Scanned Manual - 291007 PDF

2010-08-31
Assembly and operation instructions
Reciprocating compressor
Type 1+1TVL190
Read the instructions prior to performing any task!
Form: ZT028e/03
Manufacturer:
NEUMAN & ESSER GmbH & Co. KG Maschinenfabrik
Werkstraße
52531 Übach-Palenberg
Telephone: +49 (0) 2451/ 481-01
Fax: +49 (0) 2451/ 481-100
email: info@neuman-esser.de
Internet: www.neuman-esser.com
After-sales service:
The OEM Company
NEAC Compressor Service GmbH & Co.
Werkstraße
Telephone: +49 (0) 2451 / 481-03
Telephone: +49 (0) 171 / 42 58 595
Fax: +49 (0) 2451 / 481-300
email: info@neac.de
email: 24-h-service@neac.de
Internet: www.neac.de
Installation and operating instructions (translation of the original)

Neum-13035-DE, en_GB
© NEUMAN & ESSER GmbH & Co. KG 2010
2 2010-08-31
Reciprocating compressor Type 1+1TVL190
Supplemental instructions
These instructions enable you to use reciprocating compressor

108399 safely and efficiently. These instructions are a component part
of the machine and must be kept in the direct vicinity of the machine
and be accessible for staff at all times. Staff must have carefully read
through and understood these instructions before starting any work. In
addition to these instructions the instructions for the installed compo-
nents included in the appendix also apply.
Adherence to all the safety information and instructions specified in
these instructions is a basic requirement in order to ensure safety
whilst working. The local regulations for the prevention of accidents
and general safety rules for operational area of the machine also ap-
ply. The illustrations in these instructions are for purposes of basic
understanding and may differ from the actual layout of the machine.
No claims can be asserted as a result of any differences.
Liability restrictions
All the information and instructions in these instructions have been
compiled taking into account the applicable standards and regulations,
state-of-the-art technology and our own know-how, gathered from
years of experience. The manufacturer assumes no liability for dam-
ages caused by the following:
 Failure to adhere to all the stipulations of these instructions
 Improper use
 Use of untrained staff
 Arbitrary conversions or technical changes not approved by the
manufacturer
 Use of non-approved spare parts
The obligations agreed in the supply contract, the General Terms and
Conditions, the manufacturer's delivery conditions and the legal provi-
sions valid at the time of completion of the contract apply.
Copyright
These instructions are protected by copyright.
These instructions must not be made available to third parties, repro-
duced in any way – even in excerpts – and their contents must not be
utilised and/or communicated without written permission from NEU-
MAN & ESSER GmbH & Co. KG Maschinenfabrik ("manufacturer”)
except for internal purposes. Any infringement will render the offender
liable for compensation. The manufacturer reserves the right to assert
additional claims.
The manufacturer holds the copyright.
© NEUMAN & ESSER GmbH & Co. KG Maschinenfabrik
Werkstraße
52531 Übach-Palenberg, Germany
2010-08-31 3
Supplemental instructions
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NEA USA 291007 / Ser. No. 108399
Table of contents
Table of contents ........................................................................5
1 Overview ..............................................................................9
1.1 Warranty terms ..........................................................10
1.2 Customer Service ......................................................10
2 Safety .................................................................................11
2.1 Explanation of symbols ..............................................11
2.2 Proper use.................................................................13
2.3 Basic hazards ............................................................14
2.3.1 General hazards in the workplace ............... 14
2.3.2 Hazards due to electrical energies ..............14
2.3.3 Mechanical hazards ....................................15
2.3.4 Hazards due to hydraulic energies ..............15
2.3.5 Hazards due to pressurised gases ..............16
2.3.6 Hazards due to high or low temperatures ....16
2.3.7 Fire hazards................................................17
2.3.8 Explosion hazards.......................................18
2.3.9 Hazards due to chemical substances .......... 18
2.4 Staff requirements .....................................................20
2.4.1 Qualifications ..............................................20
2.4.2 Unauthorised persons .................................21
2.4.3 Training ......................................................23
2.5 Personal safety equipment and clothing .....................24
2.6 Signs .........................................................................26
2.6.1 Mandatory action signs ...............................26
2.6.2 Prohibitory signs .........................................26
2.6.3 Warning signs.............................................27
2.7 Safety devices ...........................................................29
2.8 Securing the machine to prevent it from being switched
back on......................................................................30
2.9 Behaviour in case of fire or accidents......................... 31
2.10 Responsibility of the user ...........................................32
2.11 Environmental protection ...........................................33
3 Construction and function ................................................35

3.1 Overview ...................................................................35
3.2 Short description ........................................................37
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3.3 Assembly description.................................................39

3.3.1 Drive unit .................................................... 39
3.3.2 Compressor section ....................................49
3.4 Working areas and danger areas ...............................55
4 Transportation, packaging and storage ...........................56

4.1 Safety notes for transportation...................................56
4.2 Symbols on the packaging .........................................58
4.3 Transport inspection..................................................59
4.4 Transportation ...........................................................60
4.5 Packaging .................................................................64
4.6 Storage ..................................................................... 65
5 Installation and initial commissioning .............................66
6 Operation ...........................................................................67
6.1 Safety........................................................................67
6.2 Switching on ..............................................................67
6.3 Switching off..............................................................68
6.4 Shutdown in emergency situations.............................69
6.5 Rotating the reciprocating compressor.......................70
7 Long-term removal from service ......................................71

7.1 Preservation ..............................................................71
7.2 Recommissioning after a down time...........................72
8 Maintenance ......................................................................75
8.1 Safety........................................................................75
8.2 Maintenance schedule............................................... 79
8.3 Preparing for maintenance work ................................80
8.4 Maintenance work .....................................................81
8.4.1 Checking the oil systems for leaks ..............81
8.4.2 Checking the oil level in the drive unit .........85
8.4.3 Replacing the drive unit oil ..........................86
8.4.4 Replacing the oil wiper packing ...................87
8.4.5 Replace the Intermediate partition packing..91
8.4.6 Replace the pressure packing .....................94
8.4.7 Replacing the piston rings and guide rings ..98
8.4.8 Replace the valves ................................... 101
8.4.8.1 Replacing the suction valves ...... 101
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8.4.8.2 Replacing the discharge valves ..105

8.4.9 Replacing the suction valve unloader ........109
8.4.10 Disassembling and assembling the crosshead-
piston rod connection................................111
8.4.11 Measuring and setting the rod runout ........121
8.4.12 Grinding the sealing surfaces ....................124
8.5 Actions after maintenance has been completed .......124
9 Faults ...............................................................................126
9.1 Safety ......................................................................126
9.2 Fault table ...............................................................128
9.3 Work to remedy faults ..............................................133
9.3.1 Tasks before starting to remedy faults.......133
9.3.2 Work on the oil system..............................134
9.3.3 Work on valves .........................................134
9.3.4 Draining the condensation or lubricant build-up
.................................................................135
9.3.5 Tightening the piston fastenings................135
9.4 Start-up following fault rectification...........................136
10 Disassembly and disposal ..............................................137
11 Spare parts ......................................................................138

11.1 Safety .................................................................138
11.2 Spare parts..............................................................138
12 Technical data .................................................................139

12.1 Dimensional sheet ...................................................139
12.2 Requirements for the location for installation ............139
12.3 General information .................................................141
12.3.1 Reciprocating compressor machine data ...141
12.3.2 Component weights ..................................145
12.4 Operating conditions................................................145
12.4.1 Process gas data......................................145
12.4.2 Operating data..........................................146
12.4.3 Utilities......................................................149
12.5 Bolted joints .............................................................151
12.6 Clearances and wear limits for drive unit parts .........153
12.7 Dimensions and wear limits for compressor sections154
12.8 Emissions ................................................................154
12.9 Nameplate...............................................................155
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12.10 Cylinder plate .......................................................... 155
13 Index ................................................................................ 157
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1 Overview
Fig. 1: Overview
1 Drive unit 3 Compressor section

2 Flywheel
Short description The reciprocating compressor comprises the drive unit and the com-
pressor section and is driven by an electric motor. It is used to com-
press process gases and process gas mixtures. The reciprocating
compressor and the individual assemblies are described in detail at a
later point  Chapter 3.2 „Short description“, page 37.
Only use the reciprocating compressor in accordance with its proper
use in order to ensure fault-free and proper operation.
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1.1 Warranty terms

The warranty terms are included in the manufacturer's Terms and
Conditions.
1.2 Customer Service

Our customer service division is available to provide technical infor-
mation. See page 2 for contact details.
In addition, our employees are always interested in acquiring new
information and experience gained from practical application; such
information and experience may help improve our products.
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2 Safety
This section provides an overview of all important safety aspects for
the protection of people as well as for safe and fault-free operation.
Additional task-related safety instructions are in the sections about the
individual life phases.
2.1 Explanation of symbols

Safety instructions Safety instructions are marked with symbols in these instructions. The
safety instructions are always introduced by signal words which ex-
press the extent of the danger.
DANGER This combination of symbol and signal word indicates an immedi-

ately-dangerous situation which could cause death or severe inju-
ries if not avoided.
WARNING This combination of symbol and signal word indicates a possibly-

dangerous situation which could cause death or severe injuries if it
is not avoided.
CAUTION This combination of symbol and signal word indicates a possibly-

dangerous situation which could cause slight injuries if it is not
avoided.
NOTICE This combination of symbol and signal word indicates a possibly-

dangerous situation which could cause property and environmental
damage if it is not avoided.
Tips and recommendations

This symbol highlights useful tips and recommendations as well as
information designed to ensure efficient and smooth operation.
Additional markings To emphasise operating instructions, results, lists, references and

other elements, the following markings are used in these instructions:
Marking Explanation
 Results of action steps
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Marking Explanation
References to sections of these instructions
and to other relevant documents
Listing without fixed sequence
[Buttons] Operating elements (e.g. buttons, switches),

display elements (e.g. signal lamps)
"Display" Screen elements (e.g. buttons, program-

ming of function keys)
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2.2 Proper use

The machine is designed and engineered only for the proper use de-
scribed here.
The reciprocating compressor 108399, type 1+1TVL190 is used

exclusively for compressing process gases in accordance with
process gas data specified in the technical data  Chapter 12.4.1
„Process gas data“ on page 145.
It is designed for installation in a plant.
Proper use also includes adherence to all the stipulations in these

instructions.
Any type of use going beyond proper use or any other different kind of
usage is considered improper use.
WARNING Hazard due to improper use.

- Do not use the reciprocating compressor in potentially explosive
areas.
- Do not compress any process gases which are not listed in the
customer specification.
- Never install the reciprocating compressor in plants other than
those of the manufacturer.
Improper use of the reciprocating compressor can cause danger-
ous situations.
Claims of any kind for damage which is caused by improper use will
not be recognised.
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2.3 Basic hazards

The following section describes remaining risks which can arise from
the machine even with proper use.
In order to reduce risks of personal injury and property damage and
avoid dangerous situations, the safety instructions listed here and the
safety instructions in the other sections of these instructions must be
followed.
2.3.1 General hazards in the workplace
Noise
WARNING Danger of injury from noise!
- Always wear ear protection while working.
- Do not stay in the danger zone more than necessary.
The noise levels arising in the workplace may result in serious
hearing damage.
2.3.2 Hazards due to electrical energies
Electric power
DANGER Danger to life due to electric power!
- Have all work on the electrical equipment performed by qualified
electricians.
- In the event of damage to the insulation, cut off the power sup-
ply immediately and initiate repairs.
- Before working on live components of electrical systems and
equipment, de-energize these components and secure them in
this state for the duration of the work. Adhere to the following
safety rules in this regard:
- Disconnect.
- Secure against restart.
- Verify that components have been de-energized.
- Ground and short-circuit.
- Cover or shield any adjacent live components.
- Never bypass or disable any fuses. Comply with the correct
amperage specification when replacing fuses.
- Keep moisture away from all live components. This may lead to
short circuits.
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There is an immediate risk of fatal electric shock if live components

are touched. Damage to the insulation of the individual components
can be fatal.
2.3.3 Mechanical hazards
Moving parts
WARNING Risk of injury due to moving parts!
- Do not reach into or handle moving parts while operation is in
progress.
- Never open covers in operation.
- Be aware of “over travel” time: Before opening covers make
sure that none of the parts are still moving.
- Wear tight-fitting work clothes with low tear resistance when
working in the danger area of the machine.
Moving parts can cause serious injuries.
Vibrations
WARNING Danger of injury from strong vibrations!
- Do not disable the vibration dampers.
- Keep away from the vibrating zone during operation.
In the long term, strong vibrations may result in significant injuries
and chronic damage to health. The vibration source is decoupled
from the environment by vibration dampers.
Sharp edges and pointed corners
CAUTION Danger of injury posed by sharp edges and pointed corners!

