D Encl.: NEMA/TYPE 4X, 6, IP67, IP68
Serial No: GYZ / S1034567 Amb.Temp.: – 40°C to 80°C
Power Rating: 24V Nom., 30V Max., 4-20 mA
Siemens Milltronics Process Instruments Inc., Peterborough
Made in Canada
Refer to drawing: 23650516 Ui = 30 V, II 1G
Class I, Div 1. Group A, B, C, D Ii = 120 mA,
mmmmm
EEx ia IIC T4
Class II, Div 1, Group E, F, G Pi = 0.8 W
Class III Ci = 3.6 nF, SIRA 03ATEX2142X
Li = 0
HART
WARNING: Possible static hazard, do not rub or clean on site.

mmmmm
Page 92
HAZARDOUS AREA NON-HAZARDOUS AREA
SAFE AREA APPARATUS

Load
4 – 20 mA
NOTES:
INTRINSICALLY SAFE
1. ANY CSA / FM INTRINSICALLY SAFE BARRIER / POWER SUPPLY, WITH ITS OUTPUT (SEE NOTE 1)
VOLTAGE (Uo) NOT EXCEEDING 30 V AND ITS OUTPUT CURRENT (Io) LIMITED BY
LOAD RESISTANCE (Ro); SUCH THAT Io = Uo / Ro, DOES NOT EXCEED 120 mA
2. APPROVED DUST-TIGHT AND WATER-TIGHT CONDUIT SEALS ARE REQUIRED

FOR CLASS II, DIV.1, Gr. E, F, G AND OUTDOOR NEMA 4X/TYPE 4X LOCATIONS
3. THE MAXIMUM VOLTAGE OF THE NON-INTRINSICALLY SAFE APPARATUS

MUST NOT EXCEED 250 V rms.
4. UNDER THE ENTITY EVALUATION CONCEPT, THE SITRANS Probe LU HAS THE
FOLLOWING:
Ui = 30 VOLTS D.C. Ii = 120 mA Pi = 0.8W
Ci = 3.6 nF Li = 0
5. SUBSTITUTION OF COMPONENTS MAY IMPAIR INTRINSIC SAFETY.
6. INSTALL PER NEC / CEC
7. USE SUPPLY WIRES RATED FOR 10 ° ABOVE.
8. EXTERNAL BONDING HUBS ARE REQUIRED WHEN BOTH CONDUIT ENTRIES ARE USED.
THE ENTITY EVALUATION CONCEPT IS A METHOD USED TO DETERMINE

ACCEPTABLE COMBINATIONS OF INTRINSICALLY SAFE APPARATUS AND
DEC
SITRANS Probe LU (HART) – INSTRUCTION MANUAL

CONNECTED ASSOCIATED APPARATUS THAT HAVE NOT BEEN 0 FOR APPROVAL RPC SN 17/03
INVESTIGATED IN SUCH COMBINATION.
Product Group
ULTRASONICS
ENTITY CONCEPT DEFINITION: THE ENTITY CONCEPT ALLOWS THE INTERCONNECTIONS OF INTRINSICALLY NTS B
SAFE APPARATUS TO ASSOCIATED APPARATUS NOT SPECIFICALLY EXAMINED IN SUCH COMBINATIONS. 17 / DEC / 03
Intrinsically safe connection drawing (FM)
THE CRITERIA FOR INTERCONNECTION IS THAT THE VOLTAGE AND CURRENT WITH INTRINSICALLY SAFE R. CLYSDALE
S. MILLIGAN
SITRANS Probe LU,
APPARATUS CAN RECEIVE AND REMAIN INTRINSICALLY SAFE, CONSIDERING FAULTS, MUST BE EQUAL OR
S. NGUYEN
INTRINSICALLY SAFE
GREATER THAN THE VOLTAGE (Uo) AND CURRENT (Io) LEVELS WHICH CAN BE DELIVERED BY
THE ASSOCIATED APPARATUS, CONSIDERING FAULTS AND APPLICABLE FACTORS. IN ADDITION, THE MAX. PETERBOROUGH CONNECTION DIAGRAM
FOR INTERNAL
UNPROTECTED CAPACITANCE (Ci) AND INDUCTANCE (Li) OF THE INTRINSICALLY SAFE APPARATUS, INCL.
INTERCONNECTING WIRING, MUST BE EQUAL OR LESS THAN THE CAPACITANCE AND INDUCTANCE WHICH
USE ONLY 23650516 0
CAN BE SAFELY CONNECTED TO THE ASSOCIATED APPARATUS.
2365051600 1:1 1 1
7ML19985HT02
FM Class 1, Div. 2 connection drawing
NON-HAZARDOUS LOCATION HAZARDOUS LOCATION

(SAFE) CLASS I, DIV.2, GROUPS A, B, C, D
METAL CONDUIT
mmmmm
1/2 “ NPT
24 V
POWER
SUPPLY
SITRANS Probe LU
NOTES:
1
SEPT
0 FOR CONSTRUCTION RPC SN 29/2004
Product Group
ULTRASONICS
29 / SEPT / 2004
NTS A
R. CLYSDALE
S. MILLIGAN
SITRANS Probe LU
CLASS I, Div. 2
S. NGUYEN
CONNECTION DRAWING
PETERBOROUGH
FOR INTERNAL
USE ONLY 23650583 0
2365058300 1:1 1 1

mmmmm
Page 94
HAZARDOUS LOCATION NON-HAZARDOUS LOCATION
V OC £ V max
I SC £ I max SAFE AREA
APPARATUS
C a ³ C i + C cable
Load
4-20 mA L a ³ L i + L cable
INTRINSICALLY SAFE BARRIER

(SEE NOTES 1 & 2)
Substitution of components
may impair intrinsic safety.
NOTES:
1. ANY CSA CERTIFIED INTRINSICALLY SAFE BARRIER OR ASSOCIATED

APPARATUS WITH A LINEAR OUTPUT.
2. UNDER THE ENTITY EVALUATION CONCEPT, THE SITRANS Probe LU

HAS THE FOLLOWING INPUT PARAMETERS :
Vmax = 30 VOLTS I max = 120 mA Ci = 3.6 nF Li = 0.5 mH

FEB
1 CHANGE Li VALUE TO 0.5 mH PER ECN 2004-0046 RPC SN 26/2004
DEC
Pmax = 0.8 W OR (Vmax x I max) / 4 = 0.8 W 0 FOR APPROVAL RPC SN 17/03
SITRANS Probe LU (HART) – INSTRUCTION MANUAL

3. APPROVED DUST-TIGHT AND WATER-TIGHT CONDUIT SEALS ARE REQUIRED Product Group
ULTRASONICS
FOR CLASS II, DIV.1, GROUP G AND OUTDOOR TYPE 4X LOCATIONS NTS B
17 / DEC / 03
R. CLYSDALE
3. THE MAXIMUM VOLTAGE OF THE SAFE LOCATION APPARATUS SITRANS Probe LU,
S. MILLIGAN
MUST NOT EXCEED 250 V rms. CSA INTRINSICALLY SAFE
S. NGUYEN
Intrinsically safe connection drawing (CSA)
PETERBOROUGH CONNECTION DRAWING

FOR INTERNAL
4. INSTALLATION TO BE IN ACCORDANCE WITH THE CANADIAN ELECTRICAL CODE PART 1.
.
USE ONLY 23650517 1
2365051701 1:1 1 1
7ML19985HT02
Instructions specific to hazardous area
installations
(Reference European ATEX Directive 94/9/EC, Annex II, 1/0/6)
The following instructions apply to the SITRANS Probe LU covered by certificate number SIRA
03ATEX2142X:
1. For use and assembly, refer to the main instructions.
2. The equipment is certified for use as Category 1G equipment.
3. The equipment may be used with flammable gases and vapors with apparatus
groups IIA, IIB, and IIC, and temperature classes T1, T2, T3, and T4.
4. The equipment is certified for use in an ambient temperature range of –40 °C to
80 °C.
5. The equipment has not been assessed as a safety related device (as referred to by
mmmmm
Directive 94/9/EC Annex II, clause 1.5).
6. Installation and inspection of this equipment shall be carried out by suitably trained
personnel in accordance with the applicable code of practice (EN 60079-14 and
EN 60079-17 in Europe).
7. Repair of this equipment shall be carried out by suitably trained personnel in
accordance with the applicable code of practice (e.g. EN 60079-19 within Europe).
8. Components to be incorporated into or used as replacements in the equipment shall
be fitted by suitably trained personnel in accordance with the manufacturer’s
documentation.
9. It is the responsibility of the user to ensure that manual override is possible in order
to shut down the equipment and protective systems incorporated within automatic
processes which deviate from the intended operating conditions, provided that this
does not compromise safety.
10. The ‘X’ suffix to the certificate number relates to the following special conditions for
safe use:
Parts of the enclosure may be non-conducting and may generate an ignition-
capable level of electrostatic charge under certain extreme conditions. The user
should ensure that the equipment is not installed in a location where it may be
subjected to external conditions (such as high-pressure steam) which might
cause a build-up of electrostatic charge on non-conducting surfaces.

11. If the equipment is likely to come into contact with aggressive substances, then it is
the responsibility of the user to take suitable precautions that prevent it from being
adversely affected, thus ensuring that the type of protection is not compromised.
Aggressive substances:e.g. acidic liquids or gases that may attack metals, or
solvents that may affect polymeric materials.
Suitable precautions: e.g. regular checks as part of routine inspections or
establishing from the material’s data sheet that it is
resistant to specific chemicals.
12. Equipment Marking
The equipment marking contains at least the information on the product nameplate,
shown on page 67.
mmmmm

Appendix H: Firmware Revision History
Firmware
DD Rev. Date Changes
Rev.
1.00 1.00 04 Jun 2004
2.01 2.01.01 23 Sept 2005 • Increased breakpoints to 32.

• MP&F parameters added to product.
• Fault system upgraded to use S# fault codes.
K: Firmware revision
mmmmm

K: Firmware revision Notes:
mmmmm

Glossary
acoustic noise: any undesired audible sound.
accuracy: degree of conformity of a measure to a standard or a true value.
agitator: mechanical apparatus for mixing or aerating. A device for creating turbulence.
algorithm: a prescribed set of well-defined rules or processes for the solution of a problem in a
finite number of steps.
ambient temperature: the temperature of the surrounding air that comes in contact with the
enclosure of the device.
attenuation: a term used to denote a decrease in signal magnitude in transmission from one
point to another. Attenuation may be expressed as a scalar ratio of the input magnitude to
the output magnitude or in decibels.
Auto False-Echo Suppression: a technique used to adjust the level of a TVT curve to avoid the
reading of false echoes. (See TVT.)
Auto False-Echo Suppression Distance: defines the endpoint of the TVT distance. (See TVT.)
This is used in conjunction with auto false echo suppression.
beam angle: the angle diametrically subtended by the one-half power limits (-3 dB) of the
sound beam.
beam spreading: the divergence of a beam as it travels through a medium.
blanking: the distance in front of the transducer face where level measurement is not possible.
capacitance: the property of a system of conductors and dielectrics that permits the storage of
electricity when potential differences exist between the conductors. Its value is
expressed as the ratio of a quantity of electricity to a potential difference, and the unit is a
Farad.
confidence: describes the quality of an echo. Higher values represent higher quality.
Glossary
Confidence threshold defines the minimum value. mmmmm
damping: term applied to the performance of an instrument to denote the manner in which the
measurement settles to its steady indication after a change in the value of the level.
dB (decibel): a unit used to measure the amplitude of signals.

derating: to decrease a rating suitable for normal conditions according to guidelines specified
for different conditions.
dielectric: a nonconductor of direct electric current.
echo: a signal that has been reflected with sufficient magnitude and delay to be perceived in
some manner as a signal distinct from that directly transmitted. Echoes are frequently
measured in decibels relative to the directly transmitted signal.
echo confidence: the recognition of the validity of the echo. A measure of echo reliability.
Echo Lock Window: a window centered on an echo in order to locate and display the echo’s
position and true reading. Echoes outside the window are not immediately processed.
Echo Marker: a marker that points to the processed echo.
Echo Processing: the process by which the radar unit determines echoes.
Echo Strength: describes the strength of the selected echo in dB above 1 µV rms.
Echo Profile: a graphical display of a processed echo.
electrical noise: unwanted electrical signals that produce undesirable effects in the circuits of
the control systems in which they occur.
false echo: any echo which is not the echo from the desired target. Generally, false echoes are
created by vessel obstructions.
frequency: the number of periods occurring per unit time. Frequency may be stated in cycles
per second.
hertz (Hz): unit of frequency, one cycle per second. 1 kilohertz (kHz) is equal to 103 Hz.
HART: Highway Addressable Remote Transducer. An open communication protocol used to

address field instruments.
inductance: the property of an electric circuit by virtue of which a varying current induces an
electromotive force in that circuit or in a neighboring circuit. The unit is a Henry.
multiple echoes: secondary echoes that appear as double, triple, or quadruple echoes in the
Glossary
distance from the target echo.

mmmmm
Near Blanking: see Blanking
nozzle: a length of pipe mounted onto a vessel that supports the flange.
parameters: in programming, variables that are given constant values for specific purposes or
processes.

pulse: a wave that departs from an initial level for a limited duration of time, and returns to the
initial level.
range: distance between a transmitter and a target.
range extension: the distance below the zero percent or empty point in a vessel.
repeatability: the closeness of agreement among repeated measurements of the same

variable under the same conditions.
shot: one transmit pulse or measurement.
stillpipe: a pipe that is mounted inside a vessel parallel to the vessel wall, and is open to the
vessel at the bottom.
stilling-well: see stillpipe.
TVT (time varying threshold): a time-varying curve that determines the threshold level above
which echoes are determined to be valid.
ultrasonic: having a frequency above the human ear’s audibility limit: about 20,000 hertz.
Glossary
mmmmm

Glossary Notes
mmmmm

Index
A H
Abbreviations and Identifications hand programmer
list 2 access to SITRANS Probe LU 19
accuracy 6 detailed instructions 20
agitator blade detection I
avoiding 53 Identifications and Abbreviations
agitators 53 list 2
algorithm L
select for true echo 58 language
Approvals 9 selection 22
ARROW keys level measurement 30
primary/secondary index function 29 lock value 41
Auto False-Echo Suppression Loop Voltage versus Loop Resistance 89
instructions 60 M
B maintenance 82
blanking 83 master reset 21, 65
extending 55 material mixers 53
breakpoints measurement mode 22
level 36 multidrop configuration 76
volume 39 N
C near blanking
changing parameter values 22 extending 55
Index
mmmmm
D see also blanking 83
damping 52 Noise parameter 58
default values O
factory settings 28 operation
dimensions 13 measurement modes 30
distance measurement 30 P
E parameter
echo confidence accessing 20
display 17 changing value 20
set threshold 56 parameter reset
echo confidence reading 57 factory default 20
echo strength master reset 21
update 57 PDM 75
echo verification 31 percent or units 21
F power supply requirements
factory settings 28 loop voltage vs. loop resistance 89
default values 28 specifications 6
Failsafe parameters 41 primary index 28
false echo suppression accessing 28
instructions 60 changing a value 28
false-echo suppression principles of operation 83
setting 60 programming chart 67
function keys (RUN) Q
display echo confidence 17 quick start programming

instructions 22
setup steps 21
R
range extension 56
repair 82
reset parameters
factory default 20
master reset 21
resistance
loop voltage vs. loop resistance 89
S
safety barrier selection 89
secondary index 28
accessing 29
changing value 29
security
lock value 41
unlock value 41
setup instructions
quick start programming 22
SIMATIC Process Device Manager 71
SIMATIC Process Device Manager (PDM) 75
software revision number 62
space measurement 30
T
temperature specification
Index
mmmmm
Ambient/Operating 11
U
units or percent 21
unlock value 41
V
vessel shape
conical bottoms 56
parabolic bottoms 56
selection 35
voltage
loop voltage vs. loop resistance 89
volume measurement 30
volume parameters 33
W
wire gauge 14
Z
zener diode safety barriers 88

Appendix A: Alphabetical Parameter
List
A: Parameter List
mmmmm
Parameter Name Parameter Number Page Number
20 mA Output Trim 215 45
20 mA Setpoint (high output) 211 44
4 mA Output Trim 214 45
4 mA Setpoint (low output) 210 43
Algorithm 820 58
Auto False Echo Suppression 837 60
Auto False Echo Suppression Distance 838 61
Communications Control 799 55
Confidence Threshold 804 56
Damping Filter 709 52
Distance Measurement 923 65
Echo Confidence 805 57
Echo Lock 711 52
Echo Lock Sampling 712 53
Echo Lock Window 713 54
Echo Marker Trigger 825 58
Echo Strength 806 57
Empty (process empty level) 006 32
Failsafe Level 073 42
Fail-Safe Material Level 071 41
Fail-Safe Timer 070 41
Internal Temperature 343 46
Language 010 33
Level (or Head) Breakpoints 054 36
Lock 000 29
mA Output Function 201 42
Maximum mA Limit 213 44
Minimum mA Limit 212 44

mA Output Value 911 63
A: Parameter List
Master Reset 999 65

Material 002 31
mmmmm
Material Measurement 921 64

Maximum Empty Rate 701 51
Maximum Fill Rate 700 51
Maximum Volume 051 34
Measurement Response 003 31
Memory Test 901 63
Near Blanking 800 55
Noise 807 58
Offset Calibration 650 48
Offset Correction 652 48
Operation 001 30
Power-On Resets 342 46
Range Extension 801 56
Reading Measurement 920 63
RUN Time 341 45
Serial Number 346 47
Software Revision Number 900 62
Sound Velocity at 20 oC 654 50
Sound Velocity Calibration 651 48
Space Measurement 922 64
Span (process full level) 007 32
Temperature 664 51
Temperature 912 63
Temperature fixed 661 50
Temperature source 660 50
Temperature, transducer maximum 300 45

TVT Hover Level 839 62
A: Parameter List
TVT Shaper 831 59
mmmmm
TVT Shaper Adjust 832 60
TVT Type 830 59
Units 005 32
Unlocked value 069 41
Velocity 653 49
Vessel Dimension ‘A’ 052 36
Vessel Dimension ‘L’ 053 36
Vessel Shape 050 34
Volume (or Flow) Breakpoints 055 39
Volume (or Flow) Measurement 924 65

www.siemens.com/processautomation
Siemens Milltronics Process Instruments Inc. Siemens Milltronics Process Instruments Inc. 2008
1954Technology Drive, P.O. Box 4225 Subject to change without prior notice
Peterborough, ON, Canada K9J 7B1
Tel: (705) 745-2431 Fax: (705) 741-0466 Rev. 2.3
*7ml19985HT02*
Printed in Canada
Preface
S7-200 SIMATIC Text Display (TD) User Manual
1
______________
Product Overview
Installing your Text Display

2
S7-200 ______________
(TD) Device
Using the Keypad Designer
SIMATIC ______________
to Create a Custom
3
Faceplate for your Text
Text Display (TD) User Manual Display (TD) Device
Using the Text Display

______________
Wizard to Configure the
4
S7-200 CPU for Your Text
System Manual
Display (TD) Device
Operating Your Text Display

5
______________
(TD) Device
Technical Specifications and

A
______________
Reference Information
Connecting Multiple Devices

B
______________
on a Network
C
______________
Troubleshooting
08/2007
A5E00765548-02
Safety Guidelines
Safety Guidelines
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The device/system may only be set up and used in conjunction with this documentation. Commissioning and
operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes
in this documentation qualified persons are defined as persons who are authorized to commission, ground and
label devices, systems and circuits in accordance with established safety practices and standards.
Prescribed Usage
Note the following:
WARNING
This device may only be used for the applications described in the catalog or the technical description and only
in connection with devices or components from other manufacturers which have been approved or
recommended by Siemens. Correct, reliable operation of the product requires proper transport, storage,
positioning and assembly as well as careful operation and maintenance.
Trademarks
All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this
publication may be trademarks whose use by third parties for their own purposes could violate the rights of the
owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Siemens AG A5E00765548-02 Copyright © Siemens AG 2007.

Automation and Drives Ⓟ 02/2008 Technical data subject to change
Postfach 48 48
90327 NÜRNBERG
GERMANY
Preface
Scope of this Manual

This manual describes the installation, configuration and operation of the TD 100C version
1.0, the TD 200 version 3.0, the TD 200C version 1.0, and the TD400C version 2.0. This
manual also describes the Text Display wizard of STEP 7-Micro/WIN (used to configure the
S7-200 CPU for the TD devices) and the Keypad Designer application (used to configure the
keypad of the TD 100C, the TD 200C and the TD400C).
To utilize these TD devices, you must use the following:
● STEP 7-Micro/WIN version 4.0 SP2 or greater for TD 100C version 1.0
● STEP 7-Micro/WIN version 4.0 or greater for TD 200C version 1.0 and TD 200
version 3.0
● STEP 7-Micro/WIN version 4.0 SP6 or greater for the TD400C version 2.0
Purpose of the manual

The SIMATIC Text Display (TD) User Manual is a combination user and reference manual
that describes the operation of the TD devices with an S7-200 CPU.
Required Basic Knowledge

This manual is designed for engineers, programmers, and maintenance personnel who have
a general knowledge of programmable logic controllers and operator interfaces.
Recycling and Disposal

Please contact a company certified in the disposal of electronic scrap for environmentally
safe recycling and disposal of your device.
Place of this Document in the Information Environment
Table 1 Place of the Text Display User Manual in the Information Environment
Product Family Documentation Order Number

S7-200 SIMATIC Text Display (TD) User Manual (resides on Not applicable
the STEP 7-Micro/WIN documentation CD)
Simplified Chinese Character Set (resides on the Not applicable
STEP 7-Micro/WIN documentation CD)
S7-200 S7-200 Programmable Controller System Manual 6ES7 298-8FA24-8BH0
Text Display (TD) User Manual

System Manual, 08/2007, A5E00765548-02 3
Preface
Finding Your Way

If you are a first-time (novice) user of TD devices, you should read the entire SIMATIC Text
Display (TD) User Manual. If you are an experienced user, refer to the table of contents or
index to find specific information.
The SIMATIC Text Display User Manual is organized according to the following topics:
● Chapter 1 (Product Overview) provides an overview of the TD devices
● Chapter 2 (Installing Your TD Device) provides installation instructions and guidelines.
● Chapter 3 (Using the Keypad Designer to Create a Custom Faceplate for Your TD
Device) provides information about the Keypad Designer and the steps required for
configuring the keypad and faceplate for the TD devices that can be customized..
● Chapter 4 (Using the Text Display Wizard to Configure the S7-200 CPU for Your TD
Device) provides information about using the Text Display wizard of STEP 7-Micro/WIN to
configure the S7-200 CPU for the TD device.
● Chapter 5 (Operating Your TD Device) provides information about the basic operation of
the TD devices and also describes the features and capabilities.
● Appendix A (Technical Specifications and Reference Information) provides the technical
information for the TD devices and also provides references for the character sets
supported.
● Appendix B (Connecting Multiple Devices on a Network) provides information about using
a TD device in a network with other TD devices and S7-200 CPUs.
● Appendix C (Troubleshooting) provides information to help you diagnose problems with
the TD device.
The Simplified Chinese Character Set shows the characters supported by the TD devices.
This file is an electronic file and resides on the STEP 7-Micro/WIN documentation CD.
Approvals
Agency Approvals
The SIMATIC Text Display (TD) devices meet the standards and regulations of the following
agencies.
● Underwriters Laboratories, Inc. (UL): UL 60950 for the TD 200C and TD 200; and UL
508, UL 1604 for the TD 100C and TD400C
● Canadian Standards Association: CSA C22.2 No. 60950 standard for the TD 200C and
TD 200; and CS22.2 No. 142 standard and CSA-213 for the TD 100C and TD400C
Refer to Appendix A for additional compliance information.

4 System Manual, 08/2007, A5E00765548-02
Preface
Certification
The SIMATIC Text Display devices have the following certifications:
● Underwriters Laboratories (UL) Standards
– TD 200C and TD 200: UL 60950 and CSA C22.2 No. 60950
– TD 100C and TD400C: UL 508 and CS22.2 No. 142; UL 1604 and CSA-213
● Factory Mutual Research: Standard Class Number 3611, Class I, Division 2, Group A, B,
C, D, and Class I, Zone 2, Group IIC.
Temperature class T5 is adhered to when the ambient temperature during operation does
not exceed 60 degrees C.
CE Labeling
The SIMATIC TD devices fulfil the requirements and protection guidelines of the following
EU directives:
● EC Directive 94/9/EC "ATEX directive" (TD 200 and TD 200C only)
● EC Directive 89/336/EEC "EMC directive" (TD 100C, TD 200, TD 200C and TD400C)
C-Tick
The SIMATIC devices are compliant with requirements of the following standards.
● AS/NZS CISPR22 (TD 100C, TD 200, TD 200C)
● AS/NZS CISPR11 (TD400C)
Note
The only valid approvals for the TD400C device are those shown on the label on the rear
panel of the device.
Services and Support
Additional Support
Local Siemens Sales Office or Distributor: For assistance in answering any technical
questions, for training on the S7-200 products, or for ordering S7-200 products, contact your
Siemens distributor or sales office. Because your sales representatives are technically
trained and have the most specific knowledge about your operations, process and industry,
as well as about the individual Siemens products that you are using, they can provide the
fastest and most efficient answers to any problems that you might encounter.

System Manual, 08/2007, A5E00765548-02 5
Preface
Service and Support on the Internet

In addition to our documentation, we offer our Know-How online on the internet at:
http://www.siemens.com/automation/service&support
where you will find the following:
● Access the S7-200 Internet site to find additional S7-200 product information:
www.siemens.com/S7-200
This site includes frequently asked questions (FAQs), Programming Tips (application
examples and sample programs), information about newly released products, and
product updates or downloads
● Read the newsletter, which constantly provides you with up-to-date information on your
products
● Use the Search feature of the Service & Support area to find specific documentation
● Share information and exchange experiences with a forum of other users and experts
from all over the world
● Find your local Siemens representative for Automation & Drives
● Use the "Services" link to find information on field service, repairs, spare parts and more
Contact Information and Additional Support
Service and support from your local Siemens sales office or distributor
For assistance in answering any technical questions, for training on a specific product, or for
ordering any SIMATIC products, contact your Siemens distributor or sales office. Because
the sales representatives are technically trained and have specific knowledge about your
operations, process and industry, as well as about the individual Siemens products that you
are using, they can provide the fastest and most efficient answers to any problems that you
might encounter.

6 System Manual, 08/2007, A5E00765548-02
Preface
Technical services
The highly trained staff of the SIMATIC Customer Support center is also available to help
you resolve any problems that you might encounter. Their services are available world-wide
24 hours a day, 7 days a week.
-RKQVRQ&LW\71 1XUHPEHUJ %HLMLQJ
Figure 1-1 World-Wide SIMATIC Customer Support
Table 2 Contact Information for SIMATIC Customer Support
United States: Johnson City, TN World-wide: Nuremberg Asia and Australia: Beijing
Technical Support and Authorization Technical Support Technical Support and Authorization
Local time: Monday to Friday 24 hours a day, 365 days a year Local time: Monday to Friday
8:00 AM to 5:00 PM Telephone: +49 (180) 5050-222 8:00 AM to 5:00 PM
Telephone: +1 (423) 262-2522 Fax: +49 (180) 5050-223 Telephone: +86 10 64 75 75 75
or +1 (800) 333-7421 (USA only) Fax: +86 10 64 74 74 74
Mail to:
Fax: +1 (423) 262-2289 [email protected] Mail to:
Mail to: GMT: +1:00 [email protected]
[email protected] GMT: +8:00
Authorization
GMT: -5:00
Local time: Monday to Friday
8:00 AM to 5:00 PM
Telephone: +49 (180) 5050-222
Fax: +49 (180) 5050-223
Mail to:
[email protected]
GMT: +1:00
The languages for the SIMATIC hotlines and the Authorization hotline are generally German and English.

System Manual, 08/2007, A5E00765548-02 7
Preface

8 System Manual, 08/2007, A5E00765548-02
Table of contents
Preface ...................................................................................................................................................... 3
1 Product Overview .................................................................................................................................... 13
1.1 Overview ......................................................................................................................................13
1.2 Introducing the S7-200 Text Display (TD) Device .......................................................................13
1.3 Features of the Text Display (TD) Devices..................................................................................16
1.4 Comparing the TD Devices..........................................................................................................18
1.5 Using the TD Device to Access Screens and Alarms..................................................................20
1.6 Installation and Configuration Tasks............................................................................................23
1.7 Creating a Custom Faceplate for the TD Device .........................................................................27
1.8 Printing the Custom Faceplate for the TD device ........................................................................28
2 Installing your Text Display (TD) Device .................................................................................................. 29
2.1 Overview ......................................................................................................................................29
2.2 Components Shipped with the TD Devices .................................................................................30
2.3 Mounting the TD 200, TD 200C, and TD400C in a Panel or on a Surface .................................31
2.4 Mounting the TD 100C in a Panel or on a Surface ......................................................................33
2.5 Customizing the Labels for the Keys of the TD 200 ....................................................................34
2.6 Installing a Faceplate for the TD 100C, TD 200C and TD400C ..................................................36
2.7 Connecting the TD/CPU Cable ....................................................................................................38
2.8 Supplying Power for the TD Device .............................................................................................39
2.9 Establishing a Connection for Your TD Device............................................................................40
3 Using the Keypad Designer to Create a Custom Faceplate for your Text Display (TD) Device ............... 43
3.1 Overview ......................................................................................................................................43
3.2 Using the Keypad Designer with Other Applications ...................................................................44
3.3 Starting the Keypad Designer ......................................................................................................46
3.4 Adding Buttons to the Keypad .....................................................................................................48
3.5 Defining the Properties of the Button...........................................................................................51
3.6 Exporting the Keypad Layout to a Graphics Application .............................................................54
3.7 Adding a Panel Image to the Faceplate.......................................................................................56
3.8 Saving the Keypad to a TD Configuration File.............................................................................58
3.9 Reversing the Panel Image..........................................................................................................59
3.10 Printing the Panel Image on a Faceplate.....................................................................................60

System Manual, 08/2007, A5E00765548-02 9
Table of contents
3.11 Installing the Printed Faceplate onto the TD device ................................................................... 64

4 Using the Text Display Wizard to Configure the S7-200 CPU for Your Text Display (TD) Device............ 67
4.1 Overview ..................................................................................................................................... 67
4.2 Overview of the Configuration Tasks .......................................................................................... 68
4.3 Configuring the Text Display Device........................................................................................... 70
4.4 Configuring the Screens for the Text Display Device ................................................................. 80
4.5 Configuring the Alarms................................................................................................................ 89
4.6 Configuring the Language Sets (TD 200, TD 200C, and TD400C) ............................................ 96
4.7 Assigning the V Memory Address for the Parameter Block........................................................ 99
4.8 Finishing the Configuration for the TD Device .......................................................................... 100
5 Operating Your Text Display (TD) Device .............................................................................................. 101
5.1 Overview ................................................................................................................................... 101
5.2 Using the Text Display Device to Access Screens and Alarms................................................ 101
5.3 Accessing the Menus and Screens........................................................................................... 107
5.4 Entering and Releasing a Password......................................................................................... 109
5.5 Viewing the Screens and the Alarms ........................................................................................ 110
5.6 Performing Typical or Routine Operator Tasks......................................................................... 119
5.7 Performing Specialized Operator Tasks (Diagnostic/Setup Menu) .......................................... 123
A Technical Specifications and Reference Information ............................................................................. 133
A.1 General Specifications for the Text Display Devices ................................................................ 133
A.2 Technical Specifications for the TD 100C, TD 200 and TD 200C ............................................ 134
A.3 Technical Specifications for the TD400C.................................................................................. 136
A.4 Certificates, Directives and Declarations for the TD Device ..................................................... 137
A.5 Approvals for USA, Canada and Australia................................................................................ 139
A.6 Standard TD Character Set (TD 200, TD 200C)....................................................................... 141
A.7 Arabic Character Set (TD 200, TD 200C, and TD400C) .......................................................... 144
A.8 Baltic Character Set .................................................................................................................. 145
A.9 Simplified Chinese Character Set ............................................................................................. 146
A.10 Cyrillic Character Set ................................................................................................................ 148
A.11 Greek Character Set ................................................................................................................. 149
A.12 Hebrew Character Set (TD 200, TD 200C, and TD400C) ........................................................ 150
A.13 Latin 1 Character Set ................................................................................................................ 151
A.14 Latin 2 Character Set ................................................................................................................ 152
A.15 Turkish (Latin 5) Character Set................................................................................................. 153
B Connecting Multiple Devices on a Network............................................................................................ 155
B.1 Overview ................................................................................................................................... 155

10 System Manual, 08/2007, A5E00765548-02
Table of contents
B.2 Communicating with Multiple CPUs...........................................................................................156

B.3 Determining the Distances, Transmission Rate, and Cable ......................................................157
B.4 Selecting the Network Cable......................................................................................................158
B.5 Biasing and Terminating the Network Cable .............................................................................159
B.6 Building a TD/CPU Cable ..........................................................................................................160
B.7 CPU Grounding and Circuit Reference Point Guidelines for Using Isolated Circuits ................161
C Troubleshooting ..................................................................................................................................... 163
C.1 Troubleshooting Guide...............................................................................................................163
Index...................................................................................................................................................... 165

System Manual, 08/2007, A5E00765548-02 11
Table of contents

12 System Manual, 08/2007, A5E00765548-02
Product Overview 1
1.1 Overview
Product Overview
The S7-200 TD devices provide a low-cost human-machine interface (HMI), allowing an
operator or user to interact with your application.
The TD devices allow you to configure a set of hierarchical user menus to provide additional
structure for the interaction with your application. You can also configure the TD device to
display alarms or messages that are enabled by specific bits in the S7-200 CPU.
Tip
The TD devices provide additional functionality, such as the hierarchical user-defined
menus. The TD 200C and the TD 200 are fully compatible with projects that were created
with earlier versions of the TD 200 (prior to TD 200 V3.0, which supported only the bit-
enabled messages from the S7-200 CPU).
You can use the TD 200C or the TD 200 device with an existing TD configuration without
having to modify the control program in the S7-200 CPU.
The TD 100C and the TD400C devices are not compatible with the TD 200 devices.
1.2 Introducing the S7-200 Text Display (TD) Device
Introducing the S7-200 Text Display (TD) Devices

Your S7-200 TD device is a 2- or 4-line text display device that can be connected to the
S7-200 CPU. The TD device allows you to view, monitor, and change the process variables
pertaining to your application.
The S7-200 product family provides four TD devices:
● TD 100C: The TD 100C has a 4-line text display with 2 font choices. Your display can
have 16 characters per line for a total of 64 characters, or you can use a bold font with
12 characters per line for a total of 48 characters. The faceplate of the TD 100C offers
complete flexibility of the keypad layout and faceplate design.
You can create a custom keypad with up to 14 buttons (keys) of variable size, with
varying shapes, colors, or fonts that can be layered onto any background image.

System Manual, 08/2007, A5E00765548-02 13
Product Overview
● TD 200C: The TD 200C has a 2-line text display with 20 characters per line for a total of
40 characters. The faceplate of the TD 200C offers complete flexibility of the keypad
layout and faceplate design.
You can create a custom keypad with up to 20 buttons (keys) of variable size, with
varying shapes, colors, or fonts that can be layered onto any background image.
● TD 200: The faceplate of the TD 200 provides four keys with predefined, set-bit functions
and allows up to eight set-bit functions by using the SHIFT key.
● TD400C: The TD400C can have a 2- or 4-line text display depending on your font and
character choice.The TD400C buttons (keys) are tactile and have fixed positions.
– Your display can have a 4-line display with 12 small Chinese characters per line for a
total of 48 characters, or 24 small ASCII characters per line for a total of 96
characters.
– Your display can have a 2-line display with 8 large Chinese characters per line for a
total of 16 characters, or 16 large ASCII characters per line for a total of 32 characters.
– You can create a custom keypad with up to 15 buttons (keys) of varying colors,
functions, or fonts that can be layered onto any background image.
7'& 7'
7'& 7'&
Figure 1-1 Text Display (TD) Devices
The TD devices receive power from the S7-200 CPU through the TD/CPU cable. The
TD 200, TD 200C and TD400C devices can also receive power from a separate power
supply.

14 System Manual, 08/2007, A5E00765548-02
Product Overview
The TD devices contain the following elements:

● Text display area: The TD 200C, TD 200 and TD400C have a backlit liquid crystal display
(LCD).
– The TD 200C and TD 200 displays have a resolution of 33 x 181 pixels
– The TD400C display has a resolution of 192 x 64 pixels.
– The TD 100C has a liquid crystal display (LCD) with a resolution of 132 x 65 pixels.
There is no backlight on the TD 100C.
● Communication port: 9-pin D-connector
● Power connector
– The TD 200C, TD 200, and TD400C have a connector for using an optional external
power supply (power for the TD device is typically supplied by the S7-200 CPU
through the TD/CPU cable).
– The TD 100C does not have the option of using an external power supply.
STEP 7-Micro/WIN provides tools to help you configure the TD devices. Using the following
tools, you can easily program your S7-200 to display text messages and other data:
● Text Display wizard helps you configure messages for the TD devices.
● Keypad Designer helps you to configure the custom keypad for the TD 100C, the
TD 200C, and the TD400C. The Keypad Designer includes samples and templates in the
following directories:
– Sample bitmaps for buttons and backgrounds:
C:/Program Files/Siemens/TD Keypad Designer/Images
– Sample projects:
C:/Program Files/Siemens/TD Keypad Designer/Samples
– Sample template (for printing multiple copies of the faceplate):
C:/Program Files/Siemens/TD Keypad Designer/Templates
Each TD device functions as a network master when it is connected over a network that
contains one or more S7-200 CPUs. The TD device is also designed to operate with other
masters in a network. Multiple TD devices can be used with one or more S7-200 CPUs
connected to the same network. More than one TD device can connect to the same
S7-200 CPU.

System Manual, 08/2007, A5E00765548-02 15
Product Overview
1.3 Features of the Text Display (TD) Devices
Features of the Text Display (TD) Devices

You can use your TD device to perform the following tasks:
● Viewing a hierarchy of user menus and screens that allow an operator to interact with the
application or process
You create these user menus and screens with the Text Display wizard of
STEP 7-Micro/WIN
● Displaying alarms (bit-enabled messages) that are generated by the S7-200 CPU
You define these alarms with the Text Display wizard of STEP 7-Micro/WIN
● Modifying designated program variables
The TD device allows you to define a variable as either a text string or a numeric string:
– Text string: All characters in a variable are editable
– Numeric string: Only the numeric characters are editable (the cursor skips over all
non-numeric characters)
The TD device allows you to define a variable as a word, double word, or real
● Forcing or unforcing I/O points: You can force individual I/O points in the S7-200 CPU to
be on or off (TD 200C, TD 200, and TD400C only)
● Setting the time and date (if the S7-200 CPU supports a real-time clock)
● Viewing the CPU status (including version information)
The TD 200C and TD400C provide additional functionality for interacting with the S7-200
CPU:
● You can change the operating mode (RUN or STOP) of the S7-200 CPU
● You can load the user program in the S7-200 CPU to a memory cartridge
● You can access and edit the data stored in the memory of the S7-200 CPU

16 System Manual, 08/2007, A5E00765548-02
Product Overview
International Languages and Characters Support

The TD 200C and TD 200 devices provide a default TD character set which supports bar
graph characters. The TD devices (as noted) support the following Windows character sets
for displaying messages:
● Arabic
● Baltic
● Chinese (Simplified Chinese)1
● Cyrillic
● Greek
● Hebrew
● Latin 1 (with Boldface)
● Latin 2 (with Boldface)
● Turkish (Latin 5)
The TD devices provide system menus and prompts in six languages: English, German,
French, Spanish, Italian, and Simplified Chinese.
In the TD 100C, all fonts except Simplified Chinese are available in two sizes: 12 and 16
characters per row. All the 12 character fonts are bold.
The TD400C supports the character sets in two sizes.
Table 1-1 Fonts Supported by the TD Devices
TD 100C TD 200 TD 200C TD400C V 2.0

Latin 1 Latin 1 Latin 1 Latin 1
- Latin 1 Bold Latin 1 Bold Latin 1 Bold
Latin 2 Latin 2 Latin 2 Latin 2
- Latin 2 Bold Latin 2 Latin 2 Bold
Cyrillic Cyrillic Cyrillic Cyrillic
Greek Greek Greek Greek
Turkish Turkish Turkish Turkish
Baltic Rim Baltic Rim Baltic Rim Baltic Rim
- Arabic Arabic Arabic
- Hebrew Hebrew Hebrew
- Original TD 200 Original TD 200 -
- Bar Graph Bar Graph -
Simplified Chinese1 Simplified Chinese Simplified Chinese Simplified Chinese
1 The TD 100C includes approximately 1900 out of the possible 6763 Chinese characters.

System Manual, 08/2007, A5E00765548-02 17
Product Overview
1.4 Comparing the TD Devices
Comparing the Text Display Devices
Table 1-2 Comparing the TD Devices
Feature TD 100C V 1.0 TD 200 V3.0 TD 200C V 1.0 TD400C V 2.0

Text display area 4 lines, up to 64 2 lines, up to 40 2 lines, up to 40 2 lines with large font, up
characters (up to 16 characters (up to 20 characters (up to 20 to 16 Chinese or 32 ASCII
characters per line) characters per line) characters per line) characters per line (up to
8 Chinese or 16 ASCII
characters per line)
4 lines with small font, up
to 24 ASCII characters
(up to 12 Chinese
characters per line)
Display backlight can be
configured to extend the
life of the TD400C device
Keypad options User-designed Standard keypad User-designed custom User designed custom
custom keypad keypad keypad
Standard keypad Standard keypad Standard keypad
Configurable buttons Custom keypad: Up Standard keypad: 4 Custom keypad: Up to Custom keypad: Up to 15
to 14 (user- (Up to 8 when using 20 (user-configurable) (user configurable)
configurable) SHIFT) Standard keypad: 4 (up Standard keypad: 8 (up to
Standard keypad: 2 to 8 when using SHIFT) 16 when using SHIFT)
System buttons ENTER, ESC ENTER, ESC ENTER, ESC ENTER, ESC (Escape),
(pre-configured) (Escape), UP, (Escape), SHIFT, (Escape), SHIFT, UP, SHIFT, UP, DOWN,
DOWN, LEFT and UP and DOWN DOWN, LEFT, and LEFT, and RIGHT arrows
RIGHT arrows, F1, F2 arrows RIGHT arrows
User-defined menus Maximum of 32 Maximum of 64 Maximum of 64 Maximum of 64 screens
and user screens screens screens screens Up to 8 user menus with
Up to 4 user menus, Up to 8 user menus, Up to 8 user menus up to 8 screens per user
with up to 8 screens with up to 8 screens with up to 8 screens menu
per user menu per user menu per user menu
Alarms (from the Up to 40 alarm Up to 80 alarm Up to 80 alarm Up to 80 alarm messages
S7-200 CPU) messages messages messages
Alarm indicator (icon) Yes Yes Yes Yes
Variable embedded in 1 per line Up to 6 variables Up to 6 variables per Up to 6 variables per
an alarm or screen (1 for one-line alarms; per alarm or screen alarm or screen alarm or screen
2 for two-line alarms,
4 for a screen)
Icons (graphics) No No Yes Yes
embedded in a
message

18 System Manual, 08/2007, A5E00765548-02
Product Overview
Feature TD 100C V 1.0 TD 200 V3.0 TD 200C V 1.0 TD400C V 2.0

System menu options Release the Force I/O Force I/O Force I/O
password Release the Release the password Release the password
Set the time and date password Set the time and date Set the time and date
CPU status Set the time and CPU status CPU status
Clean keypad date Switch languages (if Switch language (if
CPU status configured) configured)
Switch languages (if Change the CPU Change the CPU
configured) operating mode operating mode
Clean keypad Clean keypad Clean keypad
Edit the CPU memory Edit the CPU memory
Program a memory Program a memory
cartridge cartridge
Password protection Yes Yes Yes Yes
Multiple language No Yes Yes Yes
sets
Character sets 7 character sets: 10 character sets: 10 character sets: 9 characters sets: Latin
supported (for Latin 1, Latin 2, Latin 1/Bold, Latin Latin 1/Bold, Latin 1/Bold, Latin 2/Bold,
displaying different Chinese (Simplified)1, 2/Bold, Chinese 2/Bold, Chinese Chinese (Simplified),
languages) Cyrillic, Baltic, Greek, (Simplified), Cyrillic, (Simplified), Cyrillic, Cyrillic, Arabic, Baltic,
Turkish Arabic, Baltic, Arabic, Baltic, Greek, Greek, Hebrew, Turkish
Greek, Hebrew, Hebrew, Turkish, and
Turkish, and Standard TD (includes
Standard TD Bar Graph)
(includes Bar
Graph)
Languages for system 6 languages: 6 languages: 6 languages: 6 languages: English,
menus and error English, French, English, French, English, French, French, German, Italian,
messages German, Italian, German, Italian, German, Italian, Spanish, and Chinese
Spanish, and Chinese Spanish, and Spanish, and Chinese
Chinese
Feedback (when Visual indicator in the Tactile dome over Visual indicator in the Tactile dome over the
pressing a button) text display area the buttons on the text display area buttons on the keypad,
keypad and visual visual indicator, and audio
indicator feedback
1 The TD 100C includes approximately 1900 out of the possible 6763 Chinese characters..

System Manual, 08/2007, A5E00765548-02 19
Product Overview
1.5 Using the TD Device to Access Screens and Alarms
Using the TD Device to Access Screens and Alarms

When you configure the TD device with the Text Display wizard of STEP 7-Micro/WIN, you
create the screens and alarms for the TD device. You use the buttons on the keypad of the
TD device to navigate through the screens and menus. The TD 200 device uses the
standard TD keypad. The standard faceplates for the TD devices are shown in Figure 1-2.
The TD 100C and TD 200C allow you to create your own custom-designed buttons with
specialized functions.
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Figure 1-2 Standard Keypad Configuration for the TD Devices

20 System Manual, 08/2007, A5E00765548-02
Product Overview
Dividing Information into Screens and Bit-Enabled Alarms

As shown in Figure 1-3, you can configure the TD device to display screens (which are
initiated by operator action) and bit-enabled alarms (which are initiated by the S7-200 CPU).
● Screens: You can create screens that allow the operator (using the TD device) to initiate
the interaction with the S7-200 CPU. With the TD device, you can configure a user menu
(up to 8 entries or groups for the TD 200C, TD 200, and TD400C, and up to 4 entries or
groups for the TD 100C) that provides a hierarchy for the screens. You can create up to 8
screens for each menu item or group.
● Alarms: You can create alarm messages that allow the user program in the S7-200 CPU
to initiate interaction with the operator by displaying a message on the TD device.
During the configuration of the TD device, you also designate which type of message
(screens or alarms) will be the default display mode for the TD device. After power-up, the
TD device goes to the default display mode. Also, the TD device returns to the default
display mode after a period of inactivity (if no buttons have been pressed for one minute).
Storing the Screens and Alarms in the Parameter Block

The S7-200 CPU stores the text, embedded variables, and format information for the alarms
and screens in a parameter block located in V memory. You use the Text Display wizard to
configure the starting address for the parameter block in V memory, and the Text Display
wizard allocates the memory required to store the information for the TD device.
If you configure more than one parameter block for the S7-200 CPU (with each parameter
block having a different range of addresses in V memory), you can connect several TD
devices to that one S7-200 CPU. You configure the V memory address for the specific
parameter block for each of the TD devices. The Diagnostic Menu of the TD device provides
a TD Setup command for specifying the starting address of the parameter block.
Tip
The parameter block for the TD 100C and the TD400C is not compatible with other TD
devices. The TD 100C parameter block is only compatible with a TD 100C parameter block,
and the TD400C parameter block is only compatible with a TD400C parameter block.

System Manual, 08/2007, A5E00765548-02 21
Product Overview
Displaying the Screens and Alarms on the TD Device

When the operator uses the buttons on the TD device to select a screen, the TD device
reads the screen information from the parameter block (stored in V memory of the S7-200
CPU) and displays the appropriate screen.
When you configure an alarm, you also configure an alarm bit for enabling a specific alarm.
The logic of your user program sets this alarm bit to display the alarm on the TD device.
When you create the text for the alarm, you also designate the alarm bit. If you configured an
alarm to require acknowledgement by an operator, that alarm also has an acknowledge bit.
The TD device continuously polls the alarm bits to determine which alarms have been
enabled.
To display an alarm on the TD device, your user program in the S7-200 CPU must first set
the alarm bit for the specific alarm. When your user program sets one of the alarm bits, the
TD device then reads the alarm bits in the parameter block in the S7-200 CPU and displays
the corresponding alarm message.
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Figure 1-3 Screens and Alarms

22 System Manual, 08/2007, A5E00765548-02
Product Overview
1.6 Installation and Configuration Tasks
Installation and Configuration Tasks

As shown in Figure 1-4, you use the Text Display wizard of STEP 7-Micro/WIN to configure
the TD device. You can create a custom faceplate for the TD 100C, TD 200C, and TD400C.
The Keypad Designer creates a keypad configuration file for the Text Display wizard.
An overview of the tasks for installing your TD device is shown in the figures below. Refer to
Chapter 2.
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Figure 1-4 Configuration Tasks for the TD Devices

System Manual, 08/2007, A5E00765548-02 23
Product Overview
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Figure 1-5 Installing Your TD 200 and TD 200C Device

24 System Manual, 08/2007, A5E00765548-02
Product Overview
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Figure 1-6 Installing Your TD400C Device

System Manual, 08/2007, A5E00765548-02 25
Product Overview
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Figure 1-7 Installing Your TD 100C Device

26 System Manual, 08/2007, A5E00765548-02
Product Overview
1.7 Creating a Custom Faceplate for the TD Device
1.7 Creating a Custom Faceplate for the TD Device
Creating a Custom Faceplate for the TD Device

With the TD device, you can design a custom faceplate that can be layered onto any
background image. The TD 100C and the TD 200C lets you incorporate buttons (keys) of
varying size, with varying shapes, colors or fonts. The TD400C lets you incorporate buttons
(keys) of varying colors and fonts. The positions and size of the TD400C buttons (keys) are
fixed.
As shown in Figure 1-7, you use several applications to create a custom faceplate:
● Keypad Designer: Creates the layout and the configuration for the keypad
● Third-party graphics application: Designs the graphical appearance of the faceplate
● STEP 7-Micro/WIN (Text Display wizard): Configures the parameter block for the
TD 100C, TD 200C, and the TD400C
● Word-processing application (optional): Prints multiple copies of the faceplate
Siemens provides document files (in 6 languages) for Microsoft Word that help you to
align the panel images for the perforations on the A4 blank faceplate material. To open
these documents, browse to the Templates subdirectory under the Keypad Designer
application (C:/Program Files/Siemens/TD Keypad Designer/Templates) and select the
template for your TD device and language.
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Figure 1-8 Using the Keypad Designer and Other Applications to Create a Custom Faceplate

System Manual, 08/2007, A5E00765548-02 27
Product Overview
1.8 Printing the Custom Faceplate for the TD device
1.8 Printing the Custom Faceplate for the TD device
Printing the Custom Faceplate for the TD Device

The TD 100C and the TD 200C ship with one blank faceplate (envelope-size) for printing the
faceplate. The faceplate is constructed from durable, polyester material which has been
designed especially for use on HMI faceplates.
The TD400C does not include a blank faceplate. You can either order blank faceplates, or
use the Keypad Designer to print a TD400C custom faceplate on A4 paper and take it to a
local supplier to make a custom TD400C faceplate.
● You can print a single faceplate directly from the Keypad Designer on the envelope-sized
blank faceplate.
● To print multiple faceplates, you can use the Microsoft Word template (provided in the
Templates subdirectory) that ensures your faceplate design is properly sized. You can
print multiple faceplates onto the perforated A4-size blank faceplate sheets.
Refer to Chapter 3 for specific information about printing the custom faceplate for your
TD device.
Tip:
The faceplate material is specially treated on one side to accommodate printing with a laser
printer. The treated surface is up (or toward you) when you are holding the material with the
cut corner in the top right of the sheet.
Ensure that the material is correctly inserted into the laser printer so that the faceplate prints
the reversed image onto the treated surface of the material. You must print a reversed-image
version of the faceplate onto the faceplate material.
Before printing your custom faceplate onto the blank faceplate sheet, first test your design by
printing the faceplate onto regular paper. You can then temporarily use the paper faceplate
to test the functionality of the design with your TD device.
Printer Requirements
To print your custom-designed image onto the blank faceplate material, you must use a laser
printer that supports the following features:
● Paper size: The laser printer must be able to print on both the A4 (210 mm X 297 mm)
and envelope formats.
● Color: The laser printer must support color printing.
● Transparencies: The laser printer must support the printing of transparencies (or other
non-paper stock)
Ordering Additional Faceplate Material

You can order additional blank faceplates for the TD 100C, TD 200C, and TD400C device in
perforated A4-size sheets (10 sheets/package). The faceplate material is especially
designed for printing on a laser printer. The blank faceplate sheets also allow you to utilize
the services of professional printing vendors that specialize in laser printing in order to create
large quantities of high-quality faceplates.
Contact your local Siemens representative or distributor to purchase additional quantities of
the faceplate material. The order numbers are shown below:
● TD 200C: the order number for additional blank faceplates is 6ES7 272-1AF00-7AA0
● TD 100C: the order number for additional blank faceplates is 6ES7 272-1BF00-7AA0
● TD400C: the order number for additional blank faceplates is 6AV6671-0AP00-0AX0

28 System Manual, 08/2007, A5E00765548-02
Installing your Text Display (TD) Device 2
2.1 Overview
Installing your TD Device

You can install your TD device for easy access, whether on a panel or on a door of an
enclosure.
Installed properly, the TD devices meet the following standards (as noted) for protection.
● IP 65 (mounted on front of the panel)
● IP 20 (mounted on casing)
● UL 50 Type 4X
Refer to Appendix A for technical specification and for information about agency approvals
and other certifications.
Tip
You can use the TD 200, version 3.0 and the TD 200C, version 1.0 with an existing TD 200
configuration without having to modify the control program in the S7-200 CPU. The TD 100C
and the TD400C are not compatible with the TD 200 devices, nor with each other.