- Proceed with caution when working in the vicinity of sharp edg-
es and pointed corners.
- If in doubt, wear safety gloves.
Sharp edges and pointed corners may cause skin grazes and cuts.
2.3.4 Hazards due to hydraulic energies
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Oil mist
CAUTION Danger of injury from oil mist!

- When working on the oil system, and in the event of oil mist oc-
curring, wear breathing apparatus and protective goggles, and
ensure a supply of fresh air.
High temperatures or mechanical atomisation may create oil mist.
Oil mist may irritate the eyes and respiratory passages.
2.3.5 Hazards due to pressurised gases
Pressurised components
WARNING Danger to life from pressurised components!
Before starting work on these components:
- Pressurised components must be relieved before starting work
on them. Residual energies must also be discharged.
- Always ensure that liquid cannot accidentally escape.
- Defective components which are subject to pressure during op-
eration must be replaced immediately by the appropriate spe-
cialised personnel.
If improperly handled, pressurised components may move in an
uncontrolled manner, causing serious injury. If improperly handled
or defective, pressurised components may leak liquid under high
pressure, causing serious injury or death.
2.3.6 Hazards due to high or low temperatures
Hot surfaces
WARNING Danger of injury from hot surfaces!

- Always wear heat-resistant protective work clothing and protec-
tive gloves as a matter of principle when working in the vicinity
of hot surfaces.
- Before carrying out any work, make sure that the surfaces have
cooled down to the ambient temperature.
Component surfaces may heat up greatly during operation. Skin
contact with hot surfaces will cause severe skin burns.
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Cold surfaces
WARNING Risk of injuries from cold surfaces!

- When performing any work in the vicinity of extremely cold sur-
faces you must always wear occupational safety clothing and
protective gloves.
- Before starting any work, make sure that all surfaces have
warmed to ambient temperature.
The surfaces of components with coolants may cool down to very
low temperatures during operation. If the skin comes into contact
with cold surfaces, the skin will be severely burned.
Hot consumables
WARNING Danger of injury from hot consumables!
tive gloves as a matter of principle when carrying out any work
with consumables.
- Always check whether consumables are hot before working with
them. Allow to cool down if necessary.
Consumables may reach high temperatures during operation. Skin
contact with hot consumables will cause severe skin burns.
2.3.7 Fire hazards
Fire prevention and protection

WARNING Danger of injury due to limited or improper firefighting!
- Ensure that the only fire extinguishers available are those suited
to the fire class in question.
- Check functionality of fire extinguishers every two years.
- Refill fire extinguishers after each activation.
- Only use extinguisher propellants and spare parts which con-
form to the recognised models specified on the fire extinguisher.
- In the event of use, observe the safety and operation instruc-
tions on the fire extinguisher.
- In the event of use, observe the function temperature range.
In the event of fire, if the fire extinguisher is not operational, or is
unsuited to the specific fire class, serious injuries or death, together
with significant damage to property may result.
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Highly inflammable substances

WARNING Danger to life in the event of fire due to highly inflammable sub-
stances!
- Do not smoke within or around the danger zone. Do not handle
open flames, fire or ignition sources of any kind.
- Ensure availability of suitable extinguishing agents (fire blanket,
fire extinguisher).
- Immediately report suspicious substances, liquids or gases to
the person in charge.
- Cease work immediately in the event of fire. Leave the danger
zone until the all-clear is sounded and notify the fire brigade.
Highly inflammable substances, liquids or gases may catch fire,
causing serious or fatal injuries.
2.3.8 Explosion hazards
Explosion protection
WARNING Risk of explosion!
- Observe and adhere to the valid local organisational and explo-
sion protection measures.
- It is imperative to adhere to the stipulated maintenance inter-
vals. It is particularly important to proceed with caution with the
following components:
- Seals
- Oil system
- It is imperative that you adhere to the stipulated steps for action.
- Keep any additional ignition sources, such as cigarettes or open
fire, away from the potentially explosive area.
- Make sure that the reciprocating compressor has been earthed
during installation.
If there are any ignition sources, such as sparks, open flames and
hot surfaces, in the potentially explosive areas, there is a risk of
explosion.
2.3.9 Hazards due to chemical substances
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Toxic process gas
WARNING Risk of fatal injury from toxic process gas!

- Adhere to the manufacturer's safety data sheet.
- When handling process gas always wear safety clothing, chem-
ical-resistant protective gloves and safety goggles/glasses with
a side guard.
- Only set up or store tanks in well-ventilated places.
- Cordon off the area at risk downwind.
- Do not inhale process gas. When working with process gas, al-
ways make sure there is a supply of fresh air. After inhalation,
immediately treat the affected person with self-contained breath-
ing apparatus, lay the person on his side in a stable position in
the fresh air and keep him warm. Consult a doctor immediately.
- Quickly remove any moistened items of clothing, shoes and
socks.
- Avoid skin contact with process gas. In case of contact with the
skin, wash the affected area of skin with copious amounts of
water and hold under the running water for at least 15 minutes.
- In case of contact with the eyes immediately flush out the eyes
with clear water for 15 minutes. When doing so, direct a soft jet
of water directly into the eye. Consult a doctor immediately.
- Quell any expelled process gas with a jet of spray water and
retain the contaminated extinguishing water. When doing so,
wear self-contained breathing apparatus and a chemical protec-
tion suit.
- Keep self-contained breathing apparatus available for emergen-
cies.
- When working with process gas, do not eat, drink or smoke.
If toxic process gas comes into contact with the skin, it can cause
severe chemical burns on the skin. In case of inhalation or swallow-
ing it can cause serious chemical burns on the airways or severe
poisoning.
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2.4 Staff requirements

2.4.1 Qualifications
The different tasks described in these instructions require different

qualifications from the personnel entrusted with these tasks.
WARNING Risk in case of insufficiently qualified personnel!

- Only have any work carried out by personnel with the appropri-
ate qualifications.
- Keep insufficiently qualified staff away from the working area.
Insufficiently qualified personnel are not able to assess the risks
when using the machine and put themselves and others at risk of
serious or fatal injuries.
Staff must only be made up of personnel who can be expected to

carry out all work reliably. Personnel whose reactions are affected,
e.g. by drugs, alcohol or medication, are not permitted.
These instructions refer to the following personnel qualifications for

the various tasks:
Gas specialist
The gas specialist is qualified for the tasks for which he is employed
and is familiar with the relevant standards and regulations.
The gas specialist is capable of carrying out work on gas plants and
identifying and preventing possible hazards independently due to spe-
cialist his many years of experience.
Qualified electrician
The qualified electrician is capable of carrying out work on electrical
equipment and identifying and preventing possible hazards inde-
pendently due to his know-how and many years of experience, and
knowledge of the applicable standards and regulations.
He must also provide certification of his specialist qualification to
prove his ability to perform work on electrical equipment.
The qualified electrician must meet the valid legal regulations for acci-
dent prevention.
The qualified electrician with additional explosion protection qualifica-
tion is capable of carrying out work on electrical equipment and identi-
fying and preventing possible hazards independently due to his know-
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how and many years of experience. He is familiar with the relevant

standards and regulations.
Service staff
Certain tasks must only be carried out by the NEAC After Sales Ser-
vice department's service staff. No other staff are authorised to carry
out the work designated as such in these instructions. To have the
work carried out when it is required, contact the NEAC After Sales
Service department. See address of page 2.
Specialist staff
Specialist staff is capable of carrying out assigned work and identify-
ing and preventing possible hazards independently due to their spe-
cialist qualification, know-how, many years of experience and
knowledge of the valid standards and regulations.
Specialist staff for potentially explosive areas is capable of carrying
out work on plants or components in the potentially explosive area
due to their specialist qualification, know-how, many years of experi-
ence and knowledge of the valid standards and regulations. The spe-
cialist for potentially explosive areas can identify and prevent possible
hazards independently.
User
The user uses and operates the machine for its intended purpose
without other prior knowledge.
2.4.2 Unauthorised persons
WARNING Risk to life for unauthorised persons due to hazards in the danger
and working zone!
- Unauthorised persons must be kept away from the danger and
working zone.
- If in doubt, address the persons in question and ask them to
leave the danger and working zone.
- Cease work while unauthorised persons are in the danger and
working zone.
Unauthorised persons who do not meet the requirements described
here will not be familiar with the dangers in the working zone.
Therefore, unauthorised persons face the risk of serious injury or
death.
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2.4.3 Training
The owner must train personnel on a regular basis. Execution of the

training must be logged for better traceability.
 Date of training
 Name of the trained person
 Content of the training
 Name of the instructor
 Signatures of the trained person and of the instructor
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2.5 Personal safety equipment and clothing

Personal protective equipment serves to protect people against haz-
ards to their safety and health while working.
The personnel must wear the personal protective equipment while
working on and with the machine which is referred specially to in the
individual sections of these instructions.
Description of the personal protec- The personal protective equipment is explained below:
tive equipment
Chemical resistant safety gloves
Chemical resistant safety gloves are intended to protect hands against
aggressive chemicals.
Ear protection
Ear protection provides protection against hearing damage.
Heat-resistant protective gloves with arm protection

The protective gloves provide protection of the hands and lower arms
against contact heat in the case of touching high temperature compo-
nents.
Light respiratory protection

Light respiratory protection is used to protect against harmful dusts.
Protective clothing
Protective clothing is tight fitting working clothes with low tear re-
sistance, with tight sleeves and without any part sticking out. These
clothes primarily protect against getting caught by moving machine
parts. Do not wear rings, chains, necklaces, and other jewellery.
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Protective helmet
The protective helmet provides protection against falling and flying
parts and materials.
Safety boots
Safety boots are intended to protect against slipping hazards or foot
hazards like heavy gear.
Safety gloves
Safety gloves are intended to protect hands against friction, abrasion,
stabs or deeper wounds and against direct contact with hot surfaces.
Safety goggles
Safety goggles are intended protect the eyes against flying debris and
liquid spray.
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2.6 Signs
The following symbols and instruction signs are affixed in the work
area. These symbols and instruction signs refer to the immediate vi-
cinity in which they are affixed.
WARNING Danger due to illegible signage!