System Manual, 08/2007, A5E00765548-02 29
Installing your Text Display (TD) Device
2.2 Components Shipped with the TD Devices
2.2 Components Shipped with the TD Devices
Components Shipped with the TD Devices

The TD devices ship with the following components:
● Gasket: Protective cushion with gasket for installing the TD device in inclement
environments
● TD/CPU cable: 9-pin, straight-through cable that provides both communication and power
to the TD device. The TD 200, TD 200C, and TD400C ship with a TD/CPU cable. The
TD 100C does not include a TD/CPU cable; it must be ordered separately. The order
number for the TD/CPU cable is 6ES7-901-3EB10-0XA0.
● Spacers: Self-adhesive spacers for mounting the TD device in a panel (TD 200,
TD 200C, and TD400C only)
● Mounting brackets: Brackets for mounting the TD device in a panel (TD 100C only)
● Power connector: The TD 200, TD 200C, and the TD400C ship with a connector to power
the TD device from an external supply.
The TD 200 ships with a pull-out user label that allows you to label the function keys for your
application.
The TD 100C and TD 200C ship with a blank faceplate that you can customize. The
TD 100C, TD 200C and TD400C ship with a pre-printed faceplate for the standard TD
keypad. The faceplate is constructed from durable, polyester material which has been
designed specifically for use for HMI faceplates.
Tip
To print your custom-designed image onto the blank faceplate material, you must use a laser
printer that supports the printing of transparencies on both A4 and envelope formats and
also supports color printing.
General TD Installation Information

Tip
To ensure compliance with IP 65 or UL 50 Type 4X:
● The minimum panel thickness must be at least 1.5 mm.
● For the TD 200, TD 200C, and TD400C, the mounting screws must be tightened to a
torque of 0.7 N-m.
● For the TD 100C, the mounting screws must be tightened to a torque of 0.2 Nm (about
0.5 mm the height of the seal).
● The gasket must be replaced whenever the TD device is removed and reinstalled.
To procure new gaskets, contact your Siemens distributor or sales representative.
The TD 100C, TD 200, TD 200C, and TD400C devices are suitable for use in Class I,
Division 2, Groups A, B, C, D; Class I, Zone 2, Group IIC; or non-hazardous locations.
WARNING
WARNING - EXPLOSION HAZARD!
DO NOT DISCONNECT WHILE CIRCUIT IS LIVE UNLESS LOCATION IS KNOWN TO BE
NON-HAZARDOUS

30 System Manual, 08/2007, A5E00765548-02
2.3 Mounting the TD 200, TD 200C, and TD400C in a Panel or on a Surface
WARNING
WARNING - EXPLOSION HAZARD!
Substitution of components may impair suitability for Class I, Division 2 or Zone 2.
2.3 Mounting the TD 200, TD 200C, and TD400C in a Panel or on a

Surface
Mounting the TD 200, TD 200C, and TD400C in a Panel or on a Surface

Tip
If you are using a customized label insert for your TD device, you must first install the new
label insert before you mount the TD device.
Preparing the Mounting Surface for a TD 200, TD 200C, or TD400C

To prepare the surface where the TD device is to be mounted or installed, use the
dimensions for your TD device as shown below:
● For a TD 200 and TD 200C, cut a 138 mm x 68 mm hole in the mounting surface (DIN
43700).
● For a TD400C, cut a 163.5 mm x 93.5 mm hole in the mounting surface
● Refer to Table A-1 for the outside dimensions of your TD device.
TD 200, TD 200C TD400C
68 mm
93.5 mm
138 mm
163.5mm
Figure 2-1 Dimensions for cutting a Hole in the Mounting Surface of the TD 200, TD 200C,and
TD400C

System Manual, 08/2007, A5E00765548-02 31
2.3 Mounting the TD 200, TD 200C, and TD400C in a Panel or on a Surface
Preparing the TD 200, TD 200C, and TD400C for Mounting

Refer to the figure below and use the following procedure to separate the front cover from
the housing of your TD device:
1. For the TD 200 and TD 200C, use a flat-head screwdriver or a T8 Torx screwdriver to
remove the three screws from the rear of the device. For the TD400C, use a cross
screwdriver for M3 to remove the four screws from the rear of the device.
2. Remove the front cover of the TD device from the housing.
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Figure 2-2 Removing the Mounting Screws of the TD device
Positioning the Spacers for the TD 200, TD 200C, and TD400C

The self-adhesive spacers included with the TD 200, TD 200C, and TD400C maintain the
pressure on the TD device circuit board when the TD device is assembled. The number of
spacers required is dependant upon the thickness of the mounting surface.
Refer to Figure 2-3 and use the following procedure to position the spacers:
1. Determine the number of spacers required, based on the thickness of the panel:
– For up to 1.5 mm, use one spacer.
– For 1.5 mm to 4.0 mm, use two spacers.
2. Place the spacers over the screw holes on the inside of the backplate.
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Figure 2-3 Positioning Spacers on the TD Device

32 System Manual, 08/2007, A5E00765548-02
2.4 Mounting the TD 100C in a Panel or on a Surface
Mounting the TD 200, TD 200C, and the TD400C

Refer to Figure 2-3 and use the following procedure to complete the mounting of your
TD device:
1. Remove the gasket from the protective cushion.
2. Place the supplied gasket on the frontplate of the TD device.
3. Install the spacers (if required).
4. Fit the frontplate into the cutout you made in the mounting surface.
5. Secure the backplate onto the frontplate of the TD device using the screws you removed
from the backplate. Carefully tighten the screws until snug.
2.4 Mounting the TD 100C in a Panel or on a Surface
Mounting the TD 100C in a Panel or on a Surface
Preparing the Mounting Surface for a TD 100C

To prepare the surface where the TD 100C is to be mounted or installed:
● Cut a 69 mm x 82 mm hole in the mounting surface (DIN 43700)
● Refer to Table A-1 for the outside dimensions of the TD 100C device.
69 mm
82mm
Figure 2-4 Dimensions for Cutting a Hole in the Mounting Surface of the TD 100C

System Manual, 08/2007, A5E00765548-02 33
2.5 Customizing the Labels for the Keys of the TD 200
Mounting the TD 100C

Use the following procedure to complete the mounting of your TD 100. See figure below.
1. Remove the gasket from the protective cushion.
2. Place the supplied gasket on the frontplate of the TD device.
3. Fit the TD 100C into the cutout you made in the mounting surface.
4. Attach the special mounting brackets (included) to the TD 100C.
5. Tighten the mounting screws on the mounting brackets to secure the TD 100C to the
panel.
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Figure 2-5 Mounting the TD 100C
Customizing the Labels for the Keys of the TD Device

The TD 200 allows you to define the functions for four of the nine keys (or buttons) on the
standard faceplate. You can remove the label insert of the TD 200 and designate the
functions assigned to those user-defined keys. You can also replace the standard TD 200
insert with your own custom insert for the user-defined keys.
You must remove (at least partially) the TD housing in order to access the label insert from
underneath the front cover of the TD device.
Modifying the Label Insert of the TD 200

1. Remove the three screws on the back of the TD device and remove the front cover from
the housing.
2. Remove the label insert by pulling the label insert tab out of the label slot with a pair of
pointed tweezers.
3. Turn the label insert over and create your own label design. (The reverse side of the label
insert is blank.)
4. Insert the label by placing the corner of the label into the label slot.

34 System Manual, 08/2007, A5E00765548-02
5. Reinstall the front cover into the back housing.

6. Replace and tighten the three screws on the back of the TD device to ensure that the
cover and housing are secure.
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Figure 2-6 Removing the Label Insert
Creating a Custom Label Insert for the TD 200

The dimensions for creating your own custom label insert are shown in the figure below.
These dimensions are valid for TD 200, hardware revision 3 and later.
PP
PP PP PP PP PP

PP PP PP PP
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Figure 2-7 Dimensions for a Custom Label Insert

System Manual, 08/2007, A5E00765548-02 35
2.6 Installing a Faceplate for the TD 100C, TD 200C and TD400C
Installing a Faceplate for the TD 100C, TD 200C, and TD400C

The TD 100C and TD 200C ship with a blank faceplate (envelope size) for creating a
custom-designed faceplate. The TD400C does not ship with a blank faceplate; you can order
a package with blank faceplates (see appendix A for order information).
The TD devices do not ship with the faceplate attached. The front of the TD is an adhesive
surface (shipped with a protective paper) that allows you to attach your custom faceplate.
Refer to Chapter 3 for information about designing and printing a custom faceplate.
The figure below shows the dimensions for the faceplate of the TD devices. Blank faceplate
material for the TD 100C, TD 200C and TD400C is available in the sizes shown below.
● Envelope size for printing a single faceplate (TD 100C, TD 200C only)
● A4 size (210 mm x 297 mm) for printing multiple copies of the faceplate (TD 100C, TD
200C, and TD400C)
You must cut the faceplate from the envelope-sized material, but the A4 material is
perforated to allow you to remove the faceplates without cutting.
Use the following procedure to install your custom faceplate on the TD device. The example
shown here is for the TD 200C. Installing a faceplate on a TD 100C and TD400C is similar;
the differences are noted below. To prepare for installation, remove the protective film
covering the display window of the TD device and the back of the preprinted (standard)
faceplate. The protective film is blue for the TD 100C and the TD 200C, and is transparent
for the TD400C.
1. The dimensions for the custom faceplate are shown for the TD device.
2. If your TD device has a strip of protective paper, remove the strip to expose the strip of
the adhesive. For the TD 200C and the TD400C, it is on the left side of the device. For
the TD 100C, it is on the right side of the device.
3. Carefully align your custom faceplate on the entire TD device, and then seal the faceplate
to the exposed adhesive by pressing down on the left (TD 200C and TD400C) or on the
right (TD 100C) side of the faceplate.
4. Carefully lift back the unadhered faceplate and remove the rest of the protective paper
from the TD device.
5. Carefully position the faceplate onto the TD device. Firmly press the faceplate onto the
adhesive, taking care to remove any air bubbles that may have been trapped underneath.
CAUTION
Do not use excessive force when you install the faceplate onto the TD400C device.
If you use excessive force in pressing the faceplate onto the TD400C device, it may
cause damage to the springs under the faceplate.
Ensure that excessive force is not used when you install the faceplate onto the device.

36 System Manual, 08/2007, A5E00765548-02
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Figure 2-8 Installing a Custom Faceplate on a TD Device

System Manual, 08/2007, A5E00765548-02 37
2.7 Connecting the TD/CPU Cable
The standard TD faceplates are shown in Figure 1-2. The TD 200C comes configured as a
standard TD 200 (with LEFT and RIGHT arrows). The TD 100C comes configured with six
standard keys (UP, DOWN, LEFT and RIGHT arrows, ESC, and ENTER). The TD400C
comes configured with seven standard keys (UP, DOWN, LEFT, RIGHT, ESCAPE, ENTER,
and SHIFT).
After creating and installing the custom faceplate on your TD device you must also download
the TD configuration that you created with both the Keypad Designer and the Text Display
wizard.
● Chapter 3 describes the Keypad Designer
● Chapter 4 describes the Text Display wizard
2.7 Connecting the TD/CPU Cable
Connecting the TD/CPU Cable
CAUTION
Operating the TD device with an ungrounded voltage source can damage the TD device.
The TD device may only be connected to grounded voltage sources. Non-grounded
operation can cause the TD device to become damaged.
Always ensure that the voltage source for the TD device is properly grounded.
The TD devices can use the TD/CPU cable for communicating with the S7-200 CPU.
● You can connect the TD device directly to the S7-200 CPU, creating a one-to-one
network configuration. In this configuration, one TD device connects to one S7-200 CPU
through the TD/CPU cable.
● You can connect multiple TD devices to multiple S7-200 CPUs over a network. The
TD device defaults to address 1 and attempts to communicate to a CPU at address 2.
For more information about connecting to multiple CPUs, see Appendix B. For information
about changing the default addresses in the TD device, see Chapter 5.
If you require a longer cable (>2.5 m) to connect the TD device to the S7-200 CPU, use
PROFIBUS components for the network connection. Refer to the SINEC IK10 Catalog.

38 System Manual, 08/2007, A5E00765548-02
2.8 Supplying Power for the TD Device
2.8 Supplying Power for the TD Device
Supplying Power for the TD Device

The S7-200 CPU uses the TD/CPU cable to provide power to the TD device. Use this type of
power supply when the distance between the TD device and the S7-200 CPU is less than
2.5 m (the length of the TD/CPU cable). The TD 200, TD 200C and the TD400C have the
option of using an external power supply.
Tip
The TD 100C device must use the TD/CPU cable to provide power from the S7-200 CPU to
the TD device. The TD 100C does not have the option of using an external power supply.
Tip
If the distance between the TD 200, TD 200C or TD400C and the S7-200 CPU is greater
than 2.5 m, use an external 24 VDC power supply.
If you require a longer cable (greater than 2.5 m) to connect the TD device to the S7-200
CPU, use PROFIBUS components for the network connection. Refer to the SINEC IK10
Catalog.
Refer to Appendix B for information about using the TD device on a network.
As shown in the figure below, the TD device provides up to two options for providing power:
● The TD/CPU cable allows the S7-200 CPU to provide power to the TD device over the
communications port. This is the only option available for the TD 100C.
For information about the TD/CPU cable and the communications port, refer to
Appendix B.
● You can connect the TD 200, TD 200C or the TD400C to an external power supply.
The TD 200, TD 200C or TD400C requires 120 mA at 24 VDC to operate. An optional
power connector is provided with the TD 200, TD 200C and the TD400C.
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Figure 2-9 Connecting Power to the TD Device (TD 200, TD 200C, and TD400C)

System Manual, 08/2007, A5E00765548-02 39
2.9 Establishing a Connection for Your TD Device
Establishing a Connection for Your TD Device

As described in Chapter 4, you use the Text Display wizard of STEP 7-Micro/WIN to
configure the screens, alarms, languages, and custom keypad layout for the TD 100C,
TD 200C and the TD400C. The S7-200 CPU stores this information in a parameter block
(V memory).
The TD devices ship with a default configuration and are set to communicate at a rate of
9600 baud. The TD devices must communicate with the S7-200 CPU to be able to read the
parameter block.
You must configure your TD device to communicate at the same baud rate as your
S7-200 CPU.
TD 100C, TD 200C, and TD400C

Until the TD device successfully connects to the S7-200 CPU and reads the parameter
block, the TD device remains configured for the standard TD keypad shown in the figure
below.
To change the baud rate of your TD device, you use the ESC and ENTER buttons to
navigate to the Diagnostic/TD Setup Menu and change the TD Setup parameters. (See
Chapter 5.) Because the TD devices ship with no faceplate attached, it may be difficult to
consistently press ESC or ENTER.
The TD 100C, TD 200C, and TD400C devices ship with a faceplate for the standard
TD keypad. In addition, the Keypad Designer provides a sample faceplate for the standard
TD keypad in the following directory.
C:/Program Files/Siemens/ TD Keypad Designer/Templates
For temporary use, you can print this faceplate onto paper and lay the paper on top of the
TD device (without removing the covering from the adhesive).

40 System Manual, 08/2007, A5E00765548-02
Refer to Chapter 3 for information about opening the Keypad Designer and printing a
faceplate.

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Tip
On an initial setup for the TD 100C, TD 200C, or TD400C, use the default keypad template
shipped with the device to configure baud rates and addresses. Once the TD device has
communicated to the CPU, the TD device will use the custom keypad configuration.
Tip
If you are using a custom keypad that does not support the ENTER and ESC buttons, you
must use the standard keypad to set up the TD device.
To restore the standard TD keypad:
1. Power down the TD device
2. Press and hold the lower right corner (where ENTER key is located on the standard
keypad)
3. Power up the TD device
The default keypad is restored until the TD device is power cycled again.

System Manual, 08/2007, A5E00765548-02 41

42 System Manual, 08/2007, A5E00765548-02
3
Using the Keypad Designer to Create a Custom
Faceplate for your Text Display (TD) Device
3.1 Overview
Overview of Chapter 3
With the TD 100C, TD 200C, and the TD400C, you can design a custom keypad that
incorporates buttons (keys) of varying size, with varying shapes, colors, or fonts that can be
layered onto any background image. You can configure up to 14 buttons on the TD 100C, up
to 20 buttons on the TD 200C, and up to 15 buttons on the TD400C.
The Keypad Designer application allows you to create a custom-designed layout for the
keypad of the TD 100C, TD 200C, and TD400C, and also includes samples and templates in
the following directories:
● Sample bitmaps for buttons and backgrounds:
– C:/Program Files/Siemens/TD Keypad Designer/Images
● Sample projects:
– C:/Program Files/Siemens/TD Keypad Designer/Samples
● Templates (for printing multiple copies of the faceplate):
– C:/Program Files/Siemens/TD Keypad Designer/Templates
This chapter guides you through the tasks required for creating the layout for the keypad,
creating the configuration file for the keypad, and printing the faceplate for the TD 100C,
TD 200C, and the TD400C.
You use the configuration file when you are configuring the TD 100C, the TD 200C and the
TD400C with the Text Display wizard of STEP 7-Micro/WIN. Refer to Chapter 4 for
information about the Text Display wizard.
TIP
For more information about creating a custom faceplate, refer to FAQ 23707064 on the
Siemens Internet site at www.siemens.com/S7-200.

System Manual, 08/2007, A5E00765548-02 43
Using the Keypad Designer to Create a Custom Faceplate for your Text Display (TD) Device
3.2 Using the Keypad Designer with Other Applications
Using the Keypad Designer with Other Applications

Use the Keypad Designer to create the custom-designed layout for the keypad.
The TD 100C and the TD 200C lets you incorporate buttons (keys) of varying size, with
varying shapes, colors or fonts. The TD400C lets you incorporate buttons (keys) of varying
colors and fonts. The positions and size of the TD400C buttons (keys) are fixed.
You can configure up to 20 buttons on the TD 200C; up to 14 buttons on the TD 100C; and
up to 15 buttons on the TD400C. As shown in the figure below, you use several applications
to create a custom keypad:
● Keypad Designer: Creates the layout and the configuration for the keypad
● Third-party graphics application: Designs the graphical appearance of the faceplate
● STEP 7-Micro/WIN (Text Display wizard): Configures the parameter block for the TD
device
● Word-processing application (optional): Prints multiple copies of the faceplate
Siemens provides document files (in up to 6 languages depending upon your TD device) for
Microsoft Word that helps you to align the panel images for the perforations on the A4 blank
faceplate material. To open these documents, browse to the Templates subdirectory under
the Keypad Designer application (C:/Program Files/Siemens/TD Keypad
Designer/Templates) and select the template for your TD device and language.
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Figure 3-1 Using the Keypad Designer to Create the Custom Faceplate for Your TD Device

44 System Manual, 08/2007, A5E00765548-02
As shown in the figure below, you perform the following tasks when designing a custom
keypad:
● You use the Keypad Designer to define the layout and the functions for the buttons.
● You export the button template to a third-party graphics application. You then create the
panel image by designing the graphical representations for the buttons and the
background for the faceplate.
● After you import the panel image into the Keypad Designer, you print the faceplate for the
TD device.
● You use the Keypad Designer to create the configuration file (*.td2 for the TD 200C, *.td1
for the TD 100C, or *.td4 for the TD400C).
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Figure 3-2 Tasks for Creating a Custom Faceplate

System Manual, 08/2007, A5E00765548-02 45
3.3 Starting the Keypad Designer
Starting the Keypad Designer

You use the Keypad Designer application to create a custom-designed layout for the keypad
of the TD 100C, the TD 200C, or the TD400C.
When you install STEP 7-Micro/WIN, you also install the Keypad Designer application. The
Keypad Designer does not require STEP 7-Micro/WIN.
You can start the Keypad Designer either from within STEP 7-Micro/WIN or as a stand-alone
application:
● To start as a stand-alone application: Select the Start > SIMATIC > TD Keypad Designer
menu command
● To start from STEP 7-Micro/WIN: Click the Keypad Designer icon in the Tools window
The Keypad Designer application opens with a blank keypad template. The TD 200C and the
TD400C templates are shown in the figures below.. Select File > New to create a new
keypad layout for either the TD 100C, the TD 200C, or the TD400C. In the Keypad Designer
Type dialog, select the keypad type.
To open an existing project, select the File > Open menu command and browse to the
project.
Figure 3-3 TD 200C Keypad Template

46 System Manual, 08/2007, A5E00765548-02
Figure 3-4 TD400C Keypad Template
If you open a file with different target (for example, you are working on a TD 200C file, and
you open a TD 100C file), the panel workspace resizes for the new target. Since the
application is sized based on the panel workspace, you may have to resize and re-position
your application framework.
Table 3-1 describes the files that are used by the Keypad Designer.
You can change the language of the Keypad Designer by selecting the Tools > Options
menu command. You select the language from the Options dialog shown below.
Figure 3-5 Options Dialog

System Manual, 08/2007, A5E00765548-02 47
3.4 Adding Buttons to the Keypad
Table 3-1 Files Used by the Keypad Designer
File Type Extension Description

TD file *.td2 (TD 200C) Create the Keypad project file that stores the
Open, Save, *.td1 (TD 100C) configuration data for the custom-designed keypad
Save As (used by the Text Display wizard)
*.td4 (TD400C)
Button Template *.bmp Export the layout of the buttons on the keypad to a
Export graphics application by selecting a file
Panel Image *.bmp Import the finished bitmap of the faceplate from the
Import graphics application by selecting a file
Panel Image *.bmp Export the finished faceplate to a word-processing
Export (Optional) application for printing multiple copies of the faceplate
Adding Buttons to the Keypad

The TD 100C and the TD 200C allow you relative freedom when designing your keypad.
With the TD400C, the position and size of the buttons are fixed. You cannot add, remove, or
change the TD400C buttons.
On the TD keypad you can configure up to 20 buttons for the TD 200C, up to 14 buttons for
the TD 100C, and up to 15 buttons for the TD400C.
● You can vary the size and the location of the buttons (TD 100C and TD 200C only)
● You can define the functionality for each button.
The Keypad Designer provides a grid that aligns the location of the buttons with the physical
keypad of the TD device.
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Figure 3-6 Adding the Button to the TD 100C and TD 200C Keypad
Tip
Typically, your keypad design should always include buttons with the following functions:
Enter, Escape, Up Arrow, and Down Arrow. These functions allow you to access the pre-
configured menus and functions of the TD device.

48 System Manual, 08/2007, A5E00765548-02
Inserting a Button
With the TD 100C and the TD 200C, you can add a button to the keypad grid. The TD400C
does not have this option.
1. Click the Draw Button icon.
2. Move the cursor over the grid.
3. Move the cursor (and button) into position on the keypad grid.
4. Hold down the left mouse button and drag the cursor to adjust the size and shape of the
button.
5. Release the mouse button to insert the button onto the keypad
After you have inserted the button onto the keypad grid, you can relocate the button by
dragging it to a new location on the grid. However, you cannot resize the button.
Figure 3-7 Adding a Button (TD 100C and TD 200C)

System Manual, 08/2007, A5E00765548-02 49
Modifying the Shape of a Button

With the TD 100C and the TD 200C you can modify the shape of a button. The Keypad
Designer provides two methods for modifying the shape of a button. The TD400C does not
have this option.
● Changing the size or shape of a button by adding a second button on top of the first
button
● Erasing a portion of the button
Extending the Shape of a Button
You cannot resize a button that has been inserted onto the keypad grid. However, with the
TD 100C and the TD 200C, you can insert a second button on top of the first button to create
a new size for the button. The TD400C does not have this option.
As shown in the figure below, adding a second button also allows you to create buttons of
non-rectangular shape (combining the shapes of both buttons).
When you insert the second button, ensure that the cursor is within the boundaries of the
first button.
Figure 3-8 Extending the Shape of a Button (TD 100C and TD 200C)
Erasing an Area of the Button

With the TD 100C and the TD 200C, you can change the shape of the button by clicking the
Erase Button icon. The TD400C does not have this option.
As shown in the figure below, the Keypad Designer alerts you if the shape of the button is
invalid.
To delete the entire button, select the button and press the Delete key.
Figure 3-9 Erasing an Area of a button (TD 100C and TD 200C)
Tip
A valid button must consist of at least 4 adjacent cells, with each cell having at least 2
neighbor cells. A neighbor cell must be left, right, or up or down from the cell. Diagonal
neighbor cells are not counted.

50 System Manual, 08/2007, A5E00765548-02
3.5 Defining the Properties of the Button
Defining the Properties of the Button

After you create the button, you define the function that will be performed when an operator
presses the button.
You use the Properties dialog to configure the functionality for the button:
● Select the button to be configured.
● Select the Edit > Properties menu command to display the Properties dialog.
You can also right-click the button and select Properties from the context menu. You can
double-click the button to bring up the Set Button Properties.
● Select the function for the button and provide a valid function name. Click OK. See
Figure 3-10 for an example of the TD 200C button functions.
The TD400C has up to 15 buttons that can be defined. You do not have to define (or use) all
the buttons. Some buttons can be blank or unused.
Table 3-2 describes the functions that you can configure for the button. The default function
is to set a bit in the S7-200 CPU (Set PLC Bit).
Some functions can also be used in combination with other buttons, such as SHIFT or the
arrow buttons. The Properties dialog provides suggestions for appropriate buttons for
combining the functions.
After you configure the functions for each button on the keypad, select the File > Save or the
File > Save As menu command to create the configuration file (*.td2 for the TD 200C, *.td1
for the TD 100C, or *.td4 for the TD400C).
Tip
A button that has been configured will display the button name on the button in the panel
layout.
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Figure 3-10 Defining the Properties for the Button

System Manual, 08/2007, A5E00765548-02 51
Figure 3-11 Button Properties Dialog
Table 3-2 Button Properties for the TD 100C, TD 200C, and TD400C
Category Function Description

Navigation or Selection Enter Selects a menu item or confirms a value
Escape Exits from a menu or cancels a selection
Up Arrow Scrolls (upwards) through menu items or increments a value that can be
edited
Down Arrow Scrolls (downwards) through menu items or decrements a value that can
be edited
Left Arrow Moves the cursor to the left
Right Arrow Moves the cursor to the right
Entering data Set Bit Sets a memory bit in the S7-200 CPU. You use the Text Display wizard to
assign the specific bit address
For the TD 200C and TD400C, you can use this button to set two different
bits by defining the Shift button
Shift Allows you to use one Set PLC Bit button to control two different bits in
the S7-200 CPU (TD 200C, TD400C)
Clear Value Sets the value being entered to zero (0)
Edit V-Memory Edits a V memory location in the S7-200 CPU. You must specify the
address for the V memory at run time (TD 200C, TD400C)

52 System Manual, 08/2007, A5E00765548-02
Category Function Description

User Screens and Alarms Menu Mode Displays the standard TD menus (See Chapter 5)
(User menu or Alarms
Display Alarm Displays the current alarm message(s)
menu)
Display User Displays the user menu
See Chapters 4 and 5
Menus
Menu 1 Screen 0 Displays the first user screen in the first user menu
Menu 2 Screen 0 Displays the first user screen in the second user menu
Menu 3 Screen 0 Displays the first user screen in the third user menu
Menu 4 Screen 0 Displays the first user screen in the fourth user menu
Menu 5 Screen 0 Displays the first user screen in the fifth user menu (TD 200C, TD400C)
Menu 6 Screen 0 Displays the first user screen in the sixth user menu
(TD 200C, TD400C)
Menu 7 Screen 0 Displays the first user screen in the seventh user menu
(TD 200C, TD400C))
Menu 8 Screen 0 Displays the first user screen in the eighth user menu (TD 200C,
TD400C)
Setting up the TD 200C CPU Status Displays the View CPU Status screen
(Operator menu) Reads and displays the status of the S7-200
See Chapter 5 Select Language Displays the Set Language screen, allowing you to switch between the
Set languages that you configured for the TD 200C, TD400C)
Set PLC Time and Displays the Set Time and Date screen, allowing you to enter the time
Date and date
Diagnostics Change PLC Displays the Change CPU Mode screen, allowing you to change the
(Diagnostic Menu) Mode operating mode of the S7-200 (TD 200C, TD400C)
See Chapter 5 Edit Memory Displays the Edit CPU Memory screen (TD 200C, TD400C)
Force I/O Displays the Force I/O screen (TD 200C, TD400C)
Program Memory Displays the Make MC screen, allowing you to copy the user program to
Cartridge the memory cartridge (TD 200C, TD400C)
TD Setup Displays the TD Setup screen
View Messages Displays the View Messages screen (TD 200C, TD400C)
Password Release Password Allows you to immediately restore the password-protection for the TD
See Chapter 5 device
No Function No Function Allows you to identify a button as "not used"

System Manual, 08/2007, A5E00765548-02 53
3.6 Exporting the Keypad Layout to a Graphics Application
Exporting the Keypad Layout to a Graphics Application

After you have configured the buttons on the keypad, you can create the graphical
representation for the faceplate. You can use any third-party graphics application to add
colors, lines and other artwork to the panel design.
The Keypad Designer exports the layout of the buttons as a bitmap file (*.bmp) that you edit
with the graphics application.
As shown in the figure below, the button template provides a bitmap image of the layout of
the keypad that you can use with your graphical application to position, size and align the
graphical elements of your faceplate design. These elements can include logotype, text, or
other images.
The Keypad Designer allows you to export the layout of the buttons into your graphics
application. Use the File > Export >Button Template to File menu command to create a
bitmap file (*.bmp) that you insert into the graphics application.
After you customize the layout (adding background image, colors, buttons or logotype), you
save the file as a bitmap (*.bmp). This bitmap becomes the panel image for the Keypad
Designer.
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Figure 3-12 Creating the Panel Image: Export Button Layout

54 System Manual, 08/2007, A5E00765548-02
Tip
When you design the colors for your panel image, be aware that any white area will be
printed as transparent (clear).
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Figure 3-13 Exporting the Button Template to a Graphics Application

System Manual, 08/2007, A5E00765548-02 55
3.7 Adding a Panel Image to the Faceplate
Adding a Panel Image to the Faceplate

Using your own graphics application, you create the following graphical elements for the
faceplate of the TD 100C, TD 200C, or the TD400C:
● Button images
● Background image or color scheme
● Text (for the buttons or the background)
● Logotypes (and other images or text)
For the TD 100C and the TD 200C, you are not required to use square buttons. However,
you must ensure that your button design covers the area of the button as defined in the
button template.
After you have used your graphics application to modify the panel image for the faceplate,
save the design as a bitmap file (*.bmp).
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Figure 3-14 Creating the Panel Image: Import Panel Image

56 System Manual, 08/2007, A5E00765548-02
Importing a Panel Image

When you have completed the graphical design of panel image for the faceplate, you import
the panel image back into the Keypad Designer.
After you open your keypad project (*.td1, *.td2, or *.td4), use the File > Import >Panel Image
from File menu command to select the bitmap file that you created with your graphics
application.
Figure 3-15 Keypad with a Panel Image
Tip
When you design your faceplate, you can create the bitmap with any resolution. However,
the size of the background image for the TD device must exactly match the following
dimensions:
● For the TD 200C:
Width: 137 mm (+/- 0.15 mm) (5.42 inches)
Height: 65.7 mm (+/- 0.15 mm) (2.58 inches)
● For the TD 100C:
Width: 79 mm ((+/- 0.1 mm) (3.11 inches)
Height: 65.8 mm (+/- 0.1 mm) (2.59 inches)
● For the TD400C:
Width: 91.5 (+/- 0.1 mm) (3.6 inches)
Height: 163.5 (+/- 0.1mm) (6.44 inches)
If your faceplate design does not match these dimensions, the Keypad Designer alerts you
before importing the panel image. If you import a panel image with incorrect dimensions, the
Keypad Designer resizes your panel image, which could distort the appearance of your
faceplate design.

System Manual, 08/2007, A5E00765548-02 57
3.8 Saving the Keypad to a TD Configuration File
3.8 Saving the Keypad to a TD Configuration File
Saving the Keypad to a TD Configuration File

When you save the keypad, you create a TD configuration file (*.td1 for the TD 100C, *.td2
for the TD 200C, and *.td4 for the TD400C). This file contains the following information about
the buttons on the keypad:
● Number of buttons
● Location and sizes of the buttons
● Names of the buttons
● Functions assigned to the buttons
● Panel image (if one was imported)
Use the File > Save or File > Save As menu command to save the configuration of the
keypad.
The Text Display Wizard uses this information for configuring the TD 100C, TD 200C, or
TD400C. See Chapter 4 for more information.
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Tip
The Keypad Designer allows you to save invalid or incomplete configurations. This allows
you to save interim versions of your work. However, always ensure that the final
configuration of the keypad is valid and complete before using the configuration file (*.tdx)
with the Text Display wizard.

58 System Manual, 08/2007, A5E00765548-02
3.9 Reversing the Panel Image
3.9 Reversing the Panel Image
Reversing the Panel Image

The Reverse Panel Image option only affects the way that the panel image is saved to a file
using the File > Export > Panel Image to File menu command. The exported bitmap file can
then be inserted into the Microsoft Word template. For more information see the next
section, Printing the Panel Image on a Faceplate. The Reverse Panel Image option does not
change the layout of the keypad.
● Printing a reversed image allows you to orient the side of the faceplate with the ink from
the printing process towards the TD device. The operator then touches only the plastic
membrane and not the ink when pressing a button. See the figure below..
● Printing a non-reversed panel image allows the elements to be read correctly when
printed. Use the non-reversed panel image when you print a paper copy of the faceplate
for review. See figure below.
Use the File > Export > Reverse Panel Image menu command to select this function. A
check mark notifies you that Reverse Panel Image function is selected.
Figure 3-17 Reversed Panel Image
Figure 3-18 Non-reversed Panel Image

System Manual, 08/2007, A5E00765548-02 59
3.10 Printing the Panel Image on a Faceplate
Printing the Panel Image on a Faceplate

To print your custom-designed panel image onto the blank faceplate material, you must use
a laser printer that supports printing transparency material in both the A4 and envelope
formats and also supports color printing.
● You can print a single panel image directly from the Keypad Designer on the envelope-
sized blank faceplate (shipped with the TD 100C and TD 200C device). When you print a
single faceplate (File > Print), the panel image is always reversed.
● To print multiple panel images, you can use the Microsoft Word template that ensures
your panel image design is properly sized. You can print multiple panel images onto the
perforated A4-size blank faceplate sheets. See Appendix A for order numbers.
Tip
The faceplate material is specially treated on one side to accommodate printing with a laser
printer. The treated surface is up (or toward you) when you are holding the material with the
cut corner in the top right of the sheet.
Ensure that the material is correctly inserted into the laser printer so that the panel image is
printed onto the treated surface of the material. You must print a reversed-panel image
version onto the faceplate material. To reverse the panel image, see the previous section,
Reversing the Panel Image.
Before printing your panel image onto the blank faceplate sheet, first test your design by
printing the panel image onto regular paper. You can then temporarily use the paper
faceplate to test the functionality of the design with your TD device.
Using the blank faceplate sheets also allows you to create large quantities of high-quality
faceplates by utilizing the professional printing services of shops that specialize in laser
printing.
You can order additional blank faceplates in perforated A4-size sheets (10 sheets/package)
for the TD 100C, TD 200C and TD400C. The faceplate material is especially designed for
printing with laser printers.

60 System Manual, 08/2007, A5E00765548-02
The blank faceplate material for the TD 100C, TD 200C and TD400C is available in the sizes
below:
● Envelope size for printing a single faceplate (TD100C, TD200C): The Keypad Designer
prints registration lines for trimming the faceplate to the correct dimensions. (Use a metal
straight edge and a knife or razor blade to ensure accurate and straight cuts.) The
TD 100C and TD 200C devices ship with a single blank faceplate. The TD400C does not
include a single faceplate.
● A4 size (210 mm x 297 mm) for printing multiple copies of the faceplate (TD100C,
TD200C, and TD400C): You can use the Microsoft Word template to print the faceplate
onto perforated areas of the material. You do not have to cut the faceplates from the
material. Order these A4 sheets from your Siemens distributor. See Appendix A for order
numbers.
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Figure 3-19 Printing the Faceplate
Tip
Before attempting to print a custom faceplate, ensure that both the printer and the word-
processing application are set to the correct paper size:
● Single-copy sheet: Set both the printer and word-processing application to print on
Envelope.
● Multiple-copy A4 sheet: Set both the printer and the word-processing application to print
on A4-size paper.
Your computer and your laser printer may have other settings that cause the printer to scale
the faceplate to an incorrect size. Always first print a test copy on paper before printing your
faceplate onto the blank material.

System Manual, 08/2007, A5E00765548-02 61
Printing a Single Faceplate from the Keypad Designer

You can print individual faceplates directly from the Keypad Designer:
1. Ensure that the laser printer is set to print envelopes.
2. Insert the envelope-size faceplate material into the tray.
3. Select the File > Print menu command.
4. Select the laser printer and click OK.
5. Using the cut lines and a paper cutter, cut the faceplate from the material
Figure 3-20 Printing a Single Faceplate
Tip
For best results use a razor-blade cutting knife with a metal straight edge to cut the faceplate
from the material. You can also use a high-quality paper cutter. Be especially careful when
using scissors or similar tools. Scissors are more likely to stretch or tear the material,
causing irregular edges for the faceplate.

62 System Manual, 08/2007, A5E00765548-02
Printing the Faceplate from a Word-Processing Application

You use a word-processing application (such as Microsoft Word) to print multiple copies of
the faceplate onto A4-size blank faceplate material. After you export the panel image of the
faceplate into a document, you adjust the location of the panel images and print the
document.
Tip
Siemens provides document files (in 6 languages) for Microsoft Word that helps you to align
the panel images for the perforations on the A4 blank faceplate material. To open these
documents, browse to the Templates subdirectory under the Keypad Designer application
(C:/Program Files/Siemens/TD Keypad Designer/Templates) and select the template for
your TD device and language.
Before printing the faceplate onto the blank faceplate material, you must ensure that the
document and the printer settings are both set to print on A4 paper. Also, ensure that the
laser printer itself is configured to print A4 paper.
After you print the faceplate document, you use the perforations to remove the faceplates
from the sheet.
Figure 3-21 Printing Multiple Faceplates
To export the panel image to your word-processing application:

1. Open your word-processing application (Microsoft Word) and open the template file.
2. Open the Keypad Designer
3. In the Keypad Designer, select the File > Export > Panel Image to File menu command to
create a bitmap file that you insert into the word-processing application.
4. Insert the panel image into the document by using the word-processing application to
insert the bitmap file (*.bmp) that you created with the Keypad Designer.
5. Follow the instructions in the template file for positioning and sizing the faceplate.
6. After inserting the panel image into the document, save the document using the File >
Save As menu command of the word-processing application.
With the panel images saved in your document, you can print the document to your laser
printer.
Tip
Before printing the panel image onto the blank faceplate material, first test your design by
printing the faceplate onto regular A4 paper.

System Manual, 08/2007, A5E00765548-02 63
3.11 Installing the Printed Faceplate onto the TD device
Installing the Printed Faceplate onto the TD 100C, TD 200C, and TD400C
Use the following procedure to install your custom faceplate on the TD device. The example
shown here is for the TD 200C. Installing a faceplate on a TD 100C and TD400C is similar;
the differences are noted below. To prepare for installation, remove the protective film
covering the display window of the TD device and the back of the preprinted (standard)
faceplate. The protective film is blue for the TD 100C and the TD 200C, and transparent for
the TD400C.
1. If your TD device has a strip of protective paper, remove the strip to expose a strip of the
adhesive. For the TD 200C and TD400C, it is on the left side; for the TD 100C, it is on the
right side of the device.
2. Carefully align your custom faceplate on the entire TD device, and then seal the faceplate
to the exposed adhesive by pressing down on the left (TD 200C and TD400C) or on the
right (TD 100C) side of the faceplate.
3. Carefully lift back the unadhered faceplate and remove the rest of the protective paper
from the TD device.
4. Carefully position the faceplate onto the TD device. Firmly press the faceplate onto the
adhesive, taking care to remove any air bubbles that may have been trapped underneath.
CAUTION
Do not use excessive force or a hard (or sharp) tool when you install the faceplate onto
the TD400C device.
If you use excessive force a hard tool when you press the faceplate onto the TD400C
device, it may cause damage to the springs under the faceplate.
Ensure that excessive force or a hard (or sharp) tool is not used when you install the
faceplate onto the device

64 System Manual, 08/2007, A5E00765548-02
Refer to Chapter 2 for additional information about installing the TD devices, including the
dimensions for the faceplate.
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Figure 3-22 Adhering the Faceplate onto the TD Device

System Manual, 08/2007, A5E00765548-02 65

66 System Manual, 08/2007, A5E00765548-02
4
Using the Text Display Wizard to Configure the
S7-200 CPU for Your Text Display (TD) Device
4.1 Overview
Overview of Chapter 4
You do not configure or program the TD device. The Text Display wizard creates a
parameter block that stores the configuration, screens and alarms for the TD device. The
S7-200 CPU stores the parameter block in V memory. At power-up, the TD device reads the
parameter block from the S7-200 CPU.
You use the Text Display wizard of STEP 7-Micro/WIN to perform the following tasks:
● Configuring the parameters for the TD device
● Creating the screens and alarms to be displayed on the TD device
● Creating the language sets for the TD device (TD 200, TD 200C and TD400C only)
● Assigning the V memory address for the parameter block
Tip
To connect your TD device to a network, you use the Diagnostic or TD Setup Menu of the
TD device to set up the network addresses, baud rate and other parameters. Refer to
Chapter 5.

System Manual, 08/2007, A5E00765548-02 67
Using the Text Display Wizard to Configure the S7-200 CPU for Your Text Display (TD) Device
4.2 Overview of the Configuration Tasks
Overview of the Configuration Tasks

The S7-200 CPU stores the configuration data for the TD device, including the screens and
alarms, into a parameter block (located in V memory). The Text Display wizard creates the
parameter block. When you download your project (user program and data block) to the
S7-200 CPU, you also download the parameter block as part of the data block.
You do not configure or program the TD device. At power-up, the TD device reads the
parameter block from the S7-200 CPU.
As shown in the figure below, you use the Text Display wizard of STEP 7-Micro/WIN to
create the parameter block for the TD devices. The next figure shows the sequence of the
tasks required for configuring the parameters of the TD device.
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68 System Manual, 08/2007, A5E00765548-02
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System Manual, 08/2007, A5E00765548-02 69
4.3 Configuring the Text Display Device
Configuring the Text Display (TD) Device

STEP 7-Micro/WIN provides a wizard that makes it easy to configure the parameter block
and the messages in the data memory area of the S7-200 CPU.
Text Display Wizard Tasks

As shown below, the Text Display wizard performs the same basic tasks for configuring the
TD devices. However, the specific selections reflect the differences between the TD devices.
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70 System Manual, 08/2007, A5E00765548-02
Starting the Text Display Wizard for the TD Device

You use the Text Display wizard to configure the parameters for the TD device. You can also
use the Text Display wizard to modify an existing TD configuration.
To open the Text Display wizard:
1. Start STEP 7-Micro/WIN.
2. Select the Tools > Text Display Wizard menu command.
The Text Display wizard displays the Introduction dialog, as shown in the figure below.
If the Text Display wizard finds an existing TD configuration, the Introduction dialog provides
a list of existing TD configurations and allows you to select a TD configuration to modify.
Use the Next button to proceed through the dialogs of the wizard.
Figure 4-4 Text Display Wizard

System Manual, 08/2007, A5E00765548-02 71
Selecting the Type of Device to Configure

As shown below, the Text Display wizard prompts you to select the type of TD device to be
configured.
The Text Display wizard uses this selection to display the dialogs for configuring the
parameters for your specific TD device.
Figure 4-5 Selecting the TD Device
Selecting a Password for the TD Device

Selecting a password for the TD device helps you to protect the security of your process or
application. By enabling a four-digit password (from 0000 to 9999), you can control access to
the S7-200 CPU by requiring that an operator enter the password before editing variables
from the TD device.
The TD password also restricts access to the following TD functions:
● Set time and date
● TD Setup
● Forcing I/O
● Changing the CPU mode
● Creating a memory cartridge
● Editing CPU memory
Tip
The TD password affects only the ability of an operator to use the TD device for certain
functions.
If your S7-200 CPU is configured to require a password, the operator must enter the CPU
password to force I/O and create a memory cartridge. The TD password is used in addition
to the CPU password.

72 System Manual, 08/2007, A5E00765548-02
Enabling the TD Menu Functions

You can select the TD functions that appear on your TD device menu. The TD devices have
different functions available. Refer to Chapter 5 for information about these CPU functions.
TD 200
Select the functions you want to be available on the TD 200 menus. The TD 200 supports
the following functions:
● Setting the Time-of-Day clock: Allows you to set the time and date for the S7-200 CPU
● Forcing I/O: Allows you to force I/O points in the S7-200 CPU to be on or off
Figure 4-6 Enabling the CPU Functions for the TD 200

System Manual, 08/2007, A5E00765548-02 73
TD 200C and TD400C

Select the functions you want to be available on the TD 200C or TD400C menus. The
TD 200C and TD400C support the following functions:
● Setting the Time-of-Day clock: Allows you to set the time and date for the S7-200 CPU
● Forcing I/O: Allows you to force I/O points in the S7-200 CPU to be on or off
● Creating a memory cartridge: Allows you to create a memory cartridge which is a
complete copy of the CPU
● Changing the operating mode: Allows you to set the S7-200 CPU to STOP or RUN
● Editing the CPU memory: Allows you to view and change the values of the data stored in
the S7-200 CPU
Figure 4-7 Enabling the CPU Functions for the TD400C and TD 200C

74 System Manual, 08/2007, A5E00765548-02
TD 100C
Select the function you want to be available on the TD 100C menus.
The TD 100C supports the Setting the Time-of-Day clock function. This function allows you
to set the time and date for the S7-200 CPU function.
Figure 4-8 Enabling the CPU Functions for the TD 100C
Selecting the Update Rate for the TD Device

You can select how often the TD device performs a read operation to update the information
from the S7-200 CPU. You can select from "As fast as possible" to "Every 15 seconds" (in
one-second increments).

System Manual, 08/2007, A5E00765548-02 75
Selecting the Language and the Character Set

The Text Display wizard allows you to select the language for the system menus and
prompts of the TD device. This selection does not affect the language setting for the screens
or alarms that you enter. You select a character set that supports the language of the text
that you enter for the screens and alarms. (If the character set does not match the Windows
character set, the Text Display wizard may not display the characters correctly. The TD
device displays these characters correctly.)
● Select the language for the system menus and prompts displayed by the TD device.
The TD devices support English, French, German, Italian, Simplified Chinese, and
Spanish.
● Select the character set for the text in your alarms and screens.
Refer to Appendix A for descriptions of the character sets supported by your TD device.
The Simplified Chinese Character Set is an electronic file that resides on the STEP 7-
Micro/WIN documentation CD
These settings define a language set for the TD device. The Text Display wizard also
provides a series of dialogs for copying the alarms and screens to create additional language
sets (TD 200, TD 200C, and TD400C). For each language set, you select the language and
the character set.
Figure 4-9 Localizing the TD Device
Tip
When you create multiple language sets (TD 200, TD 200C, and TD400C), the Text Display
wizard copies the alarms and screens from the primary language set to the other language
set. You then edit the screens and alarms to translate the text displayed for the new
language set.
If you need to modify the screens or messages (such as to add a new variable or to add a
new alarm), you must edit the primary language. The Text Display wizard copies these
changes to the other language sets.
The Text Display wizard only allows you to change the text in the other language sets.

76 System Manual, 08/2007, A5E00765548-02
Selecting the Font Size (TD 100C, TD400C)

The TD 100C and TD400C support two font sizes for displaying user and alarm messages.
Larger fonts are easier to read, but will result in fewer characters per user message. You
select the font size for the TD100C as shown in the figure below. You select the font size for
the TD400C when you configure the alarm or user message (refer to the section on
configuring screens and alarms in this chapter).
The following font sizes are available:
● TD 100C:
Small font (16 ASCII or 8 Chinese characters per line)
Large font (12 ASCII characters per line)
Font selection applies to all messages and screens
● TD400C:
Small font (24 ASCII or 12 Chinese characters per line)
Large font (16 ASCII or 8 Chinese characters per line)
Each alarm or screen can have a different font
Figure 4-10 Selecting the Font Size (TD 100C)

System Manual, 08/2007, A5E00765548-02 77
Loading a Custom Keypad (TD 100C, TD 200C, and TD400C Only)

The TD 100C, TD 200C, and TD400C allow you to create a custom keypad. As described in
Chapter 3, you can insert buttons onto the keypad. The Keypad Designer saves this
configuration to a file (*.td1 for the TD 100C, *.td2 for the TD 200C, and *.td4 for the
TD400C).
To load the keypad configuration file into the Text Display wizard:
● Select the option, Use a custom keypad created with the Keypad Designer. (Find this
check box in the Options area of the Configure Keypad Buttons dialog. See Figure
below.)
● Browse to the keypad configuration file (*.tdx) that you created with the Keypad Designer.
The Text Display wizard loads the keypad configuration file and updates the table of buttons
and the button symbols.
The Text Display wizard lists only those buttons that you had defined with the Set Bit
functionality when you created the buttons with the Keypad Designer.
Figure 4-11 Configuring the Functions for the Buttons (TD 200C)
Figure 4-12 Configuring the Functions for the Buttons (TD400C)

78 System Manual, 08/2007, A5E00765548-02
Configuring the Buttons on the Keypad

As shown in previous figure, the Configure Keypad Buttons dialog allows you to select a
symbol name and an action for each of the configurable buttons on the TD device.
● The TD 200 keypad provides 4 configurable buttons and a SHIFT button that can be
configured for up to 8 bits in the S7-200 CPU
● The TD 200C can be configured for up to 20 configurable buttons
● The TD 100C can be configured for up to 14 configurable buttons
● The TD400C can be configured for up to 15 configurable buttons
Tip
The Configure Keypad Buttons dialog of the Text Display wizard displays only those buttons
that set bits in the S7-200 CPU. The Text Display wizard does not list the buttons with other
functionality, such as ESC or SHIFT.
The symbols that you assign to the buttons on the keypad allow the logic of your user
program in the S7-200 CPU to interact with the TD device. (The Text Display wizard
suggests a symbol for these buttons. You can accept the recommendation or enter a new
symbol for the button.)
For each button, you configure the type of action:
● Set bit: When you press the button on the TD device, the TD device sets the bit on in the
S7-200 CPU. The bit stays on until the logic of your user program in the S7-200 CPU
resets the bit.
● Momentary contact: When you press the button on the TD device, the TD device sets the
bit on in the S7-200 CPU. When the TD device button is released, the TD device turns
the bit off in the S7-200 CPU.

System Manual, 08/2007, A5E00765548-02 79
4.4 Configuring the Screens for the Text Display Device
Tip
The TD device only sets the bit on or off in the S7-200 CPU a single time when the TD
device button is either pressed or released.
Tip
The TD device can display a special icon that provides visual feedback to the operator and
shows that the set bit key was pressed in the CPU. To enable this feature, check the box at
the bottom of the Configure Keypad Buttons wizard screen (see the previous figure).
Configuring the Screens for the TD Device

The TD device supports a set of user-defined screens and a user menu. Screens allow the
operator using the TD device to initiate the interaction with the S7-200 CPU. See the figure
below.
● User menu: Provides a hierarchy for switching between groups of screens. For the
TD 200, TD 200C, and the TD400C you configure up to 8 entries in the user menu. For
the TD 100C, you configure up to 4 entries in the user menu.
● Screens: You create up to 8 screens for each entry in the user menu.
The TD device displays the screens and the items on the user menu in the order that you
configure them.
If you configure both alarms and screens, you also designate the default display mode for
the TD device.
The operator uses the buttons on the keypad to navigate through the user menu or the
screens that you configured.
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Figure 4-13 Configuring the Screens

80 System Manual, 08/2007, A5E00765548-02
The buttons that a TD operator could use to navigate from a user menu to the screens
associated with that item in the menu are shown below.
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Figure 4-14 Navigating through a Hierarchy of User-Defined Screens
Tip
The screens in the TD 200 and TD 200C are always two lines. The screens in the TD 100C
are always four lines. The screens in the TD400C can be 4 lines (with the small font), or 2
lines (with the large font).

System Manual, 08/2007, A5E00765548-02 81
After you have configured the TD device, you can configure the screens and the user menu.
Click the user menu icon to start creating the user menu for the screens. See the figure
below.
For the user menu, you perform the following tasks:
● Create the groups (names) to be displayed on the user menu
● Determine the sequence of the groups listed on the user menu
For the screens, you perform the following tasks:
● Add the screens to each group (on the user menu)
● Create the text message (and add variables) for each screen
● Add icons to the text message (TD 200C and TD400C only)
● Determine the sequence of the screens for each group
Figure 4-15 Selecting the Screen Configuration Tasks

82 System Manual, 08/2007, A5E00765548-02
Creating the User Menu

The process for creating the screens and user menu is not sequential: You can choose to
enter the screens for each individual group before creating the next group, or you can enter
all of the groups for the user menu before creating any of the screens.
To configure the user menu, you enter the names for each group of screens. See the figure
below for an example of the TD400C. The Text Display wizard displays a green ENTER icon
(and blue arrow) to show which group is selected.
To create the screens associated with a group on the user menu:
1. Move the cursor to the box that designates the group on the user menu.
2. Click the Add Screen button.
3. Create the text for the screen.
4. Click the Add Screen button to create the other screens in this group.
Use the Move Choice Up and Move Choice Down buttons to change the sequence of the
groups listed on the user menu.
Figure 4-16 Defining the User Menu

System Manual, 08/2007, A5E00765548-02 83
Creating the Text for a Screen

Your screen message can contain the following elements:
● Text: Enter your text in the green area that represents the text display area of the TD
device
● Icons (optional): Click the icons in the toolbar to insert the icon into the text message
(TD 200C and TD400C only)
● Variable data (optional): Click the Insert PLC Data button to embed a variable into the
text message
● Font selection (TD400C only): Select the Font button to select a font. You can select a
different font for each row of the user message.
You can designate the screen to be the default screen. The TD will show the default screen
after being powered on.
Figure 4-17 Creating the Message for a TD 200C Screen
Figure 4-18 Creating the Message for a TD400C Screen

84 System Manual, 08/2007, A5E00765548-02
Embedding a Variable into the Text of a Screen

You can embed a variable data field into the text of the screen. To open the Insert PLC Data
dialog, move the cursor to the location for the variable in your text and click the Insert PLC
Data button. As shown in the figure below, you enter the following information:
Tip
For the TD 200, TD 200C, and the TD400C, you can embed up to 6 variables per screen.
For the TD 100C, you can embed up to 1 variable per line (4 variables per screen).
● Data address:
– VB: Numeric String, Text String
– VW: Signed, Unsigned
– VD: Real, Signed, Unsigned
● Data Format: Signed, Unsigned, Real, Numeric String, or Text String
● Digits to the right of the decimal: Up to 7
Figure 4-19 Inserting PLC Data
The TD device rounds a real number to the specified decimal place. For example, if the real
number value is 123.456 and you select 2 digits to the right of the decimal, the TD 200
displays this value as: 123.46.
Tip
Refer to the SIMATIC S7-200 Programmable Controller System Manual for information
about the data types or for the memory addresses supported by the S7-200 CPU.
You can also allow the operator to modify the data stored at this memory location in the
S7-200 CPU.
● You can require the operator enter the TD password before editing the variable.
(You must have enabled password-protection for the TD device.)
● You can configure the cursor to jump to the variable field.
● You can define a symbolic name for the variable. You use the symbolic name to access
this data with your user program.

System Manual, 08/2007, A5E00765548-02 85
Clicking OK inserts the variable into the text of the screen. The Text Display wizard inserts a
block of 4 characters to show the presence of the variable. The value to be displayed for the
variable is right-justified at that location (anchored to the right-most character).
Data values are always right-justified to the right-most character of an embedded variable.
As a data value grows in magnitude, it utilizes more spaces to the left of the anchor point
and can overwrite the text characters. Always provide sufficient space between the end of
your text and the anchor point to allow for the expected range of the data value.
Tip
The actual number of characters used to display a value varies with the size of the value. To
help calculate the number of characters required for displaying the value of the variable, see
the examples listed in Table 4-1.
The TD device displays all values as decimal numbers. Positive signed values are displayed
without a sign, and negative signed values are displayed with a leading minus sign.
Unsigned values are displayed without a sign. A leading zero is used for all fractional
numbers (for example, 0.5). Real numbers are displayed with the number of decimal places
you specify. The value is rounded to the specified decimal place.
Table 4-1 Calculating the Number of Characters Required to Display a Value
Size Type Resolution Maximum Number Example

(Digits to right of Characters
of decimal)
Byte String Not applicable Line length 1 Hello, world
(VB) Numeric Not applicable Line length 1 800.333.7421
String
Word Unsigned 0 5 12345
(VW) 1 to 4 6 1234.5, 1.2345
5 7 0.12345
6 8 0.012345
7 9 0.0012345
Signed 0 6 -12345
1 to 4 7 -1234.5, -1.2345
5 8 -0.12345
6 9 -0.012345
7 10 -0.0012345
Double-Word Unsigned 0 10 1234567890
(VD) 1 to 7 11 123456789.1, 123.4567891
Signed 0 11 -1234567890
1 to 7 12 -123456789.1, -123.4567891
Real 0 Line length1 -1234567
1 to 7 Line length1 12345.6, 0.0123456
1 The length of a line (number of characters in a line) varies by TD model and character size. The line
length is always 20 for a TD 200 or TD 200C. The line length is either 12 or 16 characters for a
TD 100C. The line length for the TD400C depends on the font you selected. If you selected a small
font, you have 24 ASCII characters or 12 Chinese characters per line. If you selected a large font,
you have 16 ASCII characters or 8 Chinese characters per line.