- Keep all safety, warning, and operating instructions that are af-
fixed to the device in legible condition.
- Replace damaged signs or stickers immediately.
Over time, stickers and signs can get dirty or in some other manner
become illegible, so that dangers cannot be recognized and neces-
sary operating instructions cannot be followed. Thus an injury haz-
ard occurs.
2.6.1 Mandatory action signs
Adhering to the instructions

Do not use the designated machine until you have read the instruc-
tions.
2.6.2 Prohibitory signs
Do not eat or drink

Hazardous substances which are harmful to health are used in the
work area. Do not consume or store beverages, food or stimulants.
Fire, open fire and smoking prohib-

ited
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The following types of ignition source must not be introduced or gen-

erated:
 Open flames and hot gases (e.g. candles, matches, beads of
welding solder, welding sparks, smouldering charcoal or tobacco)
 Mechanically generated sparks (e.g. stone, concrete and metal
sparks, generated by grinding, abrasive cutting or hammer blows)
 Electrical or electrostatically generated sparks (e.g. from disruptive
breakdown in case of high voltages, friction on plastic parts)
No reaching in
Dangers from crushing, shearing, catching or winding, drawing-in or
trapping. Danger spots may not be visible.
Welding prohibited
Welding is prohibited in the marked work areas because the thermal
process could result in an apparent or concealed fire hazard.
Unauthorised access prohibited

The danger zone must only be entered by persons authorised by the
owner.
2.6.3 Warning signs
Moving machine parts

Maintenance work on opened machines must only be carried out by
specially trained technicians. There is a danger of injury as long as the
machine is moving.
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Hot surface
Hot surfaces such as hot machine parts, containers or materials, as
well as hot liquids, may not always be detected. Never touch these
without protective gloves.
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2.7 Safety devices
WARNING Danger to life from non-functional safety devices!

- Check that all safety devices are fully functional and correctly
installed before starting work.
- Never disable or bypass safety devices.
- Ensure that all safety devices are always accessible.
If safety devices are not functioning or are disabled, there is a dan-
ger of grave injury or death.
Overview The following figure shows where the safety devices are located:
Fig. 2: Safety devices
1 Vent connection for inboard distance piece 3 Vent connection for outboard distance piece
2 Relief valve
Venting elements Closed parts of housing are fitted with venting elements which prevent
excessive pressure, deflagration or disruptive pulsations inside the
housing during operation from causing damage to machine parts.
These include:
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 Vents (Fig. 21+3) which prevent disruptive pulsations caused by

crosshead movements.
 Relief valves (Fig. 2/2) which are used as relief devices for
pressurised areas.
Integration in an emergency stop The machine is designed for use within a system. It does not have its
concept is required own controller and no autonomous EMER GENCY STOP function.
Before starting up the machine, install the emergency stop devices for
the machine and integrate them into the system controller's safety
chain.
Connect the emergency stop devices so that any danger to persons or
property is prevented if the energy supply is either interrupted or reac-
tivated.
The emergency stop devices must always be freely accessible.
2.8 Securing the machine to prevent it from being switched back on

WARNING Risk of fatal injury if the machine is switched back on without au-
thorisation or in an uncontrolled manner!
- Before switching back on, make sure that all safety devices are
installed and fully functional and that there is no risk to person-
nel.
- Always adhere to the sequence described in the following to
secure the machine to prevent it from being switched back on.
If the machine is switched on without authorisation or in an uncon-
trolled manner, this can cause serious or even fatal injuries.
Securing the machine to prevent it 1. Switch off the energy supply.

from being switched back on
2. Inform the responsible parties of work in the danger area.
3. Attach a sign to the machine to indicate that work is being per-

formed in the danger area and that switching on is prohibited.
The sign must feature the following information:
 Switched off on:
 Switched off at:
 Switched off by:
 Note: Do not switch on!
 Note: Do not switch on under you have checked and made
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sure that there is no risk to personnel.
4. Once all work has been performed, make sure that there is no
risk to personnel.
5. Make sure that all safety and protective devices are installed and
fully functional.
WARNING! Risk of fatal injury if the machine is switched back

on without authorisation!
- Before switching the energy supply back on, make sure that
there is no risk to personnel.
If the energy supply is switched on without authorisation or in an
uncontrolled manner, personnel in the danger area may become
injured for life.
6. Remove the sign.
2.9 Behaviour in case of fire or accidents

Preventive measures  Be prepared for fire and accidents at all times!
 Keep first-aid equipment (first-aid kit, blankets, etc.) and fire
extinguishing devices operational and readily available.
 Make your personnel familiar with accident reporting equipment as
well as first-aid and rescue equipment.
 Keep access paths clear for rescue vehicles.
Steps in case of fire and accidents  Immediately trigger an Emergency Stop using EMERGENCY-
STOP devices.
 Provided your own health is not in danger, rescue all personnel
from the danger area.
 If necessary, initiate first aid measures.
 Alert the fire department and/or emergency medical services.
 In case of fire: provided your own health is not in danger,
extinguish the fire using fire extinguishing equipment and continue
to do so until the fire department arrives.
 Notify the person in charge at the machine's place of installation.
 Clear access paths for rescue vehicles.
 Wave rescue vehicles into position.
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2.10 Responsibility of the user

Owner The term 'owner' refers to the person who himself operates the ma-
chine for trade or commercial purposes, or who surrenders the ma-
chine to a third party for use/application, and who bears the legal
product liability for protecting the user, the personnel or third parties
during the operation.
Nomination of a responsible party The user has the obligation to nominate a responsible party who is
responsible for the safe operation of the machine and the coordination
of all work on the machine.
User obligations The machine is used commercially. The user of the machine is there-
fore subject to the legal obligations for occupational health and safety.
In addition to the safety notes in these instructions, the regulations for
safety, the prevention of accidents and environmental protection valid
for the operational area of the machine must be adhered to.
In particular the following applies:
 The user must keep informed of the valid occupational health and
safety regulations and in a risk assessment also identify any
hazards which arise as a result of the special working conditions at
the location for use of the machine. These must be applied in the
form of operating instructions for operation of the machine.
 During the entire period of use of the machine the user must check
whether the operating instructions he has compiled comply with the
current regulations and update the operating instructions as
necessary.
 The user must clearly organise and define the responsibilities for
installation, operation, fault remedying maintenance and cleaning.
 The user must make sure that all employees who come into
contact with the machine have read and understood these
instructions. He must also provide staff with trainin g and inform
them of hazards at regular intervals.
 The user must provide staff with the requisite personal safety
equipment and clothing and issue binding instructions for them to
wear the requisite personal safety equipment and clothing.
The user is also responsible for ensuring that the machine kept is in
technically perfect condition at all times. The following applies:
 The user must therefore make sure that the maintenance intervals
described in this manual are adhered to.
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 The user must have all safety devices checked regularly to make
sure they are functional and complete.
2.11 Environmental protection

NOTICE Danger to the environment due to incorrect handling of materials
which can harm the environment!
- Always heed the notes below about the handling of materials
which can harm the environment and their disposal.
- If materials which can harm the environment accidentally es-
cape into the environment, take suitable measures immediately.
In case of doubt, inform the responsible local authority about the
damage and ask what suitable measures to take might be.
In case of incorrect handling of materials which can harm the env i-
ronment, especially improper disposal, there can be significant
damage to the environment.
The following materials which might harm the environment are

used:
Coolants When released, coolants develop decomposition products which are

hazardous to the environment. Maximum care and caution are re-
quired when handling coolants. Always observe the safety data sheet
issued by the manufacturer. Ensure that personnel handling coolants
are regularly informed about potential dangers and are instructed in
the safe handling of coolants.
Cooling water - frost protection Cooling water and frost guards contain toxic substances. They must
not be allowed to escape into the environment. Disposal must be car-
ried out by a specialist disposal company.
Process chemicals The process chemicals used in the machine are hazardous substanc-
es with special waste disposal requirements.
In order to ensure proper disposal, locally applicable requirements
imposed by regulations, laws, technical regulations etc., as well as the
safety data sheets for the substances in question, must be observed
and complied with.
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Cleaning liquids Cleaning liquids incorporating solvents contain toxic substances. They
must not be allowed to escape into the environment. Disposal must be
carried out by a specialist disposal company.
Lubricants Lubricants such as greases and oils contain toxic substances. They
must not be allowed to escape into the environment. Disposal must be
carried out by a specialist disposal company.
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3 Construction and function

3.1 Overview
External view (example)
Fig. 3: External view (example)
1 Oil pump 9 Oil filler nozzle

2 Oil distribution pipe 10 Oil inspection glass
3 Relief valve 11 Oil drain
4 Flywheel 12 Oil suction line connection
5 Coupling 13 Level monitor connection
6 Compressor connections (specific to job) 14 Oil heater connection
7 Piston rod protective cover 15 Oil return line connection
8 Expansion bolt 16 Installation openings
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Internal view (example)
Fig. 4: Internal view (example)
1 Piston rod 10 Console

2 Relief valve 11 Outboard distance piece
3 Vent 12 Crosshead
4 Gas inlet 13 Connecting rod
5 Suction valve unloader 14 Crankshaft
6 Suction valve 15 Crank housing
7 Discharge valve 16 Cylinder
8 Valve cover 17 Piston
9 Gas outlet 18 Cylinder head
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3.2 Short description

The reciprocating compressor comprises the drive unit and the com-
pressor section and is driven by an electric motor. It is used to com-
press process gases and process gas mixtures.
Drive unit
Fig. 5: Drive unit assembly
The compressor's drive unit converts the crankshaft's rotary move-

ment into a translational, oscillating movement on the crosshead and
the downstream components (piston, piston rod). This facilitates suc-
tioning and compression by changing the volume inside the gas
chambers in the cylinder.
The drive unit includes the crankcase, outboard distance piece,
crankshaft, connection rod, crosshead and sliding bear-
ing Chapter 3.3.1 „Drive unit“ on page 39.
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Compressor section
Fig. 6: Compressor section assembly
The compressor section conveys the gas being compressed from a

low pressure level to a higher pressure level. The medium being con-
veyed is suctioned by the suction valves on the suction side of the
compressor section. The gas is displaced by a piston and as a result it
is compressed and ejected back out through the discharge valves on
the pressure side of the compressor section.
The compressor includes the cylinder, piston, piston rod, suction and
discharge valves and covers for closing the cylinder openings (cylin-
der cover, valve cover) Chapter 3.3.2 „Compressor section“ on
page 49. Depending on the extent of the overall pressure ratio the gas
is either compressed in one or several steps (cylinders). The com-
pression of process gases and process gas mixtures always gener-
ates compression heat. The cylinders are therefore fed with a coolant.
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3.3 Assembly description

3.3.1 Drive unit
Crank housing
Fig. 7: Crankcase
The crankcase (Fig. 7) is a single-piece, torsion-free cast housing.

The design of the crankcase depends on the type of compressor and
the number of cylinders which are to be connected and thus differs
from job to job.
The ribs cast in the crankcase are used to absorb the mass and gas
forces. All the machine elements contained in the crankcase are ac-
cessible through integrated installation openings in the crankcase.
The installation openings are sealed with covers.
The crankcase has replaceable crosshead liners and also serves as
an oil tank for the drive unit lubrication system.
The inboard distance pieces are integral parts of the crankcase.
Crosshead liner
Fig. 8: Crosshead liner
The replaceable crosshead liners (Fig. 8) made of cast iron are in-
stalled in the crankcase. A machined surface at the perimeter is fore-
seen to install a bracket with an EXLINE ® striker sensor unit.
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Crankshaft
Fig. 9: Crankshaft (example)
The crankshaft (Fig. 8) is made from forged steel. The bearing points
of the crankshaft are located in the crank housing. The inclined drill
holes through the crankpins ensure the respective bearing points are
supplied with lubricating oil. The crankshaft is sealed off to the drive
side by an oil thrower ring which is permanently attached to the shaft
and an oil collector cover which is fastened to the crank housing.
A small gland seal at the outer end of the oil collector cover protects
from penetration by dust or a corrosive atmosphere.
Main bearing All main bearings combine to form the bearing channel which supports
the crankshaft. They are a tri-material bearing design. The main bear-
ings comprise a steel casing, a bronze babbitt and a galvanically ap-
plied layer of white metal. The main bearings are either a floating
bearing or fixed bearing design. The fixed bearing is used to secure
the crankshaft in the axial direction.
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Fig. 10: Main bearing (example)
1 Expansion bolt and nut