86 System Manual, 08/2007, A5E00765548-02
Embedded String Variables

There are special considerations when you set up a string variable for the TD devices. String
variables are positioned the same as numeric variables, that is, the right-most character of
the variable is positioned at the right-most position of the embedded variable in the Text
Display wizard. This can cause problems when you want to place a text string adjacent to
other text in the message.
When you embed a string variable in a TD alarm or screen, the Text Display wizard shows
the embedded variable occupying 4 character spaces (or 2 Chinese characters) for the
variable. These 4 spaces are the right-most 4 characters of the text string. If you want to
have the text adjacent to other text, that is, to the left of the variable, the characters in the
string need to be left-justified and padded with spaces to place the text in the proper position
on the display.
For example: Assume that we want to show the pump status and that status is either "Pump
OK" or "Pump High Temp". The screen display shows the word "Pump" followed by a string
variable which is set to either "OK" or "High Temp". You set up the display in the Text
Display wizard like this:
Pump _ _ _ _ _ _
The underlines are blank spaces, and the squares are the embedded variable (which takes
up 4 character spaces). You can create 2 strings that you copy into the variable based on
the current pump status. These strings are "OK" and "High Temp". These strings are
displayed in the figure below.
3XPS+LJK7HPS RU 3XPS2.
Figure 4-20 Embedded String Variable
The right-most character of the "OK" string is placed in the right-most position of the
embedded variable. Since the string is only 2 characters, it displays on the right side of the
display where the embedded variable is placed.
To make the "OK" string display next to "Pump", simply add blank spaces to the "OK" string
to match the length of the other string. The "OK" string would become "OK ". Now the string
is displayed in the figure below.
3XPS2.
Figure 4-21 Embedded String Variable with Blank Spaces

System Manual, 08/2007, A5E00765548-02 87
The figure below shows how to create the two strings using the STR_CPY command. Note
how the "OK" string is padded with blank spaces to left justify the characters on the TD
display.
Figure 4-22 Using STR_CPY to Create Strings

88 System Manual, 08/2007, A5E00765548-02
4.5 Configuring the Alarms
Configuring the Alarms

Alarms allow the user program in the S7-200 CPU to initiate interaction with the operator by
displaying an alarm message on the TD device. When your user program sets an alarm bit,
the TD device reads the text of the alarm from the S7-200 CPU.
The figure below lists the key tasks for creating alarms. You configure the following
information for each alarm:
● Number of alarms: Up to 80 alarms for the TD 200, TD 200C and TD400C, and up to 40
alarms for the TD 100C to be configured for the TD device
● Text message for the individual alarms
● Priority for the alarms is determined by the sequence in which you configure the alarms:
– The first alarm has the highest priority
– The last alarm has the lowest priority
● Acknowledgement (if required)
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Figure 4-23 Configuring the Alarms
The TD 200, TD 200C, and TD400C devices store up to 80 alarms, and the TD 100C device
stores up to 40 alarms. The TD displays the alarm messages according to priority.

System Manual, 08/2007, A5E00765548-02 89
The operator uses the buttons on the keypad to scroll through the list of alarms. See the
figure below.
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Figure 4-24 Alarm Messages
Determining the Type of Operator Interaction for an Alarm

The Text Display wizard allows you to determine the type interaction required by the
operator for an alarm. If the user screens are set as the default display mode for the TD
device and an alarm is enabled, an alarm indicator will begin to flash on the TD display. The
indicator is large if there is an alarm enabled that requires acknowledgement. The indicator
will be small if the alarms do not require acknowledgement. The user can switch to the alarm
display to view the alarms.
The alarm display will show one or more alarms in priority order. An UP or DOWN arrow in
the right-most character position indicates more alarms are active, but not visible on the
display. The operator can press either the UP or the DOWN arrow key to scroll through the
other enabled alarms.
The operator can edit or accept variable values by pressing the ENTER key. The TD device
will write the updated variable value to the CPU and set the edit notification bit for that
variable when the operator presses the ENTER key. The TD device then moves the cursor
to the next editable variable. Pressing ENTER for the last editable variable of an alarm writes
this last value to the S7-200 CPU and the TD device then resets the alarm enable bit. For
more information on editing variables, see Editing a Variable that is Embedded in an Alarm
or a Screen in Chapter 5.
Every alarm falls into one of four possible alarm acknowledgement and editing types. This
section explains specifically how each alarm type is handled by the TD device. The four
alarm types follow:
● No acknowledgement required, no edits allowed
● Acknowledgement required, no edits allowed
● No acknowledgement required, edits allowed
● Acknowledgement required, edits allowed

90 System Manual, 08/2007, A5E00765548-02
No Acknowledgement Required, No Edits Allowed

In this combination of no acknowledgement required and no edits allowed, the TD device
simply displays the alarm. The ENTER key has no function since there are no editable
variables within the alarm. The alarm may contain variables that are updated at the update
rate of the TD device. This type of alarm is replaced on the display if a higher priority alarm is
enabled by the S7-200 CPU. The operator can either press the UP or the DOWN arrow key
to scroll to other alarms or press ESC to return to the menus.
The TD device does not clear the corresponding alarm-enable bit in the S7-200 CPU.
Acknowledgement Required, No Edits Allowed
In this combination of acknowledgement required and no edits allowed, the TD device
displays the alarm and makes the entire alarm flash (blink) until the operator presses ENTER
to acknowledge the alarm. Variable values are updated from the S7-200 CPU at the normal
update rate while the alarm is flashing.
When the operator presses ENTER, the TD device:
● Sets the acknowledgement-notification bit for this alarm.
● Clears the alarm-enable bit for this alarm. This causes the alarm to be removed from the
display on the next update cycle.
Another alarm cannot replace the one flashing until the operator acknowledges the flashing
alarm. This is also true even if a higher priority alarm is enabled in the S7-200 CPU. If the TD
device is configured for single line alarms and the CPU enables a higher priority alarm, the
flashing alarm shifts down to the next line of the display. The operator cannot press the UP
or the DOWN key to scroll through other enabled alarms until the current alarm is
acknowledged.
No Acknowledgement Required, Edits Allowed
In this combination of no acknowledgement required and edits allowed, the TD device
displays a alarm and then waits for the operator to edit a value in the alarm. All of the
variables within the alarm are updated at the update rate. Since the alarm does not require
acknowledgement, this type of alarm is removed from the TD device display if a higher
priority alarm is enabled in the S7-200 CPU.
Acknowledgement Required, Edits Allowed
In this combination of acknowledgement required and edits allowed, the TD device displays
the alarm, causes the entire alarm to flash (blink), and then waits until the operator
acknowledges the alarm and edits or accepts the values in the alarm. This type of alarm
requires that the operator edits or accepts the values displayed in the alarm. If the operator
aborts the edit by pressing the ESC key before editing all the values in the alarm, the alarm
flashes to indicate that edits are still required.
When the alarm is enabled in the S7-200 CPU, the TD device notes this and, if there is
space available on the display, reads the alarm from the CPU. The TD device then displays
the alarm and causes the entire alarm to flash to notify the operator that the alarm is present
and must be acknowledged.

System Manual, 08/2007, A5E00765548-02 91
Setting the Default Display Mode and Alarm Parameters

The TD device supports alarms that are displayed under program control. After you have
configured the TD device, you can configure the alarms. When you configure the alarms, you
also select either screens (default) or alarms as the default display mode for the TD device.
Click the Alarms icon to start creating alarms. As shown in the figure below, you select the
following information:
● Default display mode: Select either alarms or screens as the default display mode. This
selects which type of messages the TD device displays after powering up or after a
prolonged period of no key presses by the user.
● Size of the alarms: Select 1 line or 2 lines (TD 100C, TD200 and TD400C), or 4 lines
(TD400C only).
For Chinese characters, select either one row or two rows of text.
Figure 4-25 Configuring the TD 200C Alarm Options
Figure 4-26 Configuring the TD400C Alarm Options
Tip
The TD 200, TD 200C, and the TD400C support up to 80 alarms, and the TD 100C supports
up to 40 alarms. The priority for the alarms is determined sequentially, from the first alarm
(highest priority) to the last (lowest priority).

92 System Manual, 08/2007, A5E00765548-02
Entering the Text for an Alarm

Clicking Next displays the Alarms dialog shown in the figure below. You can select a
symbolic name for the alarm. The user program uses the symbolic name to enable (and
display) the alarm. Click the New Alarm button to create the alarm message. Your alarm
message can contain the following elements:
● Text: Enter your text in the green area that represents the text display area of the TD
device
● Icons (optional, TD 200C and TD400C): Click the icons in the toolbar to insert the icon
into the text message
● Variable data (optional): Click the Insert PLC Data button to embed a variable into the
text message
● Fonts: For the TD400C you select the font to use for the alarm message
To ensure that important alarms are acknowledged by an operator, you can configure the
alarm to require acknowledgement.
You select the symbolic name for the acknowledgement bit for the alarm. The user program
uses this symbolic name to report that the alarm has been acknowledged.
To acknowledge an alarm with the TD device, the operator selects the alarm and presses
ENTER.
Figure 4-27 Creating the Text for an Alarm

System Manual, 08/2007, A5E00765548-02 93
Embedding a Variable into the Text of an Alarm

You can embed a variable data field into the text of the alarm. To embed a variable, move
the cursor to the location for the variable in your text and click the Insert PLC Data button. As
shown in the figure below you enter the following information:
Tip
For the TD 200, TD 200C, and the TD400C, you can embed up to 6 variables per alarm. For
the TD 100C, you can embed up to 1 variable per line (1 for one-line alarms, and 2 for two-
line alarms).
● Data address:
– VB: Numeric String, Text String
– VW: Signed, Unsigned
– VD: Real, Signed, Unsigned
● Data Format: Signed, Unsigned, Real, Numeric String, or Text String
● Digits to the right of the decimal: Up to 7
– The TD device rounds a real number to the specified decimal place. For example, if
the real number value is 123.456 and you select 2 digits to the right of the decimal, the
TD 200 displays this value as: 123.46.
Figure 4-28 Inserting a Variable into the Text of an Alarm
Tip
Refer to the SIMATIC S7-200 Programmable Controller System Manual for information
about data types or for the memory addresses supported by the S7-200 CPU.
You can also allow the operator to modify the data stored at this memory location in the
S7-200 CPU.
● You can require the operator enter the TD password before editing the variable. (You
must have enabled password-protection for the TD device.)
● You can configure the cursor to jump to the variable field.
● You can define a symbolic name for the variable. You use the symbolic name to access
this data with your user program.

94 System Manual, 08/2007, A5E00765548-02
Clicking OK inserts the variable into the text of the alarm. The Text Display wizard inserts a
block of 4 characters to show the presence of the variable. The value to be displayed for the
variable is right-justified at that location (anchored to the right-most character).
Data values are always right-justified to the right-most character of an embedded variable.
As a data value grows in magnitude, it utilizes more spaces to the left of the anchor point
and can overwrite the text characters. Always provide sufficient space between the end of
your text and the anchor point to allow for the expected range of the data value.
Tip
The actual number of characters used to display a value varies with the size of the value. To
help calculate the number of characters required for displaying the value of the variable, see
the examples listed in Table 4-2.
The TD device displays all values as decimal numbers. Positive signed values are displayed
without a sign, and negative signed values are displayed with a leading minus sign.
Unsigned values are displayed without a sign. A leading zero is used for all fractional
numbers (for example, 0.5). Real numbers are displayed with the number of decimal places
you specify. The value is rounded to the specified decimal place.
For more information about embedding string variables in an alarm, see page 53.
Table 4-2 Calculating the Number of Characters Required to Display a Value
Size Type Resolution Maximum Number Example

(Digits to right of Characters
of decimal)
Byte String Not applicable Line length 1 Hello, world
(VB) Numeric Not applicable Line length 1 800.333.7421
String
Word Unsigned 0 5 12345
(VW) 1 to 4 6 1234.5, 1.2345
5 7 0.12345
6 8 0.012345
7 9 0.0012345
Signed 0 6 -12345
1 to 4 7 -1234.5, -1.2345
5 8 -0.12345
6 9 -0.012345
7 10 -0.0012345
Double-Word Unsigned 0 10 1234567890
(VD) 1 to 7 11 123456789.1, 123.4567891
Signed 0 11 -1234567890
1 to 7 12 -123456789.1, -123.4567891
Real 0 Line length1 -1234567
1 to 7 Line length1 12345.6, 0.0123456
1 The length of a line (number of characters in a line) varies by TD model and character size. The line
length is always 20 for a TD 200 or TD 200C. The line length is either 12 or 16 characters for a
TD 100C. The line length for the TD400C depends on the font you selected. If you selected a small
font, you have 24 ASCII characters or 12 Chinese characters per line. If you selected a large font,
you have 16 ASCII characters or 8 Chinese characters per line.

System Manual, 08/2007, A5E00765548-02 95
4.6 Configuring the Language Sets (TD 200, TD 200C, and TD400C)
Configuring the Language Sets for the TD Device (TD 200, TD 200C, TD400C)
The Text Display wizard allows you to configure multiple language sets for your TD device,
including not only the system prompts or messages, but also for the user alarms, user
menus, and screens. The Text Display wizard copies the user alarms and user screens that
you have configured into the language set. You must manually enter the translated text for
each alarm, menu, or screen.
For each language set, you select the following information:
● Language for the system prompts
● Character set
● Identifier
You also select which of the language sets is the primary language for the TD device.
/DQJXDJH6HWV
ᅛ'HILQHWKHODQJXDJHVVHWV
Ⴠ 6HOHFWWKHODQJXDJHIRUWKHV\VWHPPHQXVDQG
SURPSWV
Ⴠ 6HOHFWWKHFKDUDFWHUVHW
Figure 4-29 Configuring the Languages for the TD Device

96 System Manual, 08/2007, A5E00765548-02
Tip
When you create multiple language sets, the Text Display wizard copies the user alarms,
menus, and screens from the primary language set to the other language set. You then edit
the alarms, menus, and screens to translate the text displayed for the new language set.
If you need to modify the screens or messages (such as to add a new variable or to add a
new alarm), you must edit the primary language. The Text Display wizard copies these
changes to the other language sets.
The Text Display wizard only allows you to change the text in the other language sets.
After you have configured the alarms and screens for one language set, you can add a new
language set:
1. Click the icon to start configuring the language sets for the TD device.
2. Add a new language by selecting New Language Set.
3. Select an existing language set to be the source for the new language set.
4. (Optional) Select the option for primary language to configure the new language as the
default language set for the TD device.
5. Click the Next button to display the Localize Display dialog.
Figure 4-30 Adding a Language
The Localize dialog configures the menus and character set for the TD device
1. Select the language for the system menus and prompts of the TD device.
2. Select the character set for the text.
3. Enter the name to be displayed on the TD device for this language set.

System Manual, 08/2007, A5E00765548-02 97
After you click the Next button, the Text Display wizard copies all of the user alarms, menus,
and screens from the selected language set to the new language set.
Figure 4-31 Localizing the Display
Notes for Using the Simplified Chinese Character Set

Tip
The Simplified Chinese character set requires a Chinese version of Windows or a Chinese
emulator to properly display Chinese characters in the Text Display wizard. You must start
the Chinese emulator before you start the STEP 7-Micro/WIN software.
On the TD 200C, and the TD 200, you can display up to 20 single-byte characters per line of
your message. Because Simplified Chinese uses double-byte characters, you can display up
to 10 double-byte characters per line for a message in Chinese.
On the TD 100C, you can display up to 16 single-byte characters per line of your message.
Because Simplified Chinese uses double-byte characters, you can display up to 8 double-
byte characters per line for a message in Chinese.
On the TD400C using a small font, you can display up to 24 single-byte characters per line
of your message. Because Simplified Chinese uses double-byte characters, you can display
up to 12 double-byte characters per line for a message in Chinese. If you selected a large
font, you can display up to 16 single-byte characters or 12 Chinese characters per line.
The standard ASCII characters, such as numbers, punctuation, and upper and lowercase
alphabet characters, are available when using the Simplified Chinese character set.
Depending on your keyboard and/ or emulator, some of these standard characters may be
formatted as single-byte characters instead of the double-byte characters like the Simplified
Chinese characters. Standard ASCII characters and Chinese characters can be mixed on
the TD display.
The Text Display wizard displays 8, 10 or 12 double-byte character places for the text of a
screen or alarm. You can fit any of the following combinations into a character position:
● 1 double-byte character
● 2 single-byte characters (standard ASCII)
● 1 single-byte character and 1 single-byte blank

98 System Manual, 08/2007, A5E00765548-02
4.7 Assigning the V Memory Address for the Parameter Block
You cannot fit one single-byte character plus one double-byte character in a character
position.
The TD 100C does not support the entire Simplified Chinese character set, but does support
the most commonly used characters. Characters that are not supported by the TD 100C are
displayed as a square.
See the Simplified Chinese Characters Set on the STEP 7-Micro/WIN documentation CD for
a list of characters supported by the TD 100C.
4.7 Assigning the V Memory Address for the Parameter Block
Assigning the V Memory Address for the Parameter Block

The Text Display wizard creates the parameter block that you download to the S7-200 CPU
with your user program. The parameter block includes the configuration data for the TD
device and any screens and alarms that you created.
The Text Display wizard calculates the amount of memory required for the parameter block
and suggests a starting address in V memory.
The default location for the parameter block is VB0.
ᅛ'HILQHWKHDGGUHVVRIWKHSDUDPHWHUEORFN
9PHPRU\
Figure 4-32 Assigning the Address of the Parameter Block

System Manual, 08/2007, A5E00765548-02 99
4.8 Finishing the Configuration for the TD Device
4.8 Finishing the Configuration for the TD Device
Finishing the Configuration for the TD Device

After you complete the configuration for your TD device, the Text Display wizard displays a
summary dialog. (See the figure below.)
If you enter a name for the TD configuration, STEP 7-Micro/WIN creates an entry in the
project tree for the TD configuration.
STEP 7-Micro/WIN also creates the following subroutines:
● TD_CTRL_x (where x is the TD configuration number)
– This subroutine ensures that all updates for the TD device (such as alarms or
changing the language setting) occur immediately.
– Your user program should use SM0.0 to call this subroutine every scan
● TD_ALM_x (where x is the TD configuration number)
– Your user program uses this subroutine to call the alarm by the symbolic name
(configured by the Text Display wizard). This subroutine requires the S7-200 Symbol
Table.
Figure 4-33 Summary Dialog

100 System Manual, 08/2007, A5E00765548-02
Operating Your Text Display (TD) Device 5
5.1 Overview
Operating Your TD Device

Included in this chapter is information about routine operator tasks, such as entering and
releasing the password, editing variables embedded in a message or screen, and checking
the status information of the S7-200 CPU. This chapter also describes the less-routine
diagnostic functions provided by the TD device for troubleshooting problems in the S7-200
CPU, such as forcing I/O or changing the operating mode
5.2 Using the Text Display Device to Access Screens and Alarms
Using the TD Device to Access Screens and Alarms

The TD devices allow you to structure information as either screens or bit-enabled alarm
messages. You use the buttons of the keypad of the TD device to navigate through the
screens and menus:
● TD 200: Uses the standard TD keypad.
● TD 100C, TD 200C, and TD400C: Allow you to change the configuration and use your
own custom-designed keypad. (If there is no custom configuration, the TD 100C,TD 200C
and TD400C defaults to the standard TD keypad configuration.)
Tip
For more information about configuring the functionality of the buttons on the keypad:
● Chapter 4 provides information about configuring the buttons for the TD devices. The TD
configuration is downloaded to the S7-200 CPU with your user program.
● Chapter 3 provides information about creating a custom keypad layout for the TD device,
and assigning specific functionality for each button. (You then integrate the custom
keypad with the screens and alarm messages as described in Chapter 4.)

System Manual, 08/2007, A5E00765548-02 101
Operating Your Text Display (TD) Device
As shown in Figure 5-1 and Figure 5-2, the standard TD keypad provides the following
buttons:
● ENTER and Escape (ESC) buttons:
– ENTER selects a menu item or confirms a value.
– ESC exits from a menu or cancels a selection.
● Configurable buttons:
– Function keys perform the task that you configured with the Text Display wizard. The
TD 200, TD 200C, and TD400C uses F1 to F4, and the TD 100C uses F1 and F2.
– SHIFT on the TD 200, TD 200C and TD400C allows the function keys (F5 to F8) to
perform the task that you configured with the Text Display wizard.
6WDQGDUG)DFHSODWH7' 6WDQGDUG)DFHSODWH7'&

6,(0(16 6,(0(16
) ) ) ) ) ) ) )
) ) ) ) ) ) ) )
6+,)7 (6& (17(5 6+,)7 (6& (17(5
&RQILJXUDEOHEXWWRQV (17(5 &RQILJXUDEOHEXWWRQV (17(5

DQG6+,)7 DQG(6& DQG6+,)7 DQG(6&

M
6,(0(16 7'&
6,(0(16
7'&
F9 F10 F11 F12

) ) (6& (17(5 F1 F2 F3 F4 ESC
F13 F14 F15 F16

F5 F6 F7 F8 SHIFT ENTER
(17(5
&RQILJXUDEOHEXWWRQV DQG(6&
&RQILJXUDEOHEXWWRQV SHIFT, ENTER and ESC
Figure 5-1 Standard TD Keyboards

102 System Manual, 08/2007, A5E00765548-02
● Arrow buttons:
– UP arrow scrolls (upwards) through menu items or increments a value that can be
edited.
– DOWN arrow scrolls (downwards) through menu items or decrements a value that can
be edited.
– LEFT and RIGHT arrows move the cursor left or right within the message (TD 100C,
TD 200C, and TD400C only). For a TD 200, use SHIFT+DOWN to move right and
SHIFT+UP to move left. You can also use ENTER to move to the next variable
message.
To select a menu item, use the UP and DOWN arrows to scroll through the list of available
items. The TD device highlights the menu item.
● Pressing ENTER selects the highlighted item.
● Pressing ESC returns to the previous menu or screen.
Display Backlight on the TD400C

The TD400C allows you to set the amount of time that the display backlight is on. This allows
you to extend the life of theTD400C by turning off the backlight when the display is not
needed.
You can configure the TD400C display backlight on time:
● From 1 to 59 minutes in 1 minute increments
● Always on
● 1, 2, 4, or 8 hours
● Default on time (10 minutes)
The backlight will turn on when:
● The TD400C is powered on
● The S7-200 CPU forces a reset of the TD400C with the TD_Reset bit in the TD parameter
block.
● You press a key. The time is extended each time a key is pressed.
● A new alarm is read from the S7-200 CPU
When the display backlight is turned on, the backlight is on for the time that you configured in
the TD Setup menu.
If the backlight is currently off and you press a key, the first keypress will turn on the
backlight, but will not execute the key function. You must press the key a second time to
execute the key function. There will be no audio or visual feedback for the first keypress that
turns on the backlight. This lets you know that the key did not execute the key function and
you must press the key again.
If your TD400C has an alarm that requires acknowledgement (an alarm that flashes or
blinks), and that alarm is enabled, the display backlight will be on until you acknowledge the
alarm.

System Manual, 08/2007, A5E00765548-02 103
Displaying Information on the TD Device

The TD device provides both screens (user-defined menus with associated screens of
information) and bit-enabled alarm messages:
● Menu: A menu is a list of items that select a grouping of related screens. The TD 200,
TD 200C and the TD400C have 8 menus available; the TD 100C has 4 menus available
● Screen or alarm:
– A screen or alarm for the TD 200 and TD 200C displays up to two lines of text that
provide information for the operator. Each line can be up to 20 characters of text and
data. A screen contains up to 40 characters of text and data. An alarm can be either 1
or 2 lines.
– A screen or alarm for the TD400C displays up to four lines of text that provide
information for the operator. Each line can be up to 24 characters of text and data. A
screen contains up to 96 characters of text and data. An alarm can be either 1, 2, or 4
lines.
– A screen or alarm for the TD 100C displays up to four lines of text that provide
information for the operator. (Each line can contain either 12 or 16 characters of text
and data. A screen contains 48 or 64 characters of text and data. An alarm can be
either 1 or 2 lines.)
The textual message of the screen or alarm can convey information for the operator
and can also allow the operator to interact with the S7-200 CPU by changing the
embedded value of a variable (such as a set point or limit).
You can configure the TD device to display screens (which are initiated by operator action)
and bit-enabled alarms (which are generated by the S7-200 CPU). You can also configure
the TD 200 and TD 200C, and TD400C device to display an icon to alert the operator of
some event or action required. (Refer to Chapter 4 for information about configuring the TD
device.)

104 System Manual, 08/2007, A5E00765548-02
Tip
Pressing ESC returns you to the previous menu. If there is no activity for 20 seconds (no
button pressed), the TD device returns to the default display mode.
The operator uses the buttons on the keypad to navigate through the menu or a list of text.
Figure 5-2 shows the buttons that an operator could use to navigate from a user menu to the
screens associated with that item in the menu. Figure 5-3 shows how to navigate through the
alarms. The TD 200, TD 200C, and the TD400C have eight menus available, and the
TD 100C has four menus available.
7KH83$UURZVFUROOVXS
WKURXJKWKHOLVWDQGZUDSV
WRWKHODVWLWHP 7KH83$UURZVFUROOVXS
WKURXJKWKHOLVWDQGZUDSVWR
8VHUPHQXLWHP (17(5GLVSOD\V WKHODVWVFUHHQ
(QWHU WKHVFUHHQV
8VHUPHQXLWHP
8VHUPHQXLWHP 6FUHHQ
8VHUPHQXLWHP (6&UHWXUQVWR 6FUHHQ

(6&
8VHUPHQXLWHP WKHXVHUPHQX &DQEHLQWHUDFWLYH
8VHUPHQXLWHP 6FUHHQ
6FUHHQ
7KH'2:1$UURZVFUROOVGRZQ &DQEHLQWHUDFWLYH
WKURXJKWKHOLVWDQGZUDSVWR
WKHILUVWLWHP 7KH'2:1$UURZVFUROOV
GRZQWKURXJKWKHOLVWDQG
ZUDSVWRWKHILUVWVFUHHQ
Figure 5-2 Using the Keypad to Navigate between User Menus and Screens

System Manual, 08/2007, A5E00765548-02 105
6&38
(17(5DFNQRZOHGJHVWKHDODUPDQG
UHVHWVWKHDODUPELWLQWKH6&38
:KHQDQDODUPELWWXUQVRQWKH
6&38ZULWHVWKHDVVRFLDWHG
DODUPPHVVDJHWRWKH7'GHYLFH
7KH83$UURZVFUROOVXSWKURXJK
WKHOLVWRIDODUPVDQGZUDSVWRWKH
ODVWDODUP
$ODUPKLJKHVWSULRULW\
$ODUP
(QWHU
7KH7'GHYLFHOLVWVWKHDODUPV $ODUP
DFFRUGLQJWRSULRULW\ $ODUP
$ODUPORZHVWSULRULW\
7KH'2:1$UURZVFUROOVGRZQWKURXJK
WKHOLVWRIDODUPVDQGZUDSVWRWKHILUVW
DODUP
Figure 5-3 Displaying and Acknowledging Alarms
Using the TD Device to Edit Variables in the S7-200 CPU

A screen or alarm message can contain an embedded variable field that allows an operator
to respond by changing the value of the variable. The operator uses the keypad to edit
variables:
● Selecting the Screen: The operator uses the UP or DOWN arrows to display the screen
that contains the variable to be edited. (From a menu, the operator presses ENTER to
access the group of screens.)
● Navigating to the variable: The operator presses ENTER to navigate to the first editable
variable.
● Changing the value of the variable: Pressing the UP arrow increments (increases) the
value, and pressing the DOWN arrow decrements (decreases) the value. (Pressing and
holding the UP or DOWN arrow accelerates the operation.) Pressing both SHIFT+ENTER
resets the variable to 0. Pressing ESC aborts the edit.
● Press LEFT or RIGHT to move the cursor position within the variable. The TD 200 uses
SHIFT+UP to move left and SHIFT+DOWN to move right.
● Updating the data in the S7-200 CPU: Pressing ENTER writes the updated value for the
variable to the S7-200 CPU and moves the cursor to the next editable variable on the
screen.
For more information about editing variables, see the section Editing a Variable that is
Embedded in an Alarm or a Screen in this chapter.

106 System Manual, 08/2007, A5E00765548-02
5.3 Accessing the Menus and Screens
Accessing the Menus and Screens

When you configured the TD device (as described in Chapter 4), you created the screens
and alarms for the TD device. If you configured both alarms and screens, you also
designated which type of message (screens or the alarms) would be the default display
mode for the TD device. After power-up or after a period of inactivity, the TD device returns
to the default display mode.
In addition to the screens and alarms that you configured, the TD device provides standard
functions that the operator can access from system-level and pre-defined menus. From the
default display mode, the operator uses ESC to access the menu hierarchy. The operator
then presses ENTER to select the menu item for accessing the other menus or functions.
Figure 5-5 and Figure 5-6 show the hierarchy of menus for these functions for the TD
devices. (The menus show all of the functions that are available on the TD device. For some
of the functions to be listed on the menu, you must have enabled the function during
configuration. See Chapter 4.)
'HIDXOW'LVSOD\0RGH 6HFRQGDU\'LVSOD\

6FUHHQV $ODUPV&DQEHFRQILJXUHGDV
'HIDXOWVFUHHQ GHIDXOWVFUHHQ
3UHVV(6&WRGLVSOD\WKH8VHU 3UHVV(6&WRGLVSOD\WKH
(6& 0HQXRIWKHVFUHHQV (6& 0DLQ0HQX
8VHU0HQXRIWKH6FUHHQV
2SHUDWRU0HQX
6FUHHQV
6FUHHQV
&386WDWXV
8SWRHQWULHV 6HW7LPHDQG'DWH
6HW/DQJXDJH
3UHVV(6&WRGLVSOD\WKH
(6&
0DLQ0HQX
(6& 0DLQ0HQX
'LDJQRVWLF0HQX
0DLQ0HQX 7'6HWXS
9LHZ0HVVDJHV
'LVSOD\$ODUPV )RUFH,2
2SHUDWRU0HQX &KDQJH&380RGH
'LDJQRVWLF0HQX 0DNH0HPRU\&DUWULGJH
5HOHDVH3DVVZRUG (GLW&380HPRU\
(6& 3UHVV(6&WRUHWXUQWRWKH (6& 0DLQ0HQX
GHIDXOWGLVSOD\PRGH
Figure 5-4 Menu Hierarchy for the TD 200, TD 200C, and TD400C

System Manual, 08/2007, A5E00765548-02 107
'HIDXOW'LVSOD\0RGH
6FUHHQV
'HIDXOWVFUHHQ
3UHVV(6&WRGLVSOD\WKH8VHU
(6& 0HQXRIWKHVFUHHQV
8VHU0HQXRIWKH6FUHHQV
6FUHHQV
6FUHHQV
6FUHHQV
6FUHHQV
(6& 0DLQ0HQX
6HFRQGDU\'LVSOD\
$ODUPV&DQEHFRQILJXUHGDV
GHIDXOWVFUHHQ
0HQX
'LVSOD\$ODUPV
&386WDWXV (6& 0DLQ0HQX
6HW7LPH
5HOHDVH3DVVZRUG
&OHDQ.H\SDG
7'6HWXS
3UHVV(6&WRUHWXUQWRWKH
(6&
GHIDXOWGLVSOD\PRGH
Figure 5-5 Menu Hierarchy for the TD 100C

108 System Manual, 08/2007, A5E00765548-02
5.4 Entering and Releasing a Password
5.4 Entering and Releasing a Password
Entering and Releasing a Password

You use the Text Display wizard of STEP 7-Micro/WIN to configure the password for the TD
device. Refer to Chapter 4 for information about configuring the TD device. To ensure that
an unauthorized user does not have access to the TD device during an interval for the
automatic time-out, you can use the Release Password feature.
Certain operations (such as forcing I/O or making a memory cartridge) may also require that
the operator enter the 8-character CPU password for the S7-200 CPU. (You must have
enabled the S7-200 CPU for password-protection in order for the TD device to prompt the
operator for the CPU password.)
Entering the Password

If configured for a password, the TD device prompts the operator to enter the 4-digit
password before allowing the operator to access screens or menus. If the password uses
fewer than 4 digits, the operator must press ENTER for the unused (remaining) characters.
Use the UP or DOWN arrow to select each digit of the password, pressing ENTER to move
to the next digit. You can also use the RIGHT and LEFT arrows to move within the
password.
The TD device provides a time-out feature which automatically restores password protection
after a period of inactivity. If no buttons have been pressed after 2 minutes, the TD device
then requires a password again before allowing an operator to access menus or to edit
variables.
Releasing the Password

In order to provide additional security for your application, the TD device provides a Release
Password command that immediately restores the password-protection. The TD device then
requires that the operator enter the password before allowing access. The Release
Password command prohibits another person from using the TD device without first entering
a password (for example, before a password entered by an operator times out).
You access the Release Password command from the main menu, as shown in figure below.
The Release Password is not applicable for the CPU password: The TD device releases the
CPU password as soon as the operator exits the function that required the password.
For example: If the operator entered the CPU password in order to force an I/O point in the
S7-200 CPU, the TD device releases the CPU password as soon as the operator exits the
Force menu.
The Release Password command is available only if you defined a 4-digit password when
you configured the TD device.
'LVSOD\$ODUPV
2SHUDWRU0HQX
'LDJQRVWLF0HQX
5HOHDVH3DVVZRUG
Figure 5-6 Release Password Command

System Manual, 08/2007, A5E00765548-02 109
5.5 Viewing the Screens and the Alarms
Viewing the Screens and the Alarms

As described in Chapter 4, you can configure screens and alarms for the TD device. If you
configure both alarms and screens, you also designate which set of messages (screens or
alarms) are the default display mode for the TD device. The default configuration selects the
screens to be the default display.
After power-up or after a period of inactivity (one minute), the TD device returns to the
default display mode. As shown in the figures below, the operator can switch between the
default display mode and the secondary display mode.
Tip
For the TD 100C, TD 200C, and the TD400C: If you do not configure buttons for ESC or
ENTER, you cannot access the main menu.
7'7'&DQG7'&6FUHHQV8SWR6FUHHQV(DFKIRU8SWR*URXSV
0HQXRIWKHVFUHHQV (6&
8VHU0HQX
6FUHHQ 8VHUPHQXLWHP (QWHU

8VHWKH83RU'2:1DUURZ 8VHUPHQXLWHP
EXWWRQWRVFUROOWKURXJKWKH
VFUHHQVIRUWKLVJURXS
8SWRHQWULHV
6FUHHQV
(6&
0DLQ0HQX
'HIDXOW'LVSOD\0RGH
6HFRQGDU\'LVSOD\
0DLQ0HQX
%LW(QDEOHG$ODUPV
(6& $ODUPPHVVDJH
GHIDXOWGLVSOD\
8VHWKH83RU'2:1DUURZ
EXWWRQVWRVFUROOWKURXJKWKHOLVW
'LVSOD\$ODUPV (QWHU RIDODUPPHVVDJHV
2SHUDWRU0HQX
'LDJQRVWLF0HQX
5HOHDVH3DVVZRUG (6& 3UHVV(6&WRGLVSOD\WKH
0DLQ0HQX
Figure 5-7 TD 200, TD 200C, and TD400C - Navigating between the Default and Secondary
Displays

110 System Manual, 08/2007, A5E00765548-02
7'&6FUHHQV8SWR6FUHHQV(DFKIRU8SWR*URXSV
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System Manual, 08/2007, A5E00765548-02 111
Displaying the Alarms

If you created both screens and alarms when you configured the TD device, the main menu
of the TD device includes a command that allows you to access the secondary (non-default)
display. The TD device always returns to the default display mode after a period of inactivity.
As shown in the TD 200C example in the figure below, the main menu provides a Display
Alarms command for the default TD configuration. If you configured alarms as the default
display, the main menu lists a User Menu entry.
After displaying the alarms, you use the UP and DOWN arrows to scroll through the
sequential list of alarms.
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Figure 5-9 Displaying the Alarms
Tip
The TD 100C, TD 200C, and the TD400C allow you to configure a button specifically for
displaying alarms when you are creating your custom keypad.
The TD device displays the highest priority alarm. The TD device displays an up or down
arrow with the alarm to alert the operator that other alarms have been enabled. (The up
arrow shows that higher-priority alarms have been enabled, and the down arrow shows that
lower-priority alarms have been enabled.)
After reading a new alarm from the S7-200 CPU, the TD device sorts the alarms again to
display the highest priority alarms at the top of the list. The TD device determines the priority
based on the sequence of the alarms in the parameter block:
● The first alarm that you created has the highest priority.
● The second alarm that you created has the second-highest priority.
● The last alarm that you created has the lowest priority.
Tip
You can scroll up and down through the list of enabled alarms. However, the TD device
returns to the highest-priority alarm after a period of inactivity: If you have not pressed a
button for 10 seconds while the TD device has displayed the current alarm, then the TD
device automatically returns to the highest-priority alarm.
Acknowledging an Alarm
If an alarm requires acknowledgement, the TD device does not remove that alarm until you
acknowledge the alarm:
1. Use the UP or DOWN arrow to select the alarm.
2. Press ENTER to acknowledge the alarm.

112 System Manual, 08/2007, A5E00765548-02
Types of Alarms
The Text Display wizard allows you to determine the type interaction required by the
operator for an alarm. If the user screens are set as the default display mode for the TD
device and an alarm is enabled, an alarm indicator will begin to flash on the TD display. The
indicator is large if there is an alarm enabled that requires acknowledgement. The indicator
will be small if the alarms do not require acknowledgement. The user can switch to the alarm
display to view the alarms.
The alarm display will show one or more alarms in priority order. An UP or DOWN arrow in
the right-most character position indicates more alarms are active, but not visible on the
display. The operator can press either the UP or the DOWN arrow key to scroll through the
other enabled alarms.
The operator can edit or accept variable values by pressing the ENTER key. The TD device
will write the updated variable value to the CPU and set the edit notification bit for that
variable when the operator presses the ENTER key. The TD device then moves the cursor
to the next editable variable. Pressing ENTER for the last editable variable of an alarm writes
this last value to the S7-200 CPU and the TD device then resets the alarm enable bit. For
more information on editing variables, see Editing a Variable that is Embedded in an Alarm
or a Screen in Chapter 5.
Every alarm falls into one of four possible alarm acknowledgement and editing types. This
section explains specifically how each alarm type is handled by the TD device. The four
alarm types follow:
● No acknowledgement required. No edits allowed
● Acknowledgement required. No edits allowed
● No acknowledgement required. Edits allowed
● Acknowledgement required. Edits allowed
No Acknowledgement Required, No Edits Allowed
In this combination of no acknowledgement required and no edits allowed, the TD device
simply displays the alarm. The ENTER key has no function since there are no editable
variables within the alarm. The alarm may contain variables that are updated at the update
rate of the TD device. This type of alarm is replaced on the display if a higher priority alarm is
enabled by the S7-200 CPU. The operator can either press the UP or the DOWN arrow key
to scroll to other alarms or press ESC to return to the menus.
The TD device does not clear the corresponding alarm-enable bit in the S7-200 CPU.
Acknowledgement Required, No Edits Allowed
In this combination of acknowledgement required and no edits allowed, the TD device
displays the alarm and makes the entire alarm flash (blink) until the operator presses ENTER
to acknowledge the alarm. Variable values are updated from the S7-200 CPU at the normal
update rate while the alarm is flashing.
When the operator presses ENTER, the TD device:
● Sets the acknowledgement-notification bit for this alarm.
● Clears the alarm-enable bit for this alarm. This causes the alarm to be removed from the
display on the next update cycle.
Another alarm cannot replace the one flashing until the operator acknowledges the flashing
alarm. This is also true even if a higher priority alarm is enabled in the S7-200 CPU. If the TD
device is configured for single line alarms and the CPU enables a higher priority alarm, the
flashing alarm shifts down to the next line of the display. The operator cannot press the UP
or the DOWN key to scroll through other enabled alarms until the current alarm is
acknowledged.

System Manual, 08/2007, A5E00765548-02 113
No Acknowledgement Required, Edits Allowed

In this combination of no acknowledgement required and edits allowed, the TD device
displays a alarm and then waits for the operator to edit a value in the alarm. All of the
variables within the alarm are updated at the update rate. Since the alarm does not require
acknowledgement, this type of alarm is removed from the TD device display if a higher
priority alarm is enabled in the S7-200 CPU.
Acknowledgement Required, Edits Allowed
In this combination of acknowledgement required and edits allowed, the TD device displays
the alarm, causes the entire alarm to flash (blink), and then waits until the operator
acknowledges the alarm and edits or accepts the values in the alarm. This type of alarm
requires that the operator edits or accepts the values displayed in the alarm. If the operator
aborts the edit by pressing the ESC key before editing all the values in the alarm, the alarm
flashes to indicate that edits are still required.
When the alarm is enabled in the S7-200 CPU, the TD device notes this and, if there is
space available on the display, reads the alarm from the CPU. The TD device then displays
the alarm and causes the entire alarm to flash to notify the operator that the alarm is present
and must be acknowledged.
Clearing an Alarm
● If an alarm required acknowledgement, the TD device will clear the alarm enable at the
same time that the Alarm Acknowledgement bit is set in the CPU.
● If an alarm contains editable variables, the TD device will clear the alarm enable bit when
all of the edits are completed and the last editable variable in the messages is written to
the CPU.
● The PLC program logic may clear the alarm enable bit at any time. This will remove the
alarm message from the TD display. An alarm message will not be removed from the
display if the user is editing a variable in the message or if the message has not yet been
acknowledged.
● If the message does not require acknowledgement and/or does not contain editable
variables, then the CPU program logic MUST clear the alarm enable bit.
Editing a Variable that is Embedded in an Alarm or a Screen
If you configured a screen or an alarm to include a variable, you can enter a new value for
the variable:
● Use ENTER to move the cursor to the variable. The TD device will write the updated
variable value to the CPU and set the edit notification bit for that variable when the
operator presses the ENTER key, completing the edit of the variable.
● Use the UP or DOWN arrows to change the value of the variable.
● Use the following buttons to move the cursor to different characters within the variable:
– TD 100C, TD 200C, and TD400C: LEFT and RIGHT arrows
– TD 200: SHIFT+UP arrow and SHIFT+DOWN arrow
● ESC rereads the value of the variable from the S7-200 CPU and redisplays the value.
● ENTER writes the new value to the S7-200 CPU. (If the alarm contains other variables,
the cursor moves to the next variable.) The TD device will write the updated variable
value to the CPU and set the edit notification bit for that variable when the operator
presses the ENTER key, completing the edit of the variable.

114 System Manual, 08/2007, A5E00765548-02
If the variable was configured as a numeric string, the cursor skips over any non-numeric
characters in the message. See Chapter 4. After you have edited all of the variables in an
alarm, the TD device resets the alarm bit in the S7-200 CPU.
Notice
Due to restrictions in the format used to store real (floating-point) numbers in both the S7-
200 CPU and the TD device, the accuracy of the number is limited to six significant digits.
Editing a real number with more than six digits may not change the value of the variable, or
may cause other digits within the number to change:
● Changing the least significant (right-most) digit of a real-number variable with more than
six digits may have no effect. For example, if you try to change the "9" in "1234.56789",
the value of the variable does not change.
● Changing the most significant (left-most) digit of a real-number variable with more than
six digits may cause other (less significant) digits in the variable to change.

System Manual, 08/2007, A5E00765548-02 115
TD Bit Usage
A summary of the TD bit usage is shown in Table 5-1.
Table 5-1 Summary of TD Bit Usage
Bits Associated Enable Condition Results shown on the TD Display Clear Condition for the Bit
with Alarms and for the Bit
Screens
ALARM ENABLE The alarm must be When an alarm is enabled and the TD default There are different ways to
enabled with the display mode is set to the alarm mode, the alarm clear the alarm enable bit:
TD_ALRM message is placed on the TD display. If there are If an alarm required
instruction using multiple alarms enabled, the highest priority acknowledgement, the TD
the Alarm alarm is displayed. device will clear the alarm
Symbolic Name as If an alarm requires user acknowledgment, the enable at the same time that
the instruction message will flash (blink) until it is acknowledged the 'Alarm
input. by the user. The alarm MUST be acknowledged Acknowledgement' bit is set
before other alarms can be viewed. An alarm that in the CPU.
requires acknowledgement will not be replaced If an alarm contains editable
on the display by higher priority alarms until the variables, the TD device will
alarm is acknowledged. clear the alarm enable bit
If the alarm contains editable variables the user when all of the edits are
can edit or accept the values (by pressing the completed and the last
ENTER key). If the edits are not completed, and editable variable in the
the alarm message required acknowledgement, messages is written to the
the message will again begin to flash. CPU.
If the user screens are set as the default display The PLC program logic may
mode for the TD device and an alarm is enabled, clear the alarm enable bit at
an alarm indicator will begin to flash on the TD any time. This will remove
display. The indicator is large if there is an alarm the alarm message from the
enabled that requires acknowledgement. The TD display. An alarm
indicator will be small if the alarms do not require message will not be removed
acknowledgement. The user can switch to the from the display if the user is
alarm display to view the alarms. The alarms will editing a variable in the
be presented to the user in priority order. message or if the message
has not yet been
acknowledged.
If the message does not
require acknowledgement
and/or does not contain
editable variables, then the
CPU program logic MUST
clear the alarm enable bit.

116 System Manual, 08/2007, A5E00765548-02
Screens
ALARM Alarm The user acknowledges an alarm message by The TD device will set the
ACKNOW- acknowledgement scrolling to the message and pressing the alarm acknowledge bit. The
LEDGE is available only if ENTER key. The TD device will then set the user program logic must
the wizard acknowledge notification bit in the CPU and the clear the alarm
configuration has alarm message will stop flashing (blinking). acknowledgement bit.
the option enabled If there are no editable variables in the message
for this alarm: the TD device will also clear the alarm enable bit
Alarm should for this message.
require operator
If there are editable variables in the message, the
acknowledgement
user must either edit the variables (change them
and press ENTER) or accept the current values
(press ENTER). When the last variable in the
message is edited or accepted, the TD device will
write the variable to the CPU and clear the alarm
enable bit.
If the user does not complete editing the
variables in the message, the TD device will
begin to flash (blink) the message to notify the
user that an action is still pending.
ALARM The edit The TD device will write the updated variable The user program can
MESSAGE: notification is value to the CPU and set the edit notification bit monitor the edit notification
EMBEDDED available only for that variable when the operator presses the bit to recognize when an
VARIABLE EDIT when the alarm ENTER key, completing the edit of the variable. editable value has been
NOTIFICATION contains a variable changed by the operator.
and the user has The user program can then
enabled the take some action based on
Wizard option to the new value for the
allow editing of the variable.
variable. "Operator The user program must clear
is allowed to edit the edit notification bit so that
this data". If the subsequent edits can be
alarm message recognized.
contains multiple
editable variables,
each variable has
a unique edit
notification bit.

System Manual, 08/2007, A5E00765548-02 117
Screens
USER SCREEN: The edit The TD device will write the updated variable The user program can
EMBEDDED notification is value to the CPU and set the edit notification bit monitor the edit notification
VARIABLE EDIT available only for that variable when the operator presses the bit to recognize when an
NOTIFICATION when the user ENTER key, completing the edit of the variable. editable value has been
screen contains a changed by the operator.
variable and the The user program can then
user has enabled take some action based on
the Wizard option the new value for the
to allow editing of variable.
the variable. The user program must clear
"Operator is the edit notification bit so that
allowed to edit this subsequent edits can be
data". recognized.
If the user screen
contains multiple
editable variables,
each variable has
a unique edit
notification bit.

118 System Manual, 08/2007, A5E00765548-02
5.6 Performing Typical or Routine Operator Tasks
Performing Typical or Routine Operator Tasks

The Operator Menu allows you to perform the following tasks:
● Determining the model and version of the S7-200 CPU (CPU Status)
● Viewing the error messages generated by the S7-200 CPU (CPU Status)
● Setting the time in the S7-200 CPU (Set Time and Date)
● Selecting a language set for the TD device (Set Language) (TD 200, TD 200C, and
TD400C)
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Viewing the Status of an S7-200 CPU

The CPU Status command allows you to display the following information:
● Model and version of the S7-200 CPU
● Error messages generated by the S7-200 CPU
After you select the CPU Status command, the TD device displays the CPU model and
version.
Press the UP or DOWN arrows to display the error messages that were generated by the
S7-200 CPU.
The TD device displays an error message only if an error exists in the S7-200 CPU. The
CPU classifies errors as either fatal errors or non-fatal errors.
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Figure 5-11 CPU Status Menu for TD 100C

System Manual, 08/2007, A5E00765548-02 119
Table 5-2 lists the error messages that can be displayed by the TD devices. Refer to the
SIMATIC S7-200 Programmable Controller System Manual for information about specific
errors.
Table 5-2 Error Messages Relating to the Status of the S7-200 CPU
Type Message Description

Fatal Program Checksum Error Hardware failure (S7-200 CPU)
Compare Contact User program error: Illegal Compare contact
EEPROM/Permanent Memory Failure Hardware failure (S7-200 CPU)
Memory Cartridge Failure Memory cartridge failure
Scan Watchdog Timeout Hardware failure (S7-200 CPU)
Unknown Error XXXX CPU failure (S7-200 CPU)
(where XXXX = the error number)1
Non- I/O Error Mod X An expansion module encountered an I/O error.
Fatal (where X = the number of the I/O If there are multiple failures, the TD device
module) displays this message multiple times one time for
each failed module.
Runtime Error XXXX The S7-200 CPU encountered an error while
(where XXXX = the error number)1 executing the user program, such as:
• Indirect addressing
• HSC setup and execution errors
• Attempting to execute an illegal instruction
(ENI, DISI, or HDEF) inside an interrupt routine
• Subroutine nesting errors
• TODW data errors
• Simultaneous Transmit (XMT) and Receive
(RCV) errors
1Refer to the SIMATIC S7-200 Programmable Logic Controller System Manual for information about
specific errors.
Setting Time and Date in the S7-200 CPU

You can use the TD device to change the time-of-day settings in the S7-200 CPU. This
allows an operator to easily adjust for time changes.
The TD device does not maintain time and date settings. In order to display the time and
date values, the TD device reads the current time and date from the S7-200 CPU and
displays these values. The operator can then use this screen to edit these values and then
write the new time and date settings back to the S7-200 CPU.
Tip
The TD device does not validate the time, date or day of the week values that you enter. You
can inadvertently write an incorrect date or day of the week to the S7-200 CPU.
To allow an operator to change the time and date settings in the S7-200 CPU:
● You must have enabled (selected) the time-of-day (TOD) option when you configured the
TD device with the Text Display wizard. Refer to Chapter 4.
● The S7-200 CPU must support the TOD clock

120 System Manual, 08/2007, A5E00765548-02
Tip
If you configured a password for the TD device, the operator must enter the password before
being allowed to set the time and date.
If the TD device was not configured to allow changes to the time or if the S7-200 CPU does
not support the TOD clock, the Set Time and Date command does not appear on the
Operator Menu.
After you select the Set Time command, the TD device reads the current date and time from
the S7-200 CPU.
The Time and Date screen displays the following information:
● Date: day-month-year (for Chinese, the date is displayed as year-month-day)
● Time
● Day of the week
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Use the UP or DOWN arrow buttons to change the values in the fields.
Use the ENTER to move to the next field. (For a TD 100C, TD 200C, and TD400C, you can
also use the RIGHT arrow. For a TD 200, you can use the SHIFT+DOWN arrow.)
Use the ESC to move back to the first field. (For a TD 100C, TD 200C, and TD400C, you
can also use the LEFT arrow. For a TD 200, you can use the SHIFT+UP arrow.)
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Pressing ENTER when the cursor is located on the last field of the Time and Date screen
writes the new time and date values to the S7-200 CPU and returns to the Operator Menu.
Pressing ESC when the cursor is located on the first field of the Time and Date screen
returns to the Operator Menu.

System Manual, 08/2007, A5E00765548-02 121
Changing the Language Set (TD 200C, TD 200, and TD400C only)
You can use the TD device to change the language set in order to localize the TD device for
another country. You must have created different language sets for your alarms and screens
when you configured the TD device with the Text Display wizard. Each language set that you
configure selects the language for the system menus and prompts of the TD device, as well
as the screens and alarms. Refer to Chapter 4 for information about configuring language
sets for the TD device.
Selecting the Set Language command displays a menu of the languages that you configured
with the Text Display wizard as shown in the figure below. Use the UP or DOWN arrows to
select the language to be displayed by the TD device.
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Cleaning the Keypad

The Clean Keypad function disables the keypad for 30 seconds to allow you to clean the
keypad without affecting TD operation. The TD device displays a count down timer that
shows the remaining seconds.

122 System Manual, 08/2007, A5E00765548-02
5.7 Performing Specialized Operator Tasks (Diagnostic/Setup Menu)
Performing Specialized Operator Tasks (Diagnostic/Setup Menu)

Some of the pre-configured tasks provided by the TD device provide assistance with setting
up the TD device or troubleshooting problems with the S7-200 CPU. These functions are
typically accessed infrequently. See the figures below.
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Tip
If you are using a custom keypad that does not support the ENTER and ESC buttons, you
must use the standard keypad to set up the TD device.
To restore the standard TD keypad:
1. Power down the TD device
2. Press and hold the lower right corner (where ENTER key is located on the standard
keypad)
The default keypad is restored until the TD device is power cycled again.

System Manual, 08/2007, A5E00765548-02 123
Setting up the TD Device

As shown in the figure below, you use the TD Setup menu to configure various parameters
for the TD device, such as network addresses, address of the parameter block (stored in V
memory of the S7-200 CPU), baud rate, and other communication parameters.
● Setting the network address for the TD device: Use the UP or DOWN arrow to set the
network address (default address = 1).
● Setting the CPU address: Use the UP or DOWN arrow to select the network address for
the S7-200 CPU (default = 2).
● Setting the address for the parameter block: Designates a V memory location where the
parameter block (or an offset to the location of the parameter block) is stored in the S7-
200 CPU. Setting the address of the parameter block allows you to connect multiple TD
devices to a single S7-200 CPU.
Use the UP or DOWN arrow to select the starting V memory address of the parameter
block that stores the configuration of the TD device.
The address of the parameter block must match the address that you configured in the
S7-200 CPU (address range: VB0 to VB32000, default = VB0).
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124 System Manual, 08/2007, A5E00765548-02
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● Setting the baud rate for the TD device: choose the baud rate for the TD device. You can
choose either 9.6 kbaud (9600 baud), 19.2 kbaud, or 187.5 kbaud.
Use the UP or DOWN arrow to select the baud rate. The baud rate must match the baud
rate of the S7-200 CPU and any other device on the same network.
● Setting the Highest Station: Changes the highest station address for the TD device. This
setting tells the TD device which network addresses to check when looking for other
network master devices. The default highest station address is 31. This means that the
TD device checks addresses 0 through 31 when looking for other network masters. This
setting should only be changed when there are more than 32 master devices on the
network.
Use the UP and DOWN arrows to select the highest address on the network
(default = 31).
● Setting the Gap Factor: Changes the Gap Factor for the TD device. This setting tells the
TD device how often to check for other network master devices. The default setting of 10
causes the TD device to check once every 10 messages. A setting of 1 would cause the
TD device to check for other masters after every message.
Use the UP and DOWN arrows to select the gap factor between stations (default = 10).
● Setting the contrast:
– TD 100C, TD 200, and TD 200C: You can optimize the display for different viewing
angles and lighting conditions by adjusting the contrast of the screen on the TD
device. The default contrast value is 40, with values ranging from 25 (lighter) to 55
(darker).
Use the UP and DOWN arrows to select the contrast setting for the display area of the
TD device (default setting = 40).
● Selecting the keypad buzzer: The TD400C has a keypad buzzer setting (On or Off) to
provide audio feedback when a key is pressed. The default is set to On.