2 Bearing block cover
3 Main bearing shell
4 Crank housing
5 Bearing block
The main bearing shells (Fig. 10/3) are seated in the cast-in bearing
block (Fig. 10/5) on the crank housing. The removable stainless steel
bearing block cover (Fig. 10/2) makes it possible to install and remove
the bearing shells. The joint of the bearing is positioned so that it is
outside the loaded zone and does not disrupt the build-up of the hy-
drodynamic lubricant film.
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Crankpin bearing
Fig. 11: Crankpin bearing (example)
1 Crankshaft
2 Crankpin bearing shell
3 Connecting rod screw
4 Crankpin
6 Connecting rod
7 Connecting rod nut
The bearing shells of the crankpin bearing (Fig. 11/2+5) are seated in
the lower split connecting rod head (Fig. 11/6) and are secured by
connecting rod screws (Fig. 11/3).
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Connecting rod
Fig. 12: Connecting rod (example)
1 Crankshaft
3 Connecting rod cover
4 Connecting rod screw
6 Connecting rod head
7 Crosshead pin bushing
8 Connecting rod eye
9 Longitudinal bore
10 Connecting rod nut
The connecting rod is made from forged steel. It converts the rotary
movement of the crankshaft (Fig. 12/1) into a straight movement and
transmits it to the crosshead.
The crosshead pin bushing is supplied with oil through the longitudinal
bore (Fig. 12/9) in the shaft of the connecting rod. The supply of oil
from the crankpin bearing (Fig. 12/5+2) is thus ensured. The connect-
ing rod head (Fig. 12/6) and connecting rod cover (Fig. 12/3) enclose
the crankpin bearing (Fig. 12/5+2) on the crankshaft (Fig. 12/1) and
are secured with connecting rod screws (Fig. 12/4). The connecting
rod eye (Fig. 12/8) serves as a mount for the crosshead pin bushing.
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Crosshead
Fig. 13: Crosshead (example)
1 Round nut
2 Crosshead bolt
3 Clamping flange
4 Clamping ring, two-piece
5 Eccentric sleeve (optional)
6 Split taper sleeve
7 Pressure disc
8 Crosshead
9 Crosshead pin
10 O-ring
The crosshead (Fig. 13/8) consists of a steel cast body which is coat-
ed with bearing metal. It is the link between the connecting rod and
the piston rod.
The running surfaces of the crosshead are flattened at the sides to
reduce the pulsation during the stroke in the crank housing. The
crosshead guide in the crank housing is equipped with two external
lubricant connections. Oil pockets, attached lengthways and cross-
ways, continuously supply the running surface of the crosshead with
oil during the complete stroke.
The crosshead's is connected to the connecting rod by the crosshead
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pin bushing, which is pressed into the connecting rod eye, and the
crosshead pin (Fig. 13/9) which is inserted through it. A split taper
sleeve (Fig. 13/6) inserted into the crosshead (Fig. 13/8) on both sides
secures the crosshead pin (Fig. 13/9). Screwed-on pressure discs
(Fig. 13/7) prevent the split taper sleeve (Fig. 13/6) from coming
loose.
Crosshead-piston rod connection The piston rod is fastened to the crosshead (Fig. 13/8) with a clamp
connection. This connection comprises a clamping flange (Fig. 13/3),
a 2-piece clamping ring (Fig. 13/4), the crosshead bolts (Fig. 13/2)
and round nuts (Fig. 13/1). The O-ring (Fig. 13/10) serves only as an
installation aid.
The crosshead bolts (Fig. 13/2) pull the piston rod against the cross-
head. There is a shim seated between the crosshead and the piston
rod. It ensures that the piston clearance is correct at the upper and
bottom dead centers during a stroke once the piston rod has been
reinstalled in the crosshead after being removed.
An eccentric bushing (Fig. 13/5) allows the setting of the rod runout.
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Oil wiper packing
Fig. 14: Oil wiper packing
1 Cover
2 O-ring
3 Internal parts
4 Cage
5 Housing
The oil wiper packing is fitted directly above the crosshead. It ensures
that no drive unit oil enters into the compressor section of the co m-
pressor with the piston rod during the stroke.
Fig. 15: Cage and internal parts
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1 Chamber
2 Sealing ring
3 Cage
4 Wiper ring
The oil wiper packing comprises a sealing ring (Fig. 15/2) and two
wiper rings (Fig. 15/4). All rings are multi-piece constructions and are
equipped with wiper lips which face towards the drive unit. Tubular
springs press the rings onto the piston rod. Drill holes and channels in
the ring chambers allow the wiped off oil to flow back into the drive
unit.
Outboard distance piece
Fig. 16: Outboard distance piece
1 Outboard distance piece

2 Intermediate partition packing
3 Console
According job specification and API-requirements a type D (long/short
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two-compartment) distance piece is installed. The outboard distance

piece (Fig. 16/1) connects crankcase and cylinder whereas the in-
board distance piece is integral part of the crankcase itself.
Intermediate partition packing
Fig. 17: Intermediate partition packing
1 Housing
2 Cover
3 Sealing element
4 Chamber
5 O-ring
6 Labyrinth ring
7 Cover
The flushing gas enters the cylinder-side chamber directly into the
Intermediate partition packing. A labyrinth ring (Fig. 17/6) causes a
defined flow of flushing gas to the cylinder side. The flushing gas exits
from the cylinder-side chamber of the outboard distance piece into the
flare gas line.
The crank-side chamber is sealed off by two sealing elements
(Fig. 17/2) which are pressed against the piston rod by coil springs.
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3.3.2 Compressor section
Cylinder
Fig. 18: Cylinder (example)
1 Suction valve unloaders

2 Suction chamber
3 Gas inlet
4 Piston with piston and rider rings
5 Pressure packing
6 Pressure chamber
7 Gas outlet
8 Cylinder liner
9 Discharge valve unit
10 Valve cover
11 Cylinder cover
12 Working chamber
13 Suction valve unit
The construction of the cylinders is adapted to the operating condi-
tions and the medium to be compressed. They suction the process
gas being compressed through the gas inlet (Fig. 18/5) on the suction
side. The process gas enters into the working chambers of the cylin-
ders via the suction cylinders (Fig. 18/2). The rate of the process gas
entering can be regulated using the suction valve unloaders
(Fig. 18/3) on the suction valves.
Inside the cylinder liners (Fig. 18/10) pistons (Fig. 18/6) compress the
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gas to the required pressure with stroke movements. The overpres-

sure generated in the working chamber (Fig. 18/1) of the cylinder lin-
ers (Fig. 18/10) causes the discharge valves (Fig. 18/11) to open on
the pressure side and direct the compressed process gas into the gas
chambers on the pressure side (Fig. 18/8). The compressed process
gas is supplied to the plant's pipeline system (Fig. 18/9) through the
gas outlet.
The gas outlets (Fig. 18/9) are situated at the lowest point of the cylin-
ders.
An indicator nozzle is installed in the area of the pressure and suction
valves (Fig. 18/2+11) of the cylinders. When the appropriate device is
connected it allows indicator diagrams to be recorded. Every piston
compressor cylinder is equipped with valve covers (Fig. 18/12) and
cylinder covers (Fig. 18/13). They are seated with the cylinders on
their sealing surfaces and seal off metallically. In addition the cylinder
covers are fitted with a round cord seal (O-ring). The opening of the
cylinders on the drive unit side is sealed off by the Pressure packing
(Fig. 18/7).
Cylinder cooling The cylinders are fitted with coolant chambers and channels. The
cooling system is designed so that the generated frictional heat on the
piston rings and the compression heat is dissipated.
The cooling system must be free of pockets of air in order to be able
to dissipate the heat. Cylinders which are not self-venting have the
respective vent holes. The cooling system has to be vented before
each commissioning and after each time the coolant is drained. The
coolant in the cylinder must not heat up higher than a maximum of
10K. All components of the cylinder cooling system are designed for a
maximum coolant pressure of 10 bar(g).
Be aware of the following safety-related aspects in relation to the cyl-
inder cooling system:
 If the cylinder cooling system fails, the cylinder will overheat. This
can in turn lead to increased wear and serious damage on the
cylinder and its installed components.
 The coolant inlet temperature when it enters the cylinder cooling
system must be at least 5 K above the gas inlet temperature on the
cylinder. Otherwise the dew point may drop below the minimum
and cause condensation of gas components which in turn may
cause serious damage to the compressor.
 If the machine is erected outdoors and the compressor is at a
standstill, there is a risk of freezing and thus the destruction of the
cylinder. The coolant must be safeguarded against freezing in
accordance with the expected temperatures.
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The quality of the coolant is a prerequisite for its effectiveness.

We recommend the following water qualities:
 Hardness range: up to max. 178.57 ppm (10 °dH)
 Iron content: up to max. 6.243 * 10-6 lb/ft³ (0.1 mg/l)
 Avoid dissolved minerals, carbon dioxide, chlorine and oxygen.
If these recommendations are not adhered to, there is a risk that fix-
tures will leak and the heat transfer will become worse. There is also a
risk of corrosion.
Piston rod
Fig. 19: Piston rod (example)
1 Piston rod
2 Sealing ring
3 Guide ring
4 SUPERBOLT®
5 Upper piston section
6 Lower piston section
The piston rod (Fig. 19/1) is the connection between the crosshead
and the piston (Fig. 19/5+6).
It is screwed fixedly to the crosshead with a fastening flange. In order
to prevent oil from the drive unit from entering into the piston com-
pressor cylinders, an oil slinger passes through the piston rod in the
outboard distance piece.
Piston The piston (Fig. 19/5+6) converts the stroke with the help of the piston
rod (Fig. 19/1) and compresses the process gas inside the cylinder.
Pistons are either a two-piece hollow piston design or a solid material
design depending on the size, the ring shape and ring material.
The piston is screwed fixedly to the piston rod with a SUPERBOLT®-
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connection (Fig. 19/4).

Hollow pistons have venting bores in order to ensure they vent auto-
matically when the piston compressor is performing the flushing pro-
cess. The bores are situated on the face in the base of the piston or in
the base of the guide ring groove. The piston and piston rod form a
single unit and must only be installed or removed as a complete as-
sembly.
Sealing ring Sealing rings (Fig. 19/2) are used to seal off b etween the piston and
the cylinder liner. They are pressed onto the wall of the cylinder liner
by the gas pressure. The design, material and quantity of the sealing
rings used all depend on the type of gas and the differential pressure
on the piston.
Guide rings Guide rings (Fig. 19/3) do not perform a sealing function. They are
used to guide the piston and the piston rod and are wider than the
sealing rings. The relief grooves on the guide rings prevent the guide
rings from being pressed against the wall of the cylinder liner.
Pressure packing
Fig. 20: Pressure packing (example)
1 Tie rod
2 O-ring
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3 Cooling medium area (optional)

4 Sealing element
5 Temperature probe connection (optional)
6 Leakage sealing element
The pressure packing (Fig. 20) seals off the working chamber of the
cylinder from the outboard distance piece, i.e. the drive unit chamber.
Their chambers are equipped with different sealing elements
(Fig. 20/4) made of polytetrafluoroethylene (PTFE) in accordance with
the specific application. The individual ring chambers are held togeth-
er by tie rods (Fig. 20/1) to form a single unit.
If the differential pressure which is being sealed of demands it, sup-
port rings are fitted for each sealing ring pair. They prevent the PTFE
sealing rings from slipping and becoming stuck.
Valves The valves on the compressor section are automatic plate valves. The
pressure of the gas causes the opening and closing actions. The inte-
grated valve springs only have a stabilising effect for opening and
closing. The pressure screws in the valve covers push the valves
against the sealing strips in the reciprocating compressor cylinder with
pressure vessels.
The valves and the valve covers seal off metallically without any addi-
tional seal. The sealing surfaces are seated to each other. Tension
springs secure the valves and the pressure vessels in the reciprocat-
ing compressor cylinder to prevent them from falling out when being
installed.
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Suction valve unloader

1 Position indicator
2 Housing
3 Fastening screws
4 Tappet
The reciprocating compressor cylinder is equipped with suction valve
unloaders on the suction side for control of the delivery rate of the
process gas being compressed. When the suction valves are held
open, the suctioned process gas is forced back into the suction line.
The graduated control holds the suction valve open for the entire
stroke of the piston so that the entire delivery quantity is forced back.
This process of holding the valve open can be used to deliver 100 %,
50 % or 0 % of the delivery rate.
The continuously variable control (or dynamic pressure control) uses
grippers to hold the suction valve open for part of the stroke of the
piston so that only a part of the delivery quantity is forced back into
the suction line.
Fig. 21: Suction valve unloader
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3.4 Working areas and danger areas
Fig. 22: Working areas and danger areas
1 Danger area 2 Working area
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4 Transportation, packaging and storage
The device is installed and commissioned by the manufacturer's

plant engineer or by persons authorised by the manufacturer only.
However, it is possible that the user's staff will be required to han-
dle the packages during installation and further use. It is imperative
that you adhere to the instructions listed in the following.
4.1 Safety notes for transportation

Suspended loads
WARNING Danger of fatal injury from suspended loads!