System Manual, 08/2007, A5E00765548-02 125
● Setting the display backlight time: The TD400C allows you to set the time that the display
backlight is on allowing you to extend the life of the TD400C display.
– The backlight on time is configurable from 1 to 60 minutes in one minute increments
– You can configure the backlight to be on all the time
– The default backlight on time is 10 minutes
Tip
At 9600 baud or 19.2 kbaud, the highest station address may need to be increased, even
though the network does not contain more than 32 masters. Increasing the highest station
address allows more time for the masters to transmit messages.
Viewing the TD Messages Stored in the S7-200 CPU (TD 200, TD 200C, and TD400C only)
You can review all of the TD messages (screens and alarms) that you configured for the TD
device within the language set currently selected for the TD device.
The View Messages command allows you to verify that all of the alarms and screens were
correctly stored in the S7-200 CPU.
The View Messages command does not allow you to edit any values that are displayed in
the messages.
Selecting the View Messages command displays all of the messages and process values
stored in the S7-200 CPU. Use the UP and DOWN arrows to scroll through messages stored
in the S7-200 CPU.
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126 System Manual, 08/2007, A5E00765548-02
Forcing the Inputs and Outputs in the S7-200 CPU (TD 200, TD 200C, and TD400C only)
The Force I/O menu allows you to force inputs, force outputs, or unforce all inputs and
outputs. The Force I/O command is available only if you enabled the force-menu when you
configured the TD device with the Text Display wizard.
Caution
Turning off the power to the S7-200 CPU before the force information is written to the
permanent memory in the CPU can cause the S7-200 CPU to experience a failure the next
time you turn the S7-200 CPU on.
To clear the error condition, use the TD device to either unforce all of the I/O points or else
rewrite the force information to the S7-200 CPU. Cycling the power to the S7-200 CPU
should clear the error.
If the S7-200 CPU requires a password before allowing the I/O to be forced, the TD device
prompts the operator to enter the 8-character CPU password.
The Force I/O command provides the following options:
● Force Inputs: Allows you to force individual inputs on or off, or to turn off the Force
function
● Force Outputs: Allows you to force individual outputs on or off, or to turn off the Force
function
● Unforce All I/O: Allows you to turn off the Force function for all of the forced I/O points
Use the UP or DOWN arrow to select the specific I/O point. Pressing ENTER moves the
cursor to the Force options. (For a TD 200C and TD400C, you can also use the RIGHT
arrow. For a TD 200, you can use the SHIFT+DOWN arrow.)
Use the UP or DOWN arrow to select the type of force condition for the selected I/O point.
7'6HWXS
9LHZ0HVVDJHV
)RUFH,2
&KDQJH&380RGH
0DNH0&
(GLW&380HPRU\
)RUFH,QSXWV
)RUFH2XWSXWV
8QIRUFH$OO,2
Figure 5-20 Force I/O Command
Tip
Unforcing the I/O points does not place them in the OFF state. Unforcing only removes the
Force option. The points remain in their last state until you manually change them or they are
changed by the user program in the S7-200 CPU.

System Manual, 08/2007, A5E00765548-02 127
Changing the Operating Mode of the S7-200 CPU (TD 200C and TD400C)
The Change STOP/RUN Mode command is only available for the TD 200C and TD400C and
is only available if you selected this function when you configured the TD device with the
Text Display wizard. See Chapter 4.
You can use the TD device to change the operating mode of the S7-200 CPU from STOP to
RUN or from RUN to STOP. The operator may need to enter the TD password, if the TD
device is configured for password-protection.
In order to allow the TD device to change the operating mode, the mode selector switch on
the S7-200 must be set to either RUN or TERM.
The TD device cannot change the operating mode if the mode selector switch is set to
STOP.
7'6HWXS
9LHZ0HVVDJHV
)RUFH,2
&KDQJH67235810RGH
0DNH0&
(GLW&380HPRU\
Figure 5-21 Changing the Operator Mode
Copying the User Program to a Memory Cartridge (TD 200C and TD400C)
The Make MC (memory cartridge) command is only available for the TD 200C and TD400C
and only if you selected this function when you configured the TD device with the Text
Display wizard. See Chapter 4.
You can use the TD 200C and TD400C to copy the user program in the S7-200 CPU to a
memory cartridge (MC). The operator may need to enter both the TD password and the CPU
password, if both the TD device and the S7-200 CPU are configured for password-
protection.
Before attempting to write the user program to the memory cartridge, ensure that you have
installed a memory cartridge in the S7-200 CPU.
After you select the Make MC command, the TD device alerts you that this operation will
erase any existing data on the memory cartridge. Press the DOWN arrow to continue.
After reading the message, press ENTER to continue or press ESC to abort the operation
7'6HWXS
9LHZ0HVVDJHV
)RUFH,2
&KDQJH67235810RGH
0DNH0&
(GLW&380HPRU\
Figure 5-22 Making a Memory Cartridge

128 System Manual, 08/2007, A5E00765548-02
Editing the CPU Memory (TD 200C and TD400C)

The Edit CPU Memory command is only available for the TD 200C and TD400C and only if
you selected this function when you configured the TD device with the Text Display wizard.
See Chapter 4
You can use the TD 200C and TD400C to edit the values stored in the memory of the S7-
200 CPU. The operator may need to enter the TD password, if the TD device is configured
for password-protection.
After you select the Edit CPU Memory command (see the figure below), the TD device
displays the Edit CPU Memory screen.
7'6HWXS
9LHZ0HVVDJHV
)RUFH,2
&KDQJH67235810RGH
0DNH0&
(GLW&380HPRU\
Figure 5-23 Edit CPU Memory Command
As shown in the figure below, you press ESC to edit the data in the memory address. The
TD device places a cursor on the memory area.
● To edit the memory address: Use the UP or DOWN arrows to change the memory
address. (Use the RIGHT or LEFT arrow keys to move between the fields of the memory
address.) Press ENTER to display the value of that memory address and to move the
cursor to the data type field.
● To edit the data type: Use the UP or DOWN arrows to change the data type. Press
ENTER to display the value and to move the cursor to the value field.
● To edit the value stored in the memory address: Use the UP or DOWN arrows to change
the value.

System Manual, 08/2007, A5E00765548-02 129
Press ENTER to write the new values to the memory address in the S7-200 CPU. Pressing
ESC aborts the function.
3UHVV(6&WRHGLWWKH 3UHVV(17(5WRZULWHWKHQHZ
(6& (QWHU
&38PHPRU\ YDOXHWRWKH&38PHPRU\
(GLWWKHPHPRU\DGGUHVV (GLWWKHGDWDW\SH (GLWWKHYDOXH
(QWHU (QWHU
$UHD 6L]H $GGUHVV 'DWDW\SH 9DOXH

9 : ,17
7KH83DQG'2:1DUURZV
9:,17 FKDQJHWKHGDWDLQWKH
VHOHFWHGILHOG
Figure 5-24 Editing the Memory in the S7-200 CPU
Table 5-3 lists the memory address and data types possible. For information about the
memory areas, sizes of the data, and data types supported by your S7-200 CPU, refer to the
S7-200 Programmable Controller System Manual.
Use the UP and DOWN arrows to scroll through the list of valid entries for each field.
To change the numeric value displayed in the address and value fields:
● Use the UP and DOWN arrows to adjust each digit in the value or address.
● Use the LEFT and RIGHT arrows to move between the digits of the value or address.
● Press ENTER to write the new value to the S7-200 CPU.

130 System Manual, 08/2007, A5E00765548-02
Tip
Binary values cannot be edited.
Table 5-3 Possible Values for the CPU Memory Address and Data Type
Field Description
Memory area V Variable memory area
M Bit Memory area
SM Special Memory area
T Timers Current value only1, INT only
C Counters Current value only1, INT only
I Inputs
Q Outputs
Memory size B (byte)
W (word)
D (double-word)
Address 0 to 32000 (limited by the memory for your S7-200 CPU)
Refer to the S7-200 Programmable Controller System Manual for the range of
memory supported by the different S7-200 CPU models)
Data type INT Integer (valid for Byte, Word or Double-word)
Byte values are displayed as unsigned integers
Word and Double-word values are displayed as signed integers
REAL Real or floating-point (valid for Double-word only)
The value displayed for a Real number is rounded to 6 or 7 significant digits. The TD
device displays the Real number in fixed-point format only (no scientific notation)
The TD device cannot display Real numbers larger than 18 digits and allows up to 7
decimal places. (For example: The TD device displays
0.00000005 as 0.0000001, and displays real numbers less than
0.00000005 as "0.0".)
The TD device writes the number displayed to the S7-200 CPU without
rounding.
HEX Hexadecimal (valid for Byte, Word, and Double-word)
BIN Binary (valid for Byte and Word only)
Binary values are displayed in the same pattern (7..0) as discussed in the
S7-200 Programmable Controller System Manual and displayed by the
Status Chart of STEP 7-Micro/WIN
Binary values cannot be edited
1 The TD device displays only the current value for timers and counters. To display preset values for
timers or counters, you must store these values in V memory. The TD device does not display the
value of the timer or counter bit.

System Manual, 08/2007, A5E00765548-02 131

132 System Manual, 08/2007, A5E00765548-02
Technical Specifications and Reference Information A
A.1 General Specifications for the Text Display Devices
General Technical Specifications for the Text Display Devices
Order Number Description Dimensions (mm) (H x H x D) Weight

6ES7 272- 1BA10-0YA0 TD 100C Operator Interface 89.6 x 76 x 35.7 0.11 kg
6ES7 272-0AA30-0YA0 TD 200 Operator Interface 148 x 76 x 28 0.19 kg
6ES7 272-1AA10-0YA0 TD 200C Operator Interface 148 x 76 x 28 0.20 kg
6AV66640-0AA00-0AX1 TD400C Operator Interface 174 x 102 x 31 0.31 kg
6ES7 272-1AF00-7AA0 TD 200C Blank faceplate material, A4 size (10 sheets/package)
6ES7 272-1BF00-7AA0 TD 100C Blank faceplate material, A4 size (10 sheets/package)
6AV6671-0AP00-0AX0 TD400C Blank faceplate material, A4 size (10 sheets/package)
6ES7 901-3EB10-0XA0 TD/CPU cable 3 meters 0.15 kg

System Manual, 08/2007, A5E00765548-02 133
Technical Specifications and Reference Information
A.2 Technical Specifications for the TD 100C, TD 200 and TD 200C
Technical Specifications for the TD 100C, TD 200 and TD 200C
Table A-1 Technical Specifications for the TD 100C, TD 200 and TD 200C
General TD 100C TD 200 TD 200C

6ES7 272-1BA10-0YA0 6ES7 272-0AA30-0YA0 6ES7 272-1AA10-0YA0
Keyboard Customizable faceplate Membrane keypad with 9 Customizable faceplate
Supports up to 14 keys keys; Tab inserts for Supports up to 20 keys
customer-specific labeling
Display FSTN-Graphic Display with 132 STN-Graphic Display with 181 x 33 (Columns x Rows), LED
x 65 (columns x rows), no backlight
backlight
PLC interface RS 485 (PPI); 9.6 / 19.2 / 187.5 Kbits/s
Supply voltage (UN) Supplied by the S7-200 CPU, 24 VDC, 15 VDC ... 30 VDC, safety extra low voltage, NEC
no external supply, Class 2 or limited power source (supplied by the S7-200
(24 VDC (8 VDC ... 30 VDC) CPU, mains adapter or a 24 VDC external supply). The TD
safety extra low voltage, NEC device has no integrated means of protection against strong
Class 2 or limited power source) interference pulses in the microsecond range (surge
impulse). If the power being supplied has no appropriate
means of protection, then a surge voltage protector should
be pre-connected.
Current consumption (IN) Typical 20 mA, maximum 50 Typical 70 mA, (terminating resistors switched off)
mA, at UN 24V (no fuse in TD Maximum 120 mA at UN 24V (3.15A fuse in TD 200).
100C)
Inrush current Not applicable Maximum 0.6 A / 15 ms
Degree of protection IP651 (mounted on front of the IP 652 (mounted on front of the panel)
panel) IP 20 (mounted on casing)
IP 20 (mounted on casing) UL 50 Type 4X2
UL 50 Type 4X1
Safety
Safety standard IEC61131-2, UL508, EN 60950, IEC 60950, UL 60950, CSA C22.2 No. 60950
CSA C22.2 No. 142
Noise emission <45dB(A) to DIN 45635 (no fan)
1 To ensure compliance of the TD 100C with IP 65 and UL 50 Type 4X, you must follow these guidelines. The minimum
panel thickness must be at least 1.5 mm. The mounting screws on the TD 100C device must be tightened to a torque of
0.2 Nm (about 0.5 mm the height of the seal). The gasket must be replaced whenever the TD device is removed and
reinstalled. To procure new gaskets, contact your Siemens distributor or sales representative.
2 To ensure compliance of the TD 200C and TD 200 with IP 65 and UL 50 Type 4X, you must follow these guidelines. The
minimum panel thickness must be at least 1.5 mm. The mounting screws on the TD 200C or TD 200 device must be
tightened to a torque of 0.7 N-m. The gasket must be replaced whenever the TD device is removed and reinstalled. To
procure new gaskets, contact your Siemens distributor or sales representative.

134 System Manual, 08/2007, A5E00765548-02
Technical Specifications for the TD 100C, TD 200 and TD 200C (continued)
General TD 100C TD 200 TD 200C

6ES7 272-1BA10-0YA0 6ES7 272-0AA30-0YA0 6ES7 272-1AA10-0YA0
Electromagnetic Compatibility (EMC) (tested with TD/CPU cable 6ES7 901-3EB10-0XA0)
Emitted interference B to EN 55022 = CISPR 22
Limit class
Noise immunity on signal ±2kV according to IEC 61000-4-4 1000-4-4; Burst
lines
Noise immunity to discharge ±6kV Contact discharge (according to IEC 61000-4-2; ESD)
of static electricity ±8kV Air discharge (according to IEC 61000-4-2; ESD)
Conducted interference on Not applicable ±2kV according to IEC 61000-4-4; Burst
DC power supply line ±1kV according to IEC 61000-4-5; ms-impulse (Surge); (line
against line)
±2kV according to IEC 61000-4-5; ms-impulse (Surge); (line
against earth)
Power supplies with the same voltage can only be
used with additional means of protection, for example,
a surge voltage protector available from the Dehn company,
type RZ/E 24 V-, order No. 917 204.
Noise immunity to high 10 V/m with 80% amplitude modulation at 1 kHz, 9 kHz to 80 MHz
frequency emission (according to IEC 61000-4-6)
10 V/m with 80% amplitude modulation at 1 kHz, 80 MHz to 2 GHz
(according to IEC 61000-4-3)
Climatic Conditions
Temperature Tested according to IEC 60068-2-1, IEC 60068-2-2
Operation ±0° C to +60° C (+32° F to +140° F) (rate of temperature change max. 10° C/h)
Storage/Transport -20° C to +60°C (-4° F to +140° F) (rate of temperature change max. 20° C/h
Relative humidity Tested according to IEC 60068-2-78, IEC 600068-2-30
Operation 95% at 30°C (no condensation)
Storage/Transport 95% at 55°C (no condensation)
Mechanical Environmental Conditions
Vibration Tested according to Tested according to
IEC 60068-2-6 IEC 60068-2-6
Operation 5 Hz to 9 Hz, 10 Hz to 58 Hz,
amplitude, 3,5 mm amplitude 0.075 mm
9 Hz to 150 Hz, 58 Hz to 150 Hz,
acceleration 9.8 m/s2 acceleration 9.8 m/s2
Transport (packaged) 5 Hz to 9 Hz, 5 Hz to 9 Hz,
amplitude 3.5 mm amplitude 3.5 mm
9 Hz to 500Hz, 9 Hz to 500 Hz,
acceleration 9.8 m/s2 acceleration 9.8 m/s2
Shock Tested according to IEC 60068-2-27/29
Operation Semisinusoidal: 150 m/s2 (15g), 11 ms
Transport (packaged) Semisinusoidal: 250 m/s2 (25g), 6 ms
Special Features
Quality assurance In accordance with ISO 9001
Servicing Maintenance-free (no battery)
Panel mounting Accessories for panel mounting are enclosed

System Manual, 08/2007, A5E00765548-02 135
A.3 Technical Specifications for the TD400C
A.3 Technical Specifications for the TD400C
Technical Specifications for the TD400C
Table A-2 Technical Specifications for the TD400C
General TD400C
6AV6640--0AA00-0AX1
Keyboard Customizable faceplate
Supports up to 15 keys
Display STN-Graphic Display with 192 x 64 (Columns x Rows), backlight
PLC interface RS 485 (PPI); 9.6 / 19.2 / 187.5 Kbits/s
Supply voltage (UN) 24 VDC, 15 VDC ... 30 VDC, safety extra low voltage, NEC Class 2 or limited power source
(supplied by the S7-200 CPU, mains adapter or a 24 VDC external supply). The TD device
has no integrated means of protection against strong interference pulses in the microsecond
range (surge impulse). If the power being supplied has no appropriate means of protection,
then a surge voltage protector should be pre-connected.
Current consumption (IN) Typical 41 mA
Inrush current Maximum 570 mA
Degree of protection IP 651 (mounted on front of the panel)
IP 20 (mounted on casing)
Noise emission <45dB(A) to DIN 45635 (no fan)
1 To ensure compliance of the TD400C with IP 65 and UL 50 Type 4X, you must follow these guidelines. The minimum
panel thickness must be at least 1.5 mm. The mounting screws on the TD device must be tightened to a torque of 0.7 N-m.
The gasket must be replaced whenever the TD device is removed and reinstalled. To procure new gaskets, contact your
Siemens distributor or sales representative.
Table A-3 Technical Specifications for the TD400C (continued)
General TD400C
6AV6640-0AA00-0AX1
Electromagnetic Compatibility (EMC) (tested with TD/CPU cable)
Emitted interference A to EN 55011 = CISPR 11
Limit class
Noise immunity on signal ±1kV, Testing according to IEC 61000-4-4; Burst
lines
Noise immunity to discharge ±8kV Air discharge (according to IEC 61000-4-2; ESD)
of static electricity
Conducted interference on ±2kV, Testing according to IEC 61000-4-4; Burst
DC power supply line ±1kV according to IEC 61000-4-5; ms-impulse (Surge); (line against line)
±2kV according to IEC 61000-4-5; ms-impulse (Surge); (line against earth)
Power supplies with the same voltage can only be used with additional means of
protection, for example, a surge voltage protector available from the Dehn company, type
RZ/E 24 V-, order No. 917 204.
Noise immunity to high 10 V/m with 80% amplitude modulation at 1 kHz, 20 kHz to 80 MHz
frequency emission 10 V/m with 80% amplitude modulation at 1 kHz, 80 MHz to 1 GHz

136 System Manual, 08/2007, A5E00765548-02
A.4 Certificates, Directives and Declarations for the TD Device
General TD400C
6AV6640-0AA00-0AX1
Climatic Conditions
Temperature
Operation 0 to +50 °C
Storage/Transport -20 to +60°C
Relative humidity
Operation 5% to 85% (30℃), no condensation
Storage/Transport 5% to 85% (40℃), no condensation
Mechanical Environmental Conditions
Vibration Tested according to IEC 60068-2-6
Operation 5 Hz to 9 Hz, amplitude, 3,5 mm

9 Hz to 150 Hz, acceleration 9.8 m/s2
Transport (packaged) 5 Hz to 9 Hz, amplitude 3.5 mm,
9 Hz to 500 Hz, acceleration 9.8 m/s2
Shock Tested according to IEC 60068-2-27/29
Operation Semisinusoidal: 150 m/s2 (15g), 11 ms
Transport (packaged) Semisinusoidal: 250 m/s2 (25g), 6 ms
Special Features
Quality assurance In accordance with ISO 9001
Servicing Maintenance-free (no battery)
Panel mounting Accessories for panel mounting are enclosed
Certificates, Directives and Declarations for the TD Device
IEC 61131-2
The TD 100C and TD400C devices satisfy the requirements and criteria of the IEC 61131-2
standard (programmable controllers, part 2 on equipment requirements and tests).
Notes on the CE Symbol
The following applies to the SIMATIC product described in this operating

instruction

System Manual, 08/2007, A5E00765548-02 137
EMC Directive
This product fulfils the requirements for the EC directive 89/336/EEC on "electromagnetic
compatibility" and the following fields of application apply according to this CE symbol. See
Table A-4.
Table A-4 EMC Directive
Field of Application Requirement for

Emitted Interference Noise Immunity
Residential, commercial areas EN 61000-6-3 EN 61000-6-1
and light industrial
environments
Industry EN 61000-6-4 EN 61000-6-2
ATEX Directive (Explosion Protection Guidelines) (TD 200 and TD 200C)
The TD 200 and TD 200C devices fulfil the requirements for the EC directive
94/9/EEC on "ATEX" (Devices and protection systems to be used as prescribed
in potentially explosive areas (Guidelines for Explosion Protection)) and was
tested according to EN 50021 (Electrical apparatus for potentially explosive
atmospheres; Type of protection "n"
II 3G EEx nA OO T3.T6
Declaration of Conformity (TD 200C, TD 200, and TD400C)

The EC declarations of conformity and the documentation relating to this are available to the
authorities concerned, according to the above EC directive, from:
Siemens AG
Bereich Automatisierungs- und Antriebstechnik
A&D AS RD ST
Postfach 1963
D-92209 Amberg
Tel.: 09621 80 3283
Fax: 09621 80 3278
Siemens SNC (Siemens Numerical Control Co., Ltd.)
211100 No. 18, Siemens Road
Jiangning Development Zone
Nanjing, P.R. China
Tel.: 86 25 52101888
Fax: 86 25 52101666
Observing the Setup Guidelines

The setup guidelines and notes on safety given in the manual must be observed on startup
and during operation.

138 System Manual, 08/2007, A5E00765548-02
A.5 Approvals for USA, Canada and Australia
Approvals for USA, Canada and Australia

The characters stamped on a device are indicative of the requirements which that device
meets:
Underwriters Laboratories: cULus Approval, Hazardous Location
cULus Listed 21BP I.T.E. for Hazardous Location

Underwriters Laboratories Inc., according to:
● TD 200 and TD 200C:
UL 60950 (Information Technology)
CSA C22.2 No. 60950 (Information Technology)
● TD 100C and TD400C
UL 508 (Industrial Control Equipment)
CSA C22.2 No. 142 (Industrial Control Equipment)
UL 1604 (Hazardous Location)
CSA-213 (Hazardous Location)
APPROVED for use in:
● CI. I, Div.2, GP. A, B, C, D, T5
● CI. I, Zone 2, GP.IIC, T5
Please see the note below:
Note
This plant has to be mounted according to the NEC (National Electric Code) stipulations.
When used in environments according to class I, division 2 (see above), the SIMATIC TD
device must be mounted in a housing that corresponds to at least IP54 according to EN
60529.
FM approval to Factory Mutual Approval Standard Class Number 3611, Class

I, Division 2, Group A, B, C, D, and Class I, Zone 2, Group IIC.
Temperature Class T5 is adhered to when the ambient temperature during
operation does not exceed 60 degrees C
Note for Australia: The TD 100C, TD 200, and TD 200C devices fulfil the
requirements for Norm AS/NZS CISPR22. The TD400C device fulfils the
requirements for Norm AS/NZS CISPR 11.

System Manual, 08/2007, A5E00765548-02 139
FM Approval Notes
FM approval, if present, is to Factory Mutual Approval Standard Class Number 3611, Class I,
Division 2, Group A, B, C, D, and Class I, Zone 2, Group IIC.
Temperature class T5 is adhered to when the ambient temperature during operation does
not exceed 60 degrees C.
WARNING
Personal injury or property damage can result if you do not follow FM hazardous location
guidelines.
In hazardous areas, personal injury or property damage can result if you close or
disconnect an electrical circuit during operation (for example, plug-in connections, fuses,
switches).
Do not close or disconnect any live circuits unless explosion hazards can be definitely
excluded. Do not disconnect while the circuit is live unless the location is known to be non-
hazardous.
Note
TD400C Approvals
The only valid approvals for the TD400C device are those shown on the label on the rear
panel.

140 System Manual, 08/2007, A5E00765548-02
A.6 Standard TD Character Set (TD 200, TD 200C)
Standard TD Character Set (TD 200, TD 200C)
Figure A-1 Standard TD Character Set for the TD 200 and TD 200C

System Manual, 08/2007, A5E00765548-02 141
Figure A-2 Standard TD Character Set for the TD 200 and TD 200C (continued)
Alt Key Combinations for International and Special Characters

Certain international and special characters may not display correctly on the TD display if
entered with the Text Display wizard with the standard TD character set. For international
and special characters, use the ALT key and number combinations shown in Table A-5 to
enter the characters in the Text Display wizard.
Table A-5 ALT Key Combinations for International Special Characters
Character ALT + Key Combination

ü Alt + 0129
ä Alt + 0132
æ Alt + 0144
Æ Alt + 0145
å Alt + 0147
ö Alt + 0148
Å Alt + 0149
° Alt + 0223
α Alt + 0224
ß Alt + 0225
є Alt + 0227
ų Alt + 0228
σ Alt + 0229
¢ Alt + 0236
ñ Alt + 0238
Ω Alt + 0244
Σ Alt + 0246
∏ Alt + 0247
├ Alt + 0126 (left arrow ← )
┤ Alt + 0127 (right arrow →)
[ Alt + 0251 (single bar)

142 System Manual, 08/2007, A5E00765548-02
Character ALT + Key Combination

[[ Alt + 0252 (double bar)
[[[ Alt + 0253 ( triple bars)
[[[[ Alt + 0254 (four bars)
[[[[[ Alt + 0255 (five bars)
↑ Alt + 0249 (up arrow)
Bar Graph Character Set (TD 200, TD 200C)

The bar graph characters that are supported by the standard TD character set are shown
below.
Figure A-3 Bar Graph Character Set for the TD 200 and TD 200C

System Manual, 08/2007, A5E00765548-02 143
A.7 Arabic Character Set (TD 200, TD 200C, and TD400C)
A.7 Arabic Character Set (TD 200, TD 200C, and TD400C)
Arabic Character Set (TD 200, TD 200C, and TD400C)
Figure A-4 Arabic Character Set

144 System Manual, 08/2007, A5E00765548-02
A.8 Baltic Character Set
A.8 Baltic Character Set
Baltic Character Set
Figure A-5 Baltic Character Set

System Manual, 08/2007, A5E00765548-02 145
A.9 Simplified Chinese Character Set
Simplified Chinese Character Set

The TD devices support the Simplified Chinese character set (GB2312-80) for the People's
Republic of China. The TD devices use Microsoft Windows encoding for this character set.
The Windows encoding allows the TD devices to display the same characters as shown in
the STEP 7-Micro/WIN Text Display wizard when you are using a Chinese emulator or a
Chinese version of Microsoft Windows.
Chinese characters are represented in STEP 7-Micro/WIN by a pair of numbers which
represent the encoding of the character in the GB2312-80 specification. The TD devices also
use a pair of numbers to represent the Chinese character.
Notes for Using the Simplified Chinese Character Set

Tip
The Simplified Chinese character set requires a Chinese version of Windows or a Chinese
emulator to properly display Chinese characters in the Text Display wizard. You must start
the Chinese emulator before you start the STEP 7-Micro/WIN software.
On the TD 200C and the TD 200, you can display up to 20 single-byte characters per line of
your message. Because Simplified Chinese uses double-byte characters, you can display up
to 10 double-byte characters per line for a message in Chinese.
On the TD 100C, you can display up to 16 single-byte characters per line of your message.
Because Simplified Chinese uses double-byte characters, you can display up to 8 double-
byte characters per line for a message in Chinese.
On the TD400C using a small font, you can display up to 24 single-byte characters per line
of your message. Because Simplified Chinese uses double-byte characters, you can display
up to 12 double-byte characters per line for a message in Chinese. If you selected a large
font, you can display up to 16 single-byte characters or 8 Chinese characters.
The standard ASCII characters, such as numbers, punctuation, and upper and lowercase
alphabet characters, are available when using the Simplified Chinese character set (shown
below). Depending on your keyboard and/ or emulator, some of these standard characters
may be formatted as single-byte characters instead of the double-byte characters like the
Simplified Chinese characters. Standard ASCII characters and Chinese characters can be
mixed on the TD display.
The Text Display wizard displays 8 , 10, or 12 double-byte character places for the text of a
screen or alarm. You can fit any of the following combinations into a character position:
● 1 double-byte character
● 2 single-byte characters (standard ASCII)
● 1 single-byte character and 1 single-byte blank
You cannot fit one single-byte character plus one double-byte character in a character
position.
TD 100C does not support the entire Simplified Chinese character set, however, the most-
used characters have been included in the TD 100C. See the Simplified Chinese Characters
Set for a list of supported characters. Characters that are not supported by the TD 100C are
displayed as a square.