- Never step under suspended loads, and do not step within their
pivoting range.
- Only move loads under supervision.
- Only use approved hoists and lifting gear with a sufficient load-
bearing capacity.
- Do not use torn or abraded hoists such as ropes and straps.
- Do not place hoists such as ropes and straps against sharp
edges or corners and do not knot or twist them.
- Set the load down when leaving the workplace.
During lifting operations, loads may swing out and fall down. This
may result in serious injury or death.
Eccentric centre of gravity

WARNING Danger of injury from falling or tipping packages!
- Observe the markings and specifications on the packages relat-
ing to the centre of gravity.
- When transporting with a crane, attach the crane hook so that it
is above the package's centre of gravity.
- Lift the package carefully and observe whether it tips. Change
the attachment position if necessary.
Packages may have an eccentric centre of gravity. Incorrect at-
tachment may cause the package to tip and fall. Falling or tipping
packages may cause serious injury.
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Swivelling transport unit
WARNING Danger of injury from swivelling transport unit!

- During transport, ensure that no persons, objects or obstacles
are within the transport unit's swivel zone.
When transporting with a crane, the transport unit may swivel out
and cause serious injury and substantial damage to property.
Unauthorised transport
NOTICE Damage to property in the case of unauthorised transport by un-

trained personnel!
- Unloading of the transport units at delivery and in-house
transport must only be carried out by trained personnel under
the direction of the manufacturer's employees.
- Any unauthorised transport or fitting/removal of transport aids is
prohibited.
- Do not remove packaging without authorisation.
Transport units may fall or tip over as a result of unauthorised
transport by untrained personnel. This can cause a significant level
of property damage.
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4.2 Symbols on the packaging

The following symbols are attached to the packaging. Always adhere
to the symbols when transporting.
Top
The arrow tips on the sign mark the top of the package. They must
always point upwards; otherwise the content could be damaged.
Protect against moisture

Protect packages against moisture and keep dry.
Attach here
Lifting gear (lifting chain, lifting strap) must only be attached to points
bearing this symbol.
Centre of gravity
Marks the centre of gravity of packages.
Note the location of the centre of gravity when lifting and transporting.
Weight, attached load

Indicates the weight of packages.
Handle the marked package in accordance with its weight.
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Permitted stacking load

Indicates packages which are partially stackable.
Do not exceed the maximum load-bearing capacity specified in the
symbol in order to avoid damaging or destroying the content.
Do not damage air-tight packaging

The packaging is air-tight. Damage to the barrier layer may render the
contents unusable.
Do not pierce. Do not use sharp objects to open.
4.3 Transport inspection

On receipt, immediately inspect the delivery for completeness and
transport damage.
Proceed as follows in the event of externally apparent transport dam-
age:
 Do not accept the delivery, or only accept it subject to reservation.
 Note the extent of the damage on the transport documentation or
the shipper's delivery note.
 Initiate complaint procedures.
Issue a complaint in respect of each defect immediately following

detection. Damage compensation claims can only be asserted with-
in the applicable complaint deadlines.
Explosion protection
WARNING Loss of the explosion protection following transport damage!
- In the case of apparent transport damage to the machine, do
not commission and contact the manufacturer.
Transport damage can result in loss of the explosion protection.
Non-observance of this instruction results in loss of the explosion
protection.
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4.4 Transportation
WARNING Risk of fatal injury due to incorrect transportation!

- Only fasten the individual components of the reciprocating com-
pressor by the transport lugs.
- Never use the fastening lugs to transport the complete recipro-
cating compressor.
The fastening lugs designated in Fig. 23 are provided for transport-
ing the individual components. If the complete compressor is trans-
ported by the fastening lugs, they may break and the reciprocating
compressor may fall. This can cause potentially fatal situations,
serious injuries and cause considerable material damage.
The reciprocating compressor comprises the following components:

 Compressor section
 Outboard distance piece
 Crank housing
Fastening points for components The following fastening points are provided for transporting the indi-
vidual components:
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Fig. 23: Fastening points for components
1 Transport lugs on the compressor section 4 Transport lugs on the compressor section
2 Transport lugs on the outboard distance piece 5 Transport lugs on the crank housing
3 Transport lugs on the outboard distance piece
Fastening points for the complete The following fastening points are provided for transporting the com-
reciprocating compressor plete reciprocating compressor:
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Fig. 24: Fastening points for the complete reciprocating compressor
Fastening Protective equipment:  Protective helmet

 Safety boots
The components can be transported directly by crane under the fol-

lowing conditions:
 The crane and lifting gear have the suitable capacity for the weight
of the packages.
 The operator must be authorised to operate the crane.
1. Fasten the ropes, belts or multi-point harness as per Fig. 23.
2. Make sure that the package hangs straight. Be aware that it may
have an off-centre centre of gravity.
3. Begin transportation.
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4.5 Packaging
Information on packaging
NOTICE Risk of material damage due to missing preservation!
- Do not remove packaging until immediately before installation.
The individual packages are preserved in order to protect compo-
nents from corrosion, If packages are removed prematurely, the
anti-corrosion protection may be lost and the components may be-
come damaged as a result.
The individual packages are packaged and preserved to suit the ex-
pected transport conditions and storage periods on site. The packag-
ing protects the individual components from transport damage, corro-
sion and other damage until they are installed.
 Do not destroy the packaging and do not remove it until
immediately before installation.
NOTICE Risk of material damage due to improper handling of unpackaged

components!
- Have unpackaged components installed immediately at the in-
stallation location.
Components which are not packaged for delivery may be rendered
unusable by corrosion and considerable material damage may be
caused.
How to handle packaging materials
NOTICE Risk of environmental damage due to incorrect disposal!

- Dispose of packaging materials in an environmentally friendly
manner.
- Adhere to the local regulations on disposal. Contract a specialist
disposal company as necessary.
Packaging materials are valuable raw materials and in many cases
can be reused or treated and recycled. Incorrect disposal of pack-
aging material can cause environmental hazards.
Dispose of packaging material in accordance with the valid national

and local regulations.
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4.6 Storage
Storing the packages Store the packages under the following conditions:
 Do not store outdoors.
 Store in a dry place, free of dust.
 Do not expose to any abrasive media.
 Protect from sunlight.
 Avoid mechanical shocks.
 Storage temperature: 59 to 95 °F.
 Relative air humidity: max. 60 %.
 When storing, regularly check the general condition of all parts.
Reapply or replace preservation as necessary Chapter 7 „Long-
term removal from service“, page 71.
In some cases the packages may feature further instructions on

storage which go beyond the requirements listed here. Adhere to
these instructions accordingly.
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5 Installation and initial commissioning

Installation and initial commissioning must only be carried out by
employees of the manufacturer or persons authorised by the manu-
facturer.
WARNING Danger to life from incorrect installation and initial commissioning!

- Installation and initial commissioning must only be carried out by
employees of the manufacturer or persons authorised by the
manufacturer.
- Also consult the manufacturer in the case of subsequent loca-
tion changes.
- Desist from unauthorised installation and location changes.
Errors during installation or initial commissioning may result in po-
tentially fatal situations and may cause significant damage to prop-
erty.
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6 Operation
6.1 Safety
Improper operation
WARNING Danger of injury due to improper operation!
- Carry out all operating steps in accordance with the information
and notices in this manual.
- Pay attention to the following points before starting work:
- Ensure that all covers and safety devices are installed and
work properly.
- Ensure that that no one is in the danger zone.
- Never override or bridge safety features during operation.
Improper operation can cause serious injury and significant materi-
al damage.
Moving parts
WARNING Risk of injury due to moving parts!
- Do not reach into or handle moving parts while operation is in
progress.
- Never open covers in operation.
- Be aware of “over travel” time: Before opening covers make
sure that none of the parts are still moving.
- Wear tight-fitting work clothes with low tear resistance when
working in the danger area of the machine.
Moving parts can cause serious injuries.
Operation
The machine runs fully automatically. It does not need to be oper-
ated whilst it is running. The machine (together with the entire
plant) is monitored by the superior control system.
6.2 Switching on
Personnel:  Specialist staff
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Protective equipment:  Ear protection

 Protective helmet
 Protective clothing
 Safety gloves
 Safety boots
For safe and fault-free operation it is necessary to carry out the follow-
ing tasks in the specified order - regardless of whether the reciprocat-
ing compressor is controlled using a master control system or whether
the individual components are operated manually.
In addition to the tasks listed here, you must also adhere to the op-
erational regulations of the user and the plant engineer.
1. Switch on the cylinder lubrication and lubricate the cylinder until

oil is expelled from all unfastened cylinder screw connections of
the lubrication lines (only if cylinder lubrication is fitted).
2. Switch on the oil pump for drive unit lubrication.
3. Switch on the cooling water supply.
4. Switch on the drive for the reciprocating compressor.
5. Carry out daily maintenance work  on page 79.
6.3 Switching off

Protective equipment:  Ear protection

 Protective clothing
 Safety gloves
 Safety boots
For safe and fault-free operation it is necessary to carry out the follow-
ing tasks in the specified order - regardless of whether the reciprocat-
ing compressor is controlled using a master control system or whether
the individual components are operated manually.
In addition to the tasks listed here, you must also adhere to the op-
erational regulations of the user and the plant engineer.
1. Switch off the drive for the reciprocating compressor and secure it
to prevent it from being switched back on.
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2. Switch off the cylinder lubrication (if fitted).
3. Switch off the oil pump for drive unit lubrication.
4. Switch off the cooling water supply.
6.4 Shutdown in emergency situations

In dangerous situations component movements must be stopped as
quickly as possible and the power supply must be switched off.
Shutdown in emergency situations In an emergency situation proceed as follows:
1. Immediately trigger an emergency stop through the emergency

stop device.
2. If there is no danger to your own health get people out of the

danger zone.
3. Initiate first-aid measures if necessary.
4. Alert the fire department and/or rescue service.
5. Inform the responsible parties at the implementation site.
6. Switch off the machine and safeguard it from being switched on

again.
7. Keep entry ways clear for rescue vehicles.
8. Give directions to rescue vehicles.
After the rescue measures 9. Depending on the seriousness of the emergency situation, inform
the responsible government agencies.
10. Assign specialized personal to resolve the malfun ction.
WARNING! Life-threatening danger if restarted without author i-

zation or due to uncontrolled restart!
- Prior to restart ensure that all safety devices are mounted and
functional, and that there is no danger for personnel.
Uncontrolled or unauthorized switching on of the power supply can
cause severe or fatal injuries.
11. Prior to restarting the machine check and ensure that all safety
devices are installed and functioning.
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6.5 Rotating the reciprocating compressor

Protective equipment:  Protective clothing

 Ear protection
 Safety gloves
 Safety boots
NOTICE! Risk of material damage when spinning the rotating com-

pressor!
- Depressurise the reciprocating compressor before spinning.
- Only rotate the reciprocating compressor as described in the
following.
If the reciprocating compressor is rotated although the require-
ments are not met, it may become damaged.
Preparation 1. Switch off the reciprocating compressor and secure it to prevent it

from being switched back on Chapter 6.3 „Switching off“,
page 68.
Rotating 2. Open the cover on the flywheel protective hood.
3. Insert the turning device in the designated drill hole on the perim-
eter of the flywheel. It is on the upper edge of the opening in the
protective hood.
WARNING! Risk of injuries if you do not proceed properly!

- Make sure that the turning device is inserted to the end of the
drill hole.
If you proceed improperly, you may cause serious injuries or mate-
rial damage.
4. Manually turn the flywheel.
5. Remove the turning device from the drill hole and insert it into the
drill hole which is now at the top edge of the opening.
Turning with pneumatic turning 6. Rotate the reciprocating compressor as stipulated in the operat-
device ing instructions for the pneumatic turning device.
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7 Long-term removal from service

In case of long-term removal from service (i.e. longer than 3 months)
measures for preservation must be taken. These depend on the dura-
tion of the down time, how the machine is erected (in a hall or out-
doors) and the type of compressed medium.
Contact the NEAC After Sales Service department before a sched-

uled long-term removal from service in order to discuss the re-
quired measures. See page 2 for the address.
7.1 Preservation
Preservation Personnel:  Specialist staff
 Qualified electrician
 Gas specialist
Protective  Chemical resistant safety gloves

equipment:  Heat-resistant protective gloves with arm
protection
WARNING! Risk of injuries due to lack of qualifications!

- Only have the tasks carried out by the personnel nominated for
the individual tasks.
- In case of any doubt consult with the NEAC After Sales Service
department.
If the removal from service is performed by personnel with insuffi-
cient qualifications, there is a risk of injuries.
NOTICE! Risk of material damage due to incorrect preservation!

- Only open the covers on the installation openings and/or other
covers if it is necessary.
- After opening covers on the installation openings or other co-
vers, reapply/replace preservation. Then seal the chambers so
that they are air-tight again.
- Replace damaged packaging.
Incorrect preservation or opening or damaging the packaging de-
signed for preservation can cause corrosion damage to the com-
ponents of the reciprocating compressor.
Make the following preparations for preserving the reciprocating com-
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pressor.
1. Switch off the machine  Chapter 6.3 „Switching off“, page 68.
2. Depressurise and inert all pressurised parts of the machine.
3. Have all the electrical components disconnected from the current

and secured to prevent them from being switched back on by a
specialist electrician.
4. Have a gas specialist make sure that there is no residual gas in
the individual assemblies of the reciprocating compressor.
5. Implement preservation measures as instructed by the NEAC

After Sales Service department.
Damaged packaging Personnel:  Specialist staff
If packaging is damaged, the anti-corrosion protection may be com-

promised. Damaged packaging must therefore be replaced urgently.
1. Open and remove the damaged packaging.

2. Check the parts of the reciprocating compressor for corrosion
damage.
3. Replace the drying agent.
4. Re-pack the parts of the reciprocating compressor individually

with polythene film.
5. Remove the air from inside the packaging.
7.2 Recommissioning after a down time

NOTICE Risk of material damage due to corroded components!
- Do not perform recommissioning without authorisation.
- Have the inspection of components and recommissioning car-
ried out by NEAC After Sales Service staff only. See page 2 for
the address.
Because of the very different types of preservation the measures to
be implemented to prepare for recommissioning after a long-term
down time also vary. If the measures for recommissioning are not
performed properly or components are corroded, there is a risk of
component damage or complete failure after recommissioning.
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8 Maintenance
8.1 Safety
Electrical system
DANGER Danger to life from electric power!
- Switch off the power supply before starting work and make
sure that it cannot be switched on again.
Contact with live parts may prove fatal. When switched on, electric
components may be subject to uncontrolled movements and may
cause grave injury.
Securing to prevent restart

WARNING Danger to life from an unauthorised restart!
- Switch off all power supplies before starting work and make
sure they cannot be switched on again.
In the event of an unauthorised restart of the power supply during
maintenance, there is a danger of serious injuries or death for per-
sons in the danger zone.
Pressurised components, gas

outlet
WARNING Risk of fatal injury due to pressurised components!
Before starting work on these components:
- Depressurise. Discharge any residual energy.
- Flush all depressurised components with inert gas.
- Always make sure that process gas, flushing gas or leakage gas
cannot be expelled unintentionally.
- Have any faulty components which are pressurised during op-
eration replaced immediately by the appropriate specialist staff.
The components of the reciprocating compressor carry process gas
under high pressure during operation. Opening the covers in the
area of the cylinder and the outboard distance piece without first
carrying out pressure equalisation can cause serious injuries. Also,
improper use or a fault can cause process gas, flushing gas or
leakage gas to be expelled under high pressure and cause serious
injuries and poisoning or even death.
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Residual gas
WARNING Risk of poisoning from storage of residual gas!
- Do not start work on removed parts of the machine until they
have been ventilated for at least 30 minutes.
- Make sure that there is no other personnel in the danger area.
When performing maintenance work there is a risk that there will
still be residual poisonous process gas, flushing gas or leakage gas
in the individual assemblies and their components. The uncon-
trolled expulsion of these process gases can cause potentially fatal
situations and injuries.
Moving parts
WARNING Danger of injury from moving parts!
- Before carrying out any maintenance work on moving parts,
shut down the machine and take precautions to prevent restart-
ing. Wait until all parts have stopped moving.
- When in the danger zone, wear close-fitting protective work
clothing with low tear strength.
Rotating parts and/or parts moving in linear fashion may cause se-
rious injuries.
Improperly performed maintenance

work
WARNING Risk of injury if maintenance work is carried out improperly!
- Before starting the work make sure there is sufficient space for
installation.
- Keep the installation area clean and tidy. Loose components
and tools lying around or on top of each other are a potential
source of accidents.
- if components need to be lifted or transported in order to per-
form maintenance work, adhere to all the instructions for trans-
portation in these instructions Chapter 4.4 „Transportation“,
page 60:
- Only use lifting gear, industrial trucks and fastening equip-
ment which is sufficiently dimensioned and has sufficient
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load bearing capacity.

- Use the fastening points and transport lugs designated by
the manufacturer.
- Make sure that there is no personnel in the immediate dan-
ger area when plant components move.
- If components have been removed, make sure they are installed
correctly, re-install all fastening elements and adhere to the
specified tightening torque values for screws.
- Adhere to the following before recommissioning:
- Make sure that all maintenance work has been carried out
and completed in accordance with the stipulations in these
instructions.
- Make sure that there are no persons in the danger area.
- Make sure that all covers and safety devices are installed
and fully functional.
If you proceed improperly, you may cause serious injuries and co n-
siderable material damage.
Hydraulic tightening device
WARNING Risk of fatal injury due to pump element wear!

- Have all pump elements replaced with new pump elements
from the manufacturer of the hydraulic tightening device after
500 pressurisations or at the latest after 10 years.
If screw connections are screwed and unscrewed several times
with the hydraulic tightening device, the components of the clamp-
ing device may become worn. If, as a result, its components are not
screwed in place properly, accidents and serious injuries may be
caused.
Hot consumables
WARNING Danger of injury from hot consumables!
tive gloves as a matter of principle when carrying out any work
with consumables.
- Always check whether consumables are hot before working with
them. Allow to cool down if necessary.
Consumables may reach high temperatures during operation. Skin
contact with hot consumables will cause severe skin burns.
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Hot surfaces
WARNING Danger of injury from hot surfaces!
tive gloves as a matter of principle when working in the vicinity
of hot surfaces.
- Before carrying out any work, make sure that the surfaces have
cooled down to the ambient temperature.
Component surfaces may heat up greatly during operation. Skin
contact with hot surfaces will cause severe skin burns.
Cold surfaces
WARNING Risk of injuries from cold surfaces!
- When performing any work in the vicinity of extremely cold sur-
faces you must always wear occupational safety clothing and
protective gloves.
- Before starting any work make sure that all surfaces have
warmed to ambient temperature.
The surfaces of components with coolants may cool down to very
low temperatures during operation. If the skin comes into contact
with cold surfaces, the skin will be severely burned.
Environmental protection Observe the following environmental protection instructions during

maintenance work:
 In respect of all lubrication points supplied manually with lubricant,
remove any escaping, used or surplus grease and dispose of in
accordance with applicable local regulations.
 Catch replaced oils in suitable containers and dispose of in
accordance with applicable local regulations.
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8.2 Maintenance schedule

Maintenance tasks are described in the sections below that are re-
quired for optimal and trouble-free machine operation.
If increased wear is detected during regular inspections, then reduce
the required maintenance intervals according to the actual indications
of wear. Contact the manufacturer (see the service address on page
2), if you have questions concerning maintenance tasks and intervals.
Interval Maintenance work Personnel
Every 24 Check the oil systems for leaks User

operating  Chapter 8.4.1 „Checking the oil systems for leaks“, Specialist staff
hours page 81 Service staff
Check the oil level in the drive unit User

 Chapter 8.4.2 „Checking the oil level in the drive unit“,
page 85
Every 24000 Inspect the crankshaft Service staff

operating
hours or eve- Inspect the drive for the oil pumps Service staff
ry 48 months
Inspect the screw connections Service staff
Inspect the main bearing Service staff
Inspect the crankpin bearing Service staff
Inspect the crosshead pin bushing Service staff
Every 8000 Replace the drive unit oil Specialist staff

operating  Chapter 8.4.3 „Replacing the drive unit oil“, page 86
hours or eve-
ry 24 months Replace the oil wiper packing Specialist staff
 Chapter 8.4.4 „Replacing the oil wiper packing“,
page 87
Replace the Intermediate partition packing Specialist staff

 Chapter 8.4.5 „Replace the Intermediate partition
packing“, page 91
Replace the Pressure packing Specialist staff
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Interval Maintenance work Personnel

 Chapter 8.4.6 „Replace the pressure packing“, page 94
Replace the piston rings, inspect the piston rod and cylin- Specialist staff
der running surfaces
 Chapter 8.4.7 „Replacing the piston rings and guide
rings“, page 98
Replace the valves Specialist staff

 Chapter 8.4.8 „Replace the valves“, page 101
Replace the suction valve unloader Specialist staff

 Chapter 8.4.9 „Replacing the suction valve unloader“,
page 109
8.3 Preparing for maintenance work

Before certain maintenance tasks can be carried out, the reciprocating

compressor has to be brought into a safe status. The respective parts
of these instructions refer directly to this requirement.
1. Bring the reciprocating compressor and oil pump to a stand-

still Chapter 6.3 „Switching off“, page 68.
2. Secure the drive motor to prevent it from being switched back on.
WARNING! Risk of fatal injury from uncontrolled pressure
equalisation!
- Depressurise the reciprocating compressor before carrying out
any work.
- Discharge any residual energies.
- When compressing toxic or explosive gasses, inert the compo-
nents of the reciprocating compressor.
The reciprocating compressor carries process gas under high pres-
sure during operation. If the covers on the installation openings are
opened before pressure equalisation has been performed, serious
injuries may be caused.
3. Depressurise all the components of the reciprocating compres-

sor.
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8.4 Maintenance work

8.4.1 Checking the oil systems for leaks
Checking oil pressure Personnel:  User

 Safety goggles
 Safety gloves
 Safety boots
1. Check all the oil system's pipelines and connections outside the
compressor visually for leaks.
2. Check the oil pressure on the compressor's oil pressure indicator.
If the oil pressure is too low, the oil will need to be checked to make
sure it is functional.
Checking the oil pump Personnel:  Specialist staff

 Safety gloves
 Safety boots
1. Shut down the reciprocating compressor  Chapter 6.3

„Switching off“, page 68 and secure the drive motor to prevent it
from being switched back on.

sor.
3. Check that t he oil pump is functional.
WARNING! Risk of explosion due to incorrect lubrication.