146 System Manual, 08/2007, A5E00765548-02
Tip
The Simplified Chinese Character Set electronic file resides on the STEP 7-Micro/WIN
documentation CD. This file shows the characters supported by the different TD devices.
The Standard Character Set (ASCII) for the TD400C is shown below.
Figure A-6 Standard Character Set (ASCII Code) for TD400C

System Manual, 08/2007, A5E00765548-02 147
A.10 Cyrillic Character Set
A.10 Cyrillic Character Set
Cyrillic Character Set
Figure A-7 Cyrillic Character Set

148 System Manual, 08/2007, A5E00765548-02
A.11 Greek Character Set
A.11 Greek Character Set
Greek Character Set
Figure A-8 Greek Character Set

System Manual, 08/2007, A5E00765548-02 149
A.12 Hebrew Character Set (TD 200, TD 200C, and TD400C)
A.12 Hebrew Character Set (TD 200, TD 200C, and TD400C)
Hebrew Character Set (TD 200, TD 200C, and TD400C)
Figure A-9 Hebrew Character Set

150 System Manual, 08/2007, A5E00765548-02
A.13 Latin 1 Character Set
Latin 1 Character Set
Figure A-10 Latin 1 Character Set

System Manual, 08/2007, A5E00765548-02 151
Latin 2 Character Set
Figure A-11 Latin 2 Character Set

152 System Manual, 08/2007, A5E00765548-02
A.15 Turkish (Latin 5) Character Set
Turkish (Latin 5) Character Set
Figure A-12 Turkish (Latin 5) Character Set

System Manual, 08/2007, A5E00765548-02 153

154 System Manual, 08/2007, A5E00765548-02
Connecting Multiple Devices on a Network B
B.1 Overview
Overview of Appendix B
You can connect multiple TD devices and S7-200 CPUs together on one communication
network. The TD devices act as network masters and do not interfere with each other. You
can designate the S7-200 CPUs to be either masters or slaves on the network.

System Manual, 08/2007, A5E00765548-02 155
Connecting Multiple Devices on a Network
B.2 Communicating with Multiple CPUs
B.2 Communicating with Multiple CPUs
Communicating with Multiple CPUs

Figure B-1 shows a typical network with two TD 200s and two S7-200 CPUs. Each TD 200
communicates to one of the CPUs. The addresses of each device are noted below the
device in the figure. In this example:
● TD 200 Number 1 is configured to communicate to the S7-200 CPU at address 2 (CPU 1)
● TD 200 Number 2 is configured to communicate to the S7-200 CPU at address 3 (CPU 2)
Tip
You can connect multiple TD devices to a single S7-200 CPU. You can store separate
parameter blocks for each TD device in different V memory locations in the CPU.
If you do not store separate parameter blocks for each TD device that is connected to the
CPU, any of these TD devices can acknowledge the same messages and use function keys
to initiate operations in the CPU.
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Figure B-1 Typical Multiple CPU Network
Tip
The display time slows as more TD devices are added to the network.
Network connectors are available from Siemens. Using these connectors allows you to
isolate the CPUs from one another (the 24 VDC), but still allows you to power the TD device
from the CPU. See the SIMATIC S7-200 Programmable Controller System Manual for more
information about using network connectors.

156 System Manual, 08/2007, A5E00765548-02
B.3 Determining the Distances, Transmission Rate, and Cable
B.3 Determining the Distances, Transmission Rate, and Cable
Determining the Distances, Transmission Rate, and Cable

As shown in Table B-1, the maximum length of a network segment is determined by two
factors: isolation (using an RS-485 repeater) and baud rate.
Isolation is required when you connect devices at different ground potentials. Different
ground potentials can exist when grounds are physically separated by a long distance. Even
over short distances, load currents of heavy machinery can cause a difference in ground
potential.
Table B-1 Maximum Length for a Network Cable
Baud Rate Non-Isolated CPU Port1 CPU Port with Repeater or EM 277
9.6 kbaud to 187.5 kbaud 50 m 1,000 m
1The maximum distance allowed without using an isolator or repeater is 50 m. You
measure this distance from the first node to the last node in the segment,
Using Repeaters on the Network

An RS-485 repeater provides bias and termination for the network segment. You can use a
repeater for the following purposes:
● To increase the length of a network: Adding a repeater to your network allows you to
extend the network another 50 m. If you connect two repeaters with no other nodes in
between (as shown in Figure B-2), you can extend the network to the maximum cable
length for the baud rate. You can use up to 9 repeaters in series on a network, but the
total length of the network must not exceed 9600 m.
● To add devices to a network: Each segment can have a maximum of 32 devices
connected up to 50 m at 9600 baud. Using a repeater allows you to add another segment
(32 devices) to the network.
● To electrically isolate different network segments: Isolating the network improves the
quality of the transmission by separating the network segments which might be at
different ground potentials.
A repeater on your network counts as one of the nodes on a segment, even though it is not
assigned a network address.
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Figure B-2 Sample Network with Repeaters

System Manual, 08/2007, A5E00765548-02 157
B.4 Selecting the Network Cable
B.4 Selecting the Network Cable
Selecting the Network Cable

S7-200 networks use the RS-485 standard on twisted pair cables. Table B-2 lists the
specifications for the network cable. You can connect up to 32 devices on a network
segment.
Table B-2 General Specifications for Network Cable
Specifications Description
Cable type Shielded, twisted pair
Loop resistance ≤115 Ω /km
Effective capacitance 30 pF/m
Nominal impedance Approximately 135 Ω to 160 Ω (frequency =3 MHz to 20 MHz)
Attenuation 0.9 dB/100 m (frequency=200 kHz)
Cross-sectional core area 0.3 mm2 to 0.5 mm2
Cable diameter 8 mm ±0.5 mm

158 System Manual, 08/2007, A5E00765548-02
B.5 Biasing and Terminating the Network Cable
B.5 Biasing and Terminating the Network Cable
Biasing and Terminating the Network Cable

Siemens provides two types of network connectors that you can use to easily connect
multiple devices to a network: a standard network connector and a connector that includes a
programming port (which allows you to connect a programming station or an HMI device to
the network without disturbing any existing network connections). The programming port
connector passes all signals (including the power pins) from the S7-200 through to the
programming port, which is especially useful for connecting devices that draw power from
the S7-200 (such as a TD 200).
Both connectors have two sets of terminal screws to allow you to attach the incoming and
outgoing network cables. Both connectors also have switches to bias and terminate the
network selectively. Figure B-3 shows typical biasing and termination for the cable
connectors.
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Figure B-3 Bias and Termination of the Network Cable

System Manual, 08/2007, A5E00765548-02 159
B.6 Building a TD/CPU Cable
B.6 Building a TD/CPU Cable
Building a TD/CPU Cable

The TD/CPU cable is used for connecting a display device to an S7-200 CPU. If you do not
have a TD/CPU cable, refer to Figures B-4 and B-5 to create your own cable.
Making a Cable That Supplies Power to the TD Device
CAUTION
Connecting the 24 VDC power output (pin 7 of communication port) of multiple S7-200
CPUs may cause erratic operation of the I/O, which could potentially cause personal injury
and/or property damage.
The 24 VDC power supply is also the sensor supply for the I/O. Interconnecting the output
power supplies of multiple CPUs could possibly overload the sensor supply, which could
cause the I/O to operate incorrectly.
When networking S7-200 CPUs, connect only the communication lines (pins 3, 5, and 8).
You must not connect the power output (pin 7).
Tip
The TD 100C must use the TD/CPU cable shown in Figure B-4.
Figure B-4 shows you the pin-out of TD/CPU cable with power supplied to the TD device.
Use this option when you want the TD device to receive power from an S7-200 CPU.
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Figure B-4 TD/CPU Cable with Power Connections

160 System Manual, 08/2007, A5E00765548-02
B.7 CPU Grounding and Circuit Reference Point Guidelines for Using Isolated Circuits
Making a Cable That Does Not Supply Power to the TD Device (TD 200, TD 200C, and TD400C only)
Figure B-5 shows you the pin-out of a TD/CPU cable without power supplied to the TD
device. Use this option when you want the TD device to receive power from an external
power supply. The maximum length for the cable is 1200 meters.
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Figure B-5 TD/CPU Cable without Power Connections
B.7 CPU Grounding and Circuit Reference Point Guidelines for Using Isolated
Circuits
CPU Grounding and Circuit reference Point Guidelines for Using Isolated Circuits
The following items are CPU grounding and circuit guidelines for using isolated circuits:
● You should identify the reference point (0 voltage reference) for each circuit in the
installation, and the points at which circuits with possibly different references can connect
together. Such connections can result in unwanted current flows that can cause logic
errors or can damage circuits. A common cause of different reference potentials is
grounds that are physically separated by long distances. When devices with widely
separated grounds are connected with a communication or sensor cable, unexpected
currents can flow through the circuit created by the cable and the ground. Even over short
distances, load currents of heavy machinery can cause differences in ground potential or
can directly induce unwanted currents by electromagnetic induction. Power supplies that
are improperly referenced with respect to each other can cause damaging currents to
flow between their associated circuits.
● When you connect CPUs with different ground potentials to the same PPI network, you
should use an isolated RS-485 repeater.
● S7-200 products include isolation boundaries at certain points to help prevent unwanted
current flows in your installation. When you plan your installation, you should consider
where these isolation boundaries are provided, and where they are not provided. You
should also consider the isolation boundaries in associated power supplies and other
equipment, and where all associated power supplies have their reference points.
● You should choose your ground reference points and use the isolation boundaries
provided to interrupt unneeded circuit loops that could allow unwanted currents to flow.
Remember to consider temporary connections which may introduce a new circuit
reference, such as the connection of a programming device to the CPU.
● When locating grounds, you must also consider safety grounding requirements and the
proper operation of protective interrupting devices.

System Manual, 08/2007, A5E00765548-02 161
B.7 CPU Grounding and Circuit Reference Point Guidelines for Using Isolated Circuits
● In most installations, you will have the best noise immunity if you connect the CPU sensor
supply M terminal to ground.
The following descriptions are an introduction to general isolation characteristics of the
S7-200 family, but some features may be different on specific products. Consult your product
specifications in the appropriate manual for information about which circuits include isolation
boundaries and the ratings of the boundaries. Isolation boundaries rated less than 1,500
VAC are designed as functional isolation only, and should not be depended on as safety
boundaries.
● Logic circuit reference is the same as DC sensor supply M.
● Logic circuit reference is the same as the input power supply M on a CPU with DC power
supply.
● CPU communication ports have the same reference as logic circuit.
● Analog inputs and outputs are not isolated from logic circuit. Analog inputs are full
differential to provide low voltage common mode rejection.
● Logic circuit is isolated from ground to 500 VAC.
● DC digital inputs and outputs are isolated from logic circuit to 500 VAC.
● DC digital I/O groups are isolated from each other by 500 VAC.
● Relay outputs are isolated from logic circuit to 1,500 VAC.
● Relay output groups are isolated from each other by 1,500 VAC.
● AC power supply line and neutral are isolated from ground, the logic circuit, and all I/O to
1,500 VAC.

162 System Manual, 08/2007, A5E00765548-02
Troubleshooting C
C.1 Troubleshooting Guide
Troubleshooting
Refer to Table C-1 for a list of the problems that could occur with the TD device and possible
causes and solutions.
Table C-1 Error Messages
Problem Possible Cause Possible Solution

NO PARAMETER BLOCK The TD device could not find a Configure a parameter block for the TD
parameter block in the programmable device using the Text Display wizard,
logic controller. and download it to the S7-200.
Be sure the parameter block address in
the TD device matches the actual
address of the parameter block.
The TD device found a parameter block Be sure all fields are within range.
in the programmable logic controller, Be sure all addresses are valid for the
but it contains errors. S7-200 CPU.
No CPU COMM Address of the S7-200 CPU is incorrect Correct the address error
S7-200 CPU does not have power Power up the CPU
Cable problems Check the cable connections
Wrong baud rate configured Correct the baud rate
Multiple CPUs at the same address Remove other CPUs and retry
May need network terminations Refer to Appendix B
Network too long or too many devices Refer to Appendix B
on network
HARDWARE ERROR TD device is inoperable The TD device could be defective
Replace with a new TD device.
NETWORK ERROR Multiple masters with the same Remove other masters and retry
TD device cannot establish a network address.
connection or enter an existing network Cable problems Check the cable connections
Multiple CPUs at the same address Remove the other CPUs and retry
CPU BUSY Some other master has locked the S7- Wait - The message disappears in a
200 CPU by uploading or downloading few seconds
a program to that CPU
CPU IN STOP MODE RUN/STOP switch is in STOP Put CPU in RUN mode

System Manual, 08/2007, A5E00765548-02 163
Troubleshooting
C.1 Troubleshooting Guide
Problem Possible Cause Possible Solution

Display backlight is on, but no message Program checksum failure Defective hardware: Replace with a
is displayed new TD device
User cannot access the TD system The custom keypad does not contain To restore the standard TD keypad:
menus the ESC and ENTER buttons 1. Power down the TD device
2. Press and hold the lower right
corner (where ENTER key is
located on the standard keypad)
The default keypad is restored until the
TD device is power cycled again.

164 System Manual, 08/2007, A5E00765548-02
Index
Cable for network, 158
cable, TD/CPU, 30
A CE Labeling, 5
CE Symbol, 138
agency approvals
certification, 5
Canadian Standards Association (CSA), 4
character set
Underwriters Laboratories (UL), 4
selecting, 76
alarms, 101, 107, 110
Character sets
accessing, 20
Standard Character Set, 147
alarm parameters, 92
Character Sets
configuring, 89
Arabic, 144
default display, 92
Cyrillic, 148
determining type of operator interaction, 90
Greek, 149
displaying, 22
Hebrew, 150
embedding variable, 94
Latin 1, 151
storing in parameter block, 21
Latin 2, 152
text for, 93
Simplified Chinese, 146
Approvals for TD devices, 139
Standard TD, 141
Arabic Character Set, 144
Turkish (Latin 5), 153
arrow buttons, 103
Characters Sets
ATEX, 138
Baltic, 145
characters supported, 17
Characters, International and Special, 142
B
clearing keypad, 122
Baltic Character Set, 145 cnfiguration
Bar Graph character set, 143 saving keypad to, 58
baud rate, 40, 125 Communicating on a network, 156
bitmaps, sample, 15 communication port, 15
button properties by TD device, 52 comparing TD features, 18
buttons compatibility with other TD devices, 13
adding to keypad, 48 configurable buttons, 102
arrow, 103 configuration overview, 24
configurable, 102 Configure
configuring on keypad, 79 Text Display device, 72
defining properties, 51 configuring
Enter and Escape, 102 alarms, 89
Buttons language sets, 96
Inserting, 49 screens, 80
configuring buttons
TD 100C, TD 200C, and TD400C, 44
C configuring the TD
completing, 100
cable
with Text Display wizard, 70
connecting the TD/CPU cable, 38
connecting
Cable
TD/CPU cable, 38
building a network, 160

System Manual, 08/2007, A5E00765548-02 165
Index
connection to CPU, establishing, 40 F

contact information, 7
faceplate
technical support, 7
creating a custom, 27
contrast, 125
installing, 36
copy user program to memory cartridge, 128
printing, 28
CPU address, 124
printing panel image to, 60
CPU Grounding, 161
procedure to install, 36
CPU memory
faceplate for TD 100C and TD 200C, 30
editing, 129
faceplate, blank
CPU memory address and data type, 131
ordering information, 28
CPU operating mode, 128
Factory Mutual (FM) approvals, 140
CPU Status, 119
Factory Mutual Research Standards, 5
creating a custom faceplate, 27
features of TD device, 16
Creating text for screen, 84
font size
C-Tick Standards, 5
selecting, 77
cULs, 139
fonts supported, 17
custom faceplate, 44
Force I/O, 127
creating, 27
printing, 28
custom keypad
G
loading to the TD device, 78
custom label for TD 200 gap factor, 125
dimensions, 35 gaphics application
customizing label export layout, 54
keys of TD 200, 34 gasket, 30
Cyrillic Character Set, 148 Greek Character Set, 149
D H
data type, 131 Hebrew Character Set, 150
default display mode, 110 highest station, 125
defining properties of buttons, 51
Diagnostic/Setup Menu, 123
Dimensions, 133 I
dimensions for mounting hole, 31
installation of TD device
dimensions for TD 200 label, 35
general, 30
display backlight, 126
installation overview, 23
display backlight TD400C, 103
installing
displaying screens and alarms, 22
printed faceplate to TD device, 64
installing faceplate, 36
installing TD device, 26
E
Internet site for Text Display, 5
EC declarations, 138
edit variables, 106
editing CPU memory, 129 K
embedded string variables, 87
kepad
embedding a variable, 85
save to TD configuration file, 58
EMC directive, 138
keypad
error messages, 120
adding buttons, 48
keypad buzzer, 125
Keypad Designer, 15, 44

166 System Manual, 08/2007, A5E00765548-02
Index
adding buttons, 48 O
starting the, 46
operator interaction for alarms, 90
templates, 44
Operator Menu, 119
keypad Llyout
Order numbers, 133
export to graphics application, 54
keypad, clearing, 122
P
L panel image
printing, 60
language set
reversing, 59
selecting, 76
panel thickness, 30
language sets, 122
parameter block
configuring, 96
assigning V memory address, 99
languages supported, 17
screens and alarms, 21
Latin 1 Character Set, 151
parameter block address, 124
Latin 2 Character Set, 152
password, 109
Password, selecting, 72
pnel image
M
adding to faceplate, 56
manuals importing, 56
S7-200 Programmable Controller System Manual, 3 power connector, 15
memory cartridge power, supplying, 39
copying to, 128 printing
menu hierarchy, 107 custom faceplate, 28
message printing panel image, 60
creating for screen, 84 program files, 15
messages projects, sample, 15
viewing, 126
mounting
preparing the TD device, 32 R
spacers, 32
Repeaters on Network, 157
TD device, 31
reversing panel image, 59
mounting brackets, 30
mounting dimensions, 31
mounting procedure
S
TD 100C, 33
mounting the TD 100C, 33 S7-200 Programmable Controller System Manual, 3
mounting the TD device sample bitmaps, 15
steps required, 33 sample projects, 15
sample templates, 15
screen
N creating text, 84
message, 84
network
screens, 101, 107, 110
TD as master, 15
accessing, 20
Network
configuring, 80
communicating with multiple CPUS, 156
displaying, 22
isolation and baud rate, 157
storing in parameter block, 21
network address, 124
screws, mounting, 30
Network cable, 158
service and support, 5
biasing and terminating, 159
Setting up TD device, 124

System Manual, 08/2007, A5E00765548-02 167
Index
Simplified Chinese Character Set, 146 TD400C, 14

spacers, 30, 32 components shipped with, 30
Specifications, 133 display backlight, 103
Standard Character Set (ASCII), 147 features, 18
standard faceplate, 20, 40 technical support, 7
standard functions, 107 templates, 44
Standard TD Character Set, 141 templates, sample, 15
STEP 7-Micro/WIN, 15 Text Display
versions, 3 configure, 72
STOP/RUN mode, 128 text display area, 15
summary of configuration, 100 Text Display device versions, 3
Text Display wizard, 15
starting, 71
T tasks for configuring, 70
Time and Date, 120
TD 100C, 13
Troubleshooting the TD device, 163
components shipped with, 30
Turkish (Latin 5) Character Set, 153
features, 18
TD 200, 14
components shipped with, 30
U
customizing label for keys, 34
features, 18 UL Standards, 5
TD 200C, 14 Update rate
components shipped with, 30 selecting for TD device, 75
features, 18 user menu, 83
TD device
commmunication baud rate, 40
configuring the buttons on keypad, 79 V
displaying information, 104
values
installing printed faceplate, 64
calculating, 86
loading a custom keypad, 78
variable
selecting font size, 77
embedding into text of screen, 85
selecting update rate, 75
variables
standard faceplate, 20
editing, 106
supplying power, 39
view TD messages, 126
TD devices, 13
V-memory address
comparing features, 18
assigning for parameter block, 99
compatibility, 13
fonts supported, 17
TD devoce
W
select language and character set, 76
TD features, 16 Weight, 133
TD Menu functions
enabling CPU, 73
TD Setup Menu, 125

168 System Manual, 08/2007, A5E00765548-02
s
SIMATIC TP070
Touch Panel - Ideal for the SIMATIC S7-200
Product Brief
TP070 – extremely low-cost version

The SIMATIC® TP070 is a remarkably
low-priced Touch Panel - tailored in
particular to suit applications with the
SIMATIC S7-200® microsystem. It
features an interface that provides
point-to-point communication with the
controller.
The TP070 is the smallest Windows
CE-based Touch Panel of the SIMATIC
HMI® family. Its rugged front in degree
of protection IP 65 makes it highly suit-
able for use direct on site.
Intuitive touch operator interfaces
Intuitive operator control and visualiza-
tion is the highlight of this touch-
sensitive display. No mechanical keys
are required. Self-explanatory buttons
enable users to create their own
intuitive displays. Control operations
are carried out simply by touching the
buttons depicted on the screen. These
reduce the time required for the opera-
tor to get to know the system and are a
great help in avoiding operator errors.
Fast and efficient parameterization -
and simple as well
The TP070 is configured using the
Windows-based configuring software
TP Designer1) – with the Look&Feel of
the programming software of the
S7-200, STEP® 7-Micro/Win. The
TP Designer can also be called directly
from Micro/Win1), which is part of the
STEP 7 Micro/WIN Toolbox CD.
Functions for buttons (indicator lights), · Connects to SIMATIC S7-200 · Suitable for use worldwide:
diagrams, bar charts, input/output · Service-friendly thanks to mainte- five languages already available -
fields and fixed texts are available for nance-free design and long service (Asiatic characters soon)
machine control and monitoring and for life of the backlighting of 50,000 h · Future-oriented thanks to the innova-
dynamic visualization tasks. (corresponds to 6 years of tive Windows CE standard operating
Highlights round-the-clock continuous opera- system
tion)
· Low-cost starter device with the · Bus cable instead of parallel wiring 1) Version 3.1 and higher
required basic functions
· Extremely fast configuring and
startup times
Technical specifications
TP070
Display STN, CCFL backlit (Cold Cathode Fluorescence Lamps)
Resolution (pixels) 320 x 240
Screen area (W x H in mm) 116 x 87 (5.7")
Color Blue Mode (4 levels)
MTBF of backlighting at
25˚C ambient temperature Approx. 50.000h (corresponds to 6 years of round-the-clock continuous operation)
Keyboard type Touch (analog/resistive)
Processor 32-bit RISC/ 66 MHz
User memory Flash
Size 128 Kbyte
Interfaces RS485, max. 19.2 kbit/s1)

Supply voltage 24 V DC (18 to 30 V)
Power consumption, typical 200 mA at 24 V
Clock Yes, not battery-backed
Degree of protection (front/rear) IP 65/ IP 20
Dimensions [mm]
Front panel W x H 212 x 156
Installation cutout W x H x D 198 x 142 x 45
Ambient conditions
Temperature
· Operation (installed vertically) 0 to +50 ˚C
· Operation (max. angle of inclination 35˚ to the 0 to +40 ˚C
vertical)
· Transport/storage -20 to +60 ˚C
Humidity £ 85% RH; no condensation
Functionality The size of the user memory is designed for small configurations (typically 20 process
diagrams, 30 I/O fields, 50 variables, 10 graphics, diverse buttons and approx. 80 texts).
Process diagrams
Graphic objects
Fixed texts
Bar charts max. 5 per process diagram
Variables max. 10 per process diagram
Languages 1 online language, choice of 5 languages: English, French, German, Italian and Spanish
(Chinese available soon)
Configuring1) TP Designer configuring software, part of the optional Toolbox CD V3.1 from
STEP 7-Micro/Win
Runs under Windows 95/98/NT
1) A PPI adapter cable is additionally required for project download.
For information All designations marked in this Product Brief

with ® are registered trademarks of Siemens AG.
on this product Other designations used in this publication may
visit our website be trademarks whose use by third parties for
under their own purposes could violate the rights of
the owners.
http://www.ad.siemens.de/panels
Siemens AG
Automation and Drives
P.O. Box 4848, D-90327 Nuremberg © Siemens AG 2000
Germany Subject to change without prior notice
Order No.: 6ZB5310-0HX02-0BA0

Siemens Aktiengesellschaft Printed in Germany
26100/001433 SB 08005.

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Flush By II Equipamientos para Servicios al Pozo

B-Piping Alta Presión

Pump Performance Data zp20

T Series Double Features/Bene? ts

Refer back to tables on pages 34

B22 22.28 B45 46.19 P = Pressure Port; S = Suction Port

Motores hidráulicos MLHS y MLHSY

ESPECIFICACIONES TECNICAS MLHSY

Para mayor información consultar a nuestro departamento técnico.

Dimensiones para motor MLHS

Para mayor información consultar a nuestro departamento técnico.

Brida muy corta V

Dimensiones para motor MLHSS, MLHSV y MLHSZ

Para mayor información consultar a nuestro departamento técnico.

Cara de montaje del motor.

Para mayor información consultar a nuestro departamento técnico.

las permitidas disminuirán la vida útil del motor. 2000

horas a 200 RPM. 500

DESIGNACIÓN PARA ORDENAR:

Para mayor información consultar a nuestro departamento técnico.

READ THIS MANUAL BEFORE INSTALLING, OPERATING OR

PML THE LOGICAL

If an article is claimed to be defective in material or workmanship, or not to conform to the applicable

365 REV.051117 PAGE 1

✛ Hydraulic gear motor

FUNCTION IN FORWARD ROTATION (HOISTING):

FUNCTION IN REVERSE ROTATION (LOWERING):

PAGE 2 365 REV.050718

BASIC UNIT SERIES

365 REV.050718 PAGE 3

EXTERNAL BRAKE RELEASE:

CABLE DRUM SIZES:

OPTIONAL GEAR SECTION FOR THE HYDRAULIC MOTOR:

HYDRAULIC MOTORS FOR HIGH PRESSURE HYDRAULIC SYSTEMS:

PAGE 4 365 REV.050718

CABLE DRUM DIMENSIONS (STANDARD DRUM):

CABLE STORAGE CAPACITY:

MAXIMUM OPERATING PRESSURE: 2100 psi 145 bar

MAXIMUM OPERATING VOLUME: 24 (US) gpm 91 l/min

MINIMUM OPERATING VOLUME: 6 (US) gpm 23 l/min

DRUM TORQUE AT MAXIMUM PRESSURE: 17,578 lb-in 1986 Nm

DRUM RPM AT MAXIMUM VOLUME: 66 rpm

LINE PULL AT MAXIMUM PRESSURE:

LINE SPEED AT MAXIMUM VOLUME:

PERMISSIBLE SYSTEM BACK PRESSURE

365 REV.050718 PAGE 5

OIL PRESSURE - bar

LINE SPEED VS. OIL VOLUME

LINE SPEED - m/min

LINE SPEED - fpm

PAGE 6 365 REV.050718

PRESSURE 800 PSI [55 BAR]

HYDRAULIC WINCH CONTROL

1. TYPICAL HYDRAULIC CIRCUIT - STANDARD CONTROL VALVE

CONTROL VALVE STACK

2. TYPICAL HYDRAULIC CIRCUIT - POWER BEYOND CONTROL VALVE

365 REV.050718 PAGE 7

MOTOR DRAIN LINE

3. TYPICAL HYDRAULIC CIRCUIT - STACKED CONTROL VALVE