- If the oil pump is faulty, replace it urgently with a new one.
If the oil pump is faulty, there is a risk of explosion due to im-
proper lubrication.
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Checking the oil lines on the exter- Personnel:  Specialist staff

nal oil system
 Safety goggles
 Safety gloves
 Safety boots
In case of leaks on the oil lines of the external oil system, take the
following measures:
1. Place a collection container under the leak.
2. Drain the oil through the oil drain and collect the oil.
3. Dispose of the oil in an environmentally friendly manner.
4. Check all connections and flange connections.

5. If components of the oil system have to be replaced, switch off
the oil pump.
6. Replace faulty components.
7. Tighten all screw connections.
Checking the oil system on the Personnel:  Specialist staff

inside of the reciprocating com-
pressor
 Light respiratory protection
 Safety goggles
 Safety gloves
 Safety boots
CAUTION! Risk of injuries from oil mist!
- When working on the oil system and in case of oil mist, wear
respiratory protection and protective eye wear and make sure
there is a supply of fresh air.
High temperatures or mechanical nebulisation may cause oil mists.
Oil mist can irritate the eyes and airways.
1. Unfasten the nuts which fasten the covers on the installation

openings.
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WARNING! Risk of injuries from falling installation opening co-

vers!
- The covers on the installation openings should be installed and
removed with the help of a second person as far as possible. If
necessary, use suitable tools (e.g. a crane).
- When performing the work, always wear the stipulated personal
safety equipment and clothing.
The covers on the installation openings may be very heavy. If al-
lowed to fall, they may cause serious injuries.
2. Remove the covers on the installation openings from the fas-

tening screws.
3. Switch on the oil pump.
4. Visually inspect all components of the oil system inside the reci p-
rocating compressor to check for leaks.
WARNING! Risk of explosion due to incorrect lubrication!

- Replace any faulty components with new ones.
In case of leaks, there is a risk of explosion due to improper
lubrication.
Replacing the components of the 1. Switch off the oil pump.

oil system
2. Replace any damaged components of the oil system with new
ones.
3. Switch the oil pump back on in order to check the oil system for
leaks.
4. Make sure that there are no more leaks.
5. Switch off the oil pump.

vers!
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6. Re-fit the covers on the installation openings.
7. Switch on the oil pump.
8. Allow the oil pump to run with the reciprocating compressor

switched off for 30 minutes.
 The oil is distributed to all lubrication points.

9. Switch on the reciprocating compressor Chapter 6.2 „Switching
on“, page 67.
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8.4.2 Checking the oil level in the drive unit
Personnel:  User

 Safety goggles
 Safety gloves
 Safety boots
WARNING! Risk of injury if the oil level in the drive unit is too
low!
- Make sure that the oil level is always between the markings for
the minimum and maximum oil level.
If the bearings of the reciprocating compressor heat up because
the oil level is too low, there is a risk of explosion.
NOTICE! Risk of material damage if the oil lev el in the drive unit is
too low!
- Make sure that the reciprocating compressor is not operated
with the oil level too low. If the oil level is too low, shut down the
reciprocating compressor immediately.
- Top up the drive unit oil through the oil filling nozzle in accord-
ance with the steps described in these instructions.
If the oil level in the drive unit is too low, the bearings and other
floating parts of the drive unit inside the drive unit will be supplied
with too little oil. This can cause considerable damage to the com-
ponents.
1. Read the oil level from the oil inspection glass on the crank hous-
ing whilst the reciprocating compressor is running.
Fig. 25: Checking the oil level
If the oil level is not between the marking "H" (Fig. 25/1) and the
marking "L" (Fig. 25/2), top up the oil Chapter 8.4.3 „Replacing
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the drive unit oil“, page 86.
8.4.3 Replacing the drive unit oil

 Safety goggles
 Safety gloves
 Safety boots
NOTICE! Risk of environmental damage due to drive unit oil leaks!
- Always have a sufficient quantity of oil binding agent on hand.
- If drive unit oil leaks, inform the fire services urgently.
Drive unit oil leaks whilst changing the oil will contaminate the envi-
ronment.
1. Prepare for maintenance work Chapter 8.3 „Preparing for

maintenance work“, page 80.
The reciprocating compressor does not need to be depressurised.
Draining drive unit oil
Fig. 26: Drive unit
2. Place a collection container under the oil drain opening

(Fig. 26/3) on the crank housing.
Adhere to the minimum volume of the container Chapter 12.4.3

„Utilities“, page 149.
3. Remove the sealing flange and seal from the oil drain and keep
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them safe.
 The drive unit oil flows into the collection container.
Topping up drive unit oil 4. Fit the seal and sealing flange to the oil drain opening (Fig. 26/3).
5. Check the oil inspection glass (Fig. 26/2) for damage and leaks.
6. Remove the sealing cap from the oil filling nozzle (Fig. 26/1).
WARNING! Risk of explosion due to insufficient lubrication.

- Top up with enough oil so that the oil level is between the
markings for the minimum and maximum oil level.
If not enough oil is topped up, there is a risk of explosion due to
improper lubrication.
7. Top up the drive unit oil so that the oil level at the oil inspection
glass reaches the marking "H" (Fig. 27/1).
8. Re-fit the sealing cap on the oil filling nozzle (Fig. 26/1).
Fig. 27: Oil inspection glass
8.4.4 Replacing the oil wiper packing

 Safety goggles
 Safety gloves
 Safety boots
Special tool:  Protective cone
In order to change the oil wiper packing the piston rod has to be un-
fastened from the crosshead and pulled back.
1. Prepare for maintenance work  Chapter 8.3 „Preparing for

maintenance work “, page 80.
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Removing the oil wiper packing WARNING! Risk of injuries from falling installation opening co-
vers!
2. Remove all covers from the installation openings.
3. Rotate the reciprocating compressor manually or with the help of

a device so that the piston is positioned at the top dead cen-
ter Chapter 6.5 „Rotating the reciprocating compressor“,
page 70.
WARNING! Risk of poisoning in case of improper removal!

- Always proceed with caution when removing.
- Replace any components and sealing surfaces which become
damaged during removal.
If sealing surfaces become damaged during removal, there is a risk
of poisoning due to leakages.
4. Unscrew and remove the nuts from the fastening screws on the
cylinder cover and keep them safe.
5. Unfasten the cylinder cover with the jacking screws.
6. Attach the cylinder cover to the crane using lifting gear which is
engineered for the weight of the cylinder cover.
7. Remove the cylinder cover.
8. Unfasten the crosshead-piston rod connection Chapter 8.4.10

„Disassembling and assembling the crosshead-piston rod
connection“, page 111.
9. Pull out the piston with the piston rod so that the oil wiper packing
is exposed.
10. Unfasten and remove the nuts on the cover fastening and keep
them safe.
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Fig. 28: Removing the oil wiper packing
11. Remove the cover (Fig. 28/1) and O-ring (Fig. 28/2).
12. Remove the internal parts of the oil wiper packing (Fig. 28/3),
including the corresponding cage (Fig. 28/4), from the housing
(Fig. 28/5).
 The internal parts of the oil wiper packing can be replaced.
Replacing the sealing elements NOTICE! Risk of material damage due to incorrect installation!
- Make sure the rings are correctly arranged (Fig. 29).
- When installing, make sure that the wiper blades on the sealing
rings point towards the drive unit.
- Make sure the fastening pin is positioned correctly.
If the oil wiper packing is installed incorrectly, it will not function
properly. There is a risk that the reciprocating compressor will be-
come damaged.
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Fig. 29: Replacing the sealing and wiper rings
13. Insert two new wiper rings (Fig. 29/4+5) into the cage (Fig. 29/3).
14. Insert the sealing ring (Fig. 29/2) into the chamber (Fig. 29/1).
Installing the oil wiper packing
Fig. 30: Oil wiper packing, installing
15. Insert the cage (Fig. 30/4). with the internal parts (Fig. 30/3) into
the housing (Fig. 30/5).
16. Insert the O-ring (Fig. 30/2) into the cover (Fig. 30/1).
17. Fit the cover (Fig. 30/1).
18. Fit and tighten the nuts on the cover fastening.
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Fig. 31: Fitting the protective cone
19. Screw the protective cone (Fig. 31/2) to the bottom end of the
piston rod (Fig. 31/1).
20. Carefully push the piston rod (Fig. 31/1) through the new oil wiper
packing to just before the crosshead.
21. Remove the protective cone (Fig. 31/2).
22. Re-establish the crosshead-piston rod connec-

tion  Chapter 8.4.10 „Disassembling and assembling the
crosshead-piston rod connection“, page 111.
23. Refit the installation cover with seals.
24. Fit the cylinder cover.
25. Fit and tighten the nuts on the cylinder cover

screws  Chapter 12.5 „Bolted joints“, page 151.
8.4.5 Replace the Intermediate partition packing

 Safety goggles
 Safety gloves
 Safety boots
Special tool:  Hydraulic tightening device

 Installation device
 Protective cone
NOTICE! Risk of material damage due to incorrect reworking and
repair of the Intermediate partition packing!
- Reworking and repair must only be performed by the manufac-
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turer.
If the Intermediate partition packing is incorrectly reworked or re-
paired, considerable material damage may be caused to the recip-
rocating compressor and its components.
The NEAC After Sales Service department decides whether the In-
termediate partition packing can be reworked or repaired.
If this is not the case, the Intermediate partition packing will need to be
replaced. To do so the piston rod has to be unfastened from the
crosshead and pulled back.

Removing the Intermediate parti- WARNING! Risk of injuries from falling installation opening co-
tion packing vers!

ter Chapter 6.5 „Rotating the reciprocating compressor“,
page 70.
WARNING! Risk of suffocation from nitrogen leak!

- Switch off the nitrogen supply and make sure there is sufficient
supply of fresh air.
- In case of doubt wear self-contained breathing apparatus.
If nitrogen leaks, there is a risk of suffocation.
4. Disconnect the N2 flushing line from the housing flange.

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9. Unfasten the crosshead-piston rod connection  Chapter 8.4.10

10. Remove the piston with piston rod so that the pi ston rod end is
positioned just below the Pressure packing.
Fig. 32: Removing the Intermediate partition packing
11. Unscrew and remove the nuts from the fastening screws
(Fig. 32/3) and keep them safe.
12. Remove the Intermediate partition packing (Fig. 32/1) from the
housing (Fig. 32/2).
Installing the intermediate partition WARNING! Risk of injury due to incorrect installation!
packing - Re-insert the removed O-ring.
- Make sure that the flushing line is connected correctly.
- It is imperative to adhere to the following steps.
In case of incorrect installation there is a risk that toxic process gas
or nitrogen will enter into the chamber on the drive unit side. This
can cause poisoning.
13. Insert the new Intermediate partition packing (Fig. 32/1).
14. Fit and tighten the nuts on the fastening screws Chapter 12.5
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„Bolted joints“, page 151.
15. Connect the N2 flushing line.
Fig. 33: Fitting the protective cone
17. Carefully push the piston rod (Fig. 33/1) through the new Inter-
mediate partition packing and oil wiper packing to just before the
crosshead.
19. Re-establish the crosshead-piston rod connec-

tion  Chapter 8.4.10 „Disassembling and assembling the
crosshead-piston rod connection“, page 111.
20. Ref t the installation cover with seals.

screws Chapter 12.5 „Bolted joints“, page 151.
8.4.6 Replace the pressure packing

 Safety goggles
 Safety gloves
 Safety boots

 Protective cone
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WARNING! Risk of injuries due to heavy weight!

- Always install and remove the piston rod carefully and beware
of other parts slipping as a result.
- Always wear the required personal safety equipment and cloth-
ing.
Depending on the pressure which is to be sealed, the pressure
packing may be very long or comprise several connected parts.
They can be very heavy and may move under the influence of
gravity. This can cause serious injuries.

repair of the Pressure packing!
- Reworking and repair must only be performed by the NEAC
If the Pressure packing is incorrectly reworked or repaired, consid-
erable material damage may be caused to the reciprocating com-
pressor and its components.
The NEAC After Sales Service department decides whether the Pres-
sure packing can be reworked or repaired.
If this is not the case, the Pressure packing will need to be replaced.
To do so the piston and piston rod will have to be removed.
1. Prepare for maintenance work  Chapter 8.3

„Preparing for maintenance work“, page 80.
Removing the pressure packing WARNING! Risk of injuries from falling installation opening co-
vers!

ter  Chapter 6.5 „Rotating the reciprocating compressor“,
page 70.
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9. Pull out the piston so that the piston rod end is positioned just in
front of the oil wiper packing.
Fig. 34: Protective cone
11. Use lifting gear which is engineered for the weight to attach the
piston with piston rod to a crane Chapter 12.3.2 „Component
weights“, page 145.
12. Pull back the piston with piston rod so that the piston rod end is
positioned just below the Pressure packing.
13. Disconnect all the lines from the fastening flange of the Pressure
packing.
If necessary, also remove the parts of the lines.
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Fig. 35: Removing the Pressure packing
14. Unfasten and remove the nuts (Fig. 35/1) from the fastening
screws (Fig. 35/3) and keep them safe.
15. Remove the Pressure packing (Fig. 35/2) from the cylinder.
Installing the pressure packing WARNING! Risk of injury due to incorrect installation!
- Re-insert the removed O-ring.
- It is imperative to adhere to the following steps.
In case of incorrect installation there is a risk that toxic process gas
or nitrogen will enter into the outboard distance piece. This can
cause poisoning.
16. Insert the new Pressure packing (Fig. 35/2).
17. Fit the nuts (Fig. 35/1) on the fastening screws (Fig. 35/3) and
tighten them gradually and evenly  Chapter 12.5 „Bolted joints“,
page 151.
WARNING! Risk of injury from mixing up the lines!

- Move the Pressure packing back into the original position so
that the prefabricated line pieces match up with the connections
on the fastening flange.
- Check that the lines are laid properly.
If you mix up the lines during installation, gas may be expelled in
an uncontrolled manner. This can cause serious or even fatal inju-
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ries.
18. Re-fit all lines to the fastening flange.
19. Carefully insert the piston and piston rod (Fig. 36/1) into the ma-
chine with the protective cone (Fig. 36/2) screwed on.
21. Establish the crosshead-piston rod connection  Chapter 8.4.10

22. Install the installation covers and seals.

screws Chapter 12.5 „Bolted joints“, page 151.
8.4.7 Replacing the piston rings and guide rings

 Safety goggles
 Safety gloves
 Safety boots

 Protective cone
In order to be able to replace the piston rings and guide rings, the
piston rod and piston have to be removed.
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1. Prepare for maintenance work  Chapter 8.3 „Preparing for

maintenance work “ on page 80.
Removing the piston and piston WARNING! Risk of injuries from falling installation opening co-
rod vers!

ter  Chapter 6.5 „Rotating the reciprocating compressor”,
page 70.


9. Pull out the piston so that the piston rod end is positioned just in
front of the oil wiper packing.
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11. Use lifting gear which is engineered for the weight to attach the
piston with piston rod to a crane Chapter 12.3.2 „Component
weights“, page 145.
12. Remove the piston with piston rod from the reciprocating com-
pressor and place it down on suitable V-blocks.
13. Clean the piston rod.
14. Check the piston rod for damage.
In case of damage contact the NEAC After Sales department.
15. Measure the diameter of the running area.
Determine the minimum permitted diameter Chapter 0 „

Dimensions and wear limits for compressor sections“ on page 153.
16. Check the cylinder running surface for damage.
In case of damage contact the NEAC After Sales department.
17. Measure the diameter of the drill hole on the cylinder.
Determine the maximum permitted diameter Chapter 0 „

Dimensions and wear limits for compressor sections“, page 153.
18. Bend open the grooves on the piston and remove the PTFE pis-
ton rings.
Determine the permitted wear values Chapter 0 „

Dimensions and wear limits for compressor sections“, page 153.
NOTICE! Risk of material damage due to knocked out piston ring
grooves which are not true to the dimensions or incorrect rework-
ing!
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- Inspections, reworking and repair must only be performed by

the NEAC After Sales Service department.
Incorrect piston ring grooves can cause considerable material
damage to the reciprocating compressor and its components.
19. Check and clean the piston ring grooves. If necessary, consult
with the NEAC After Sales Service department.
Replacing the sealing and guide 20. Carefully bend open new PTFE sealing and guide rings, pull them
rings over the piston and push them into the grooves provided.
If the piston rings are too stiff or are too small in diameter and
therefore cannot be bent open, heat them up in warm water.
Installing the piston and piston rod
21. Carefully insert the piston and piston rod (Fig. 38/1) into the ma-
chine with the protective cone (Fig. 38/2) screwed on.
23. Establish the crosshead-piston rod connection  Chapter 8.4.10

24. Install the installation covers and seals.

screws  Chapter 12.5 „Bolted joints“, page 151.
8.4.8 Replace the valves

8.4.8.1 Replacing the suction valves

 Safety goggles
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 Safety gloves
 Safety boots
repair of the valve!
If the components of the valves are incorrectly reworked or re-

Removing the suction valves WARNING! Risk of poisoning in case of improper removal
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2. Unfasten and remove the cap nuts (Fig. 39/3) and seals
3. Unfasten the pressure screws (Fig. 39/1) in the suction valve

cover (Fig. 39/5).
4. Unfasten and remove the nuts (Fig. 39/4) from the valve cover
WARNING! Risk of injury from falling components!

- The components should be installed and removed with the help
of a second person as far as possible. If necessary, use suitable
tools (e.g. a crane).
The valve covers, the valve cages and the valves themselves may
be very heavy depending on their size. If allowed to fall, they may
cause serious injuries.
5. Carefully remove the suction valve cover (Fig. 39/5) from the
valve opening.
6. Check whether the sealing surfaces (valve cover and cylinder)

are free from damage.
Fig. 39: Removing the suction valves

(example illustration)
Have damaged valve cover surfaces ground before re-installation.
7. Remove the retaining ring (Fig. 39/6) from the valve opening.
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8. Pull out the suction valve cage (Fig. 39/7).
9. Remove the suction valve (Fig. 39/8) from the valve seat.
10. Make sure that the valve, valve seat and valve cage are free from
damage.
Have a damaged valve replaced before re-installation.

Have a damaged valve seat ground before re-installation.
Have a damaged valve cage replaced before re-installation.
Installing the suction valves NOTICE! Risk of material damage due to use of damaged compo-
nents!
- Only install functional and undamaged components in the cylin-
der.
- Replace or repair damaged components.
If damaged or faulty components are installed, considerable mate-
rial damage to the reciprocating compressor and its components
may be caused.

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11. Carefully insert the suction valve (Fig. 40/8) into the suction valve
opening/the valve seat in the cylinder.
12. Insert the suction valve cage (Fig. 40/7) into the suction valve
opening in the cylinder.
13. Insert the retaining ring (Fig. 40/6) into the groove.
14. Carefully put on the suction valve cover (Fig. 40/5).
15. Fit the nuts (Fig. 40/4) on the valve cover screws (Fig. 40/9) and
tighten them with a torque wrench. Adhere to the stipulated
torque value when doing so Chapter 12.5 „Bolted joints“,
page 151.
16. Tighten the pressure screws (Fig. 40/1) on the valve cover
(Fig. 40/5) with a torque wrench. Adhere to the stipulated torque
value when doing so  Chapter 12.5 „Bolted joints“, page 151.
17. Fit the seals (Fig. 40/2) and cap nuts (Fig. 40/3).
18. Tighten the cap nuts (Fig. 40/3) with a torque wrench. Adhere to
the stipulated torque value when doing so  Chapter 12.5 „Bolted
joints“, page 151.
19. Check the torque of the nuts (Fig. 40/4) on the valve cover
screws (Fig. 40/9) and tighten them with a torque wrench as
necessary.
Fig. 40: Removing the suction valves

(example illustration)
8.4.8.2 Replacing the discharge valves
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 Safety goggles
 Safety gloves
 Safety boots
Special tool:  Installation device

repair of the valve!
If the components of the valves are incorrectly reworked or re-
Removing the discharge valves 1. Bring the reciprocating compressor and oil pump to a stand-
2. Secure the drive motor to prevent it from being switched back on.
equalisation!
any work.

sor.

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4. Unfasten and remove the cap nuts (Fig. 41/7) and seals
5. Unfasten the pressure screws (Fig. 41/9) in the discharge valve

cover (Fig. 41/5).
6. Unfasten and remove the nuts (Fig. 41/6) from the valve cover

- When installing and removing the discharge valve always use
the installation device.
- The components should installed and removed with the help of
a second person as far as possible. If necessary, use suitable
The valve covers, the valve cages and the valves themselves
may be very heavy depending on their size. If allowed to fall,
they may cause serious injuries.
7. Remove the valve cover (Fig. 41/5) from the valve opening.
8. Check whether the valve sealing surfaces (valve cover and cylin-
der) are free from damage.
Fig. 41: Removing the discharge valves
Have damaged valve cover surfaces ground before re-installation.
9. Remove the retaining ring (Fig. 41/4) from the valve opening.
10. Remove the discharge valve cage (Fig. 41/3) and discharge valve
(Fig. 41/2) from the valve opening.
11. Make sure that the valve, valve seat and valve cage are free from
damage.
Have a damaged valve replaced before re-installation.

Have a damaged valve seat ground before re-installation.
Have a damaged valve cage before re-installation.
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Installing the discharge valves WARNING! Risk of injury from falling components!
- When installing and removing the discharge valve always use
the installation device.
NOTICE! Risk of material damage due to use of damaged compo-

nents!
der.
If damaged or faulty components are installed, considerable mate-
may be caused.
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12. Insert the discharge valve (Fig. 42/2) into the discharge valve
cage (Fig. 42/3).
13. Insert the discharge valve cage (Fig. 42/3) with the discharge
valve (Fig. 42/2) into the valve opening on the cylinder.
14. Insert the retaining ring (Fig. 42/4) into the groove on the valve
opening.
15. Carefully put on the discharge valve cover (Fig. 42/5).
16. Fit the nuts (Fig. 42/6) on the valve cover screws (Fig. 42/1) and
tighten them with a torque wrench. Adhere to the stipulated
torque value when doing so Chapter 12.5 „Bolted joints“,
page 151.
17. Tighten the pressure screws (Fig. 42/9) on the valve cover
(Fig. 42/5) with a torque wrench. Adhere to the stipulated torque
value when doing so  Chapter 12.5 „Bolted joints“, page 151.
18. Fit the seals (Fig. 42/8) and cap nuts (Fig. 42/7).
19. Tighten the cap nuts (Fig. 42/7) with a torque wrench. Adhere to
the stipulated torque value when doing so  Chapter 12.5 „Bolted
20. Check the torque of the nuts (Fig. 42/6) on the valve cover
screws (Fig. 42/1) and tighten them with a torque wrench as
necessary.
Fig. 42: Installing the discharge valves
8.4.9 Replacing the suction valve unloader

 Safety goggles
 Safety gloves
 Safety boots
repair of the suction valve unloader!
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If the suction valve unloader is incorrectly reworked or repaired,
considerable material damage may be caused to the reciprocating
compressor and its components.

Removing the suction valve un-

loader
2. Disconnect all the lines from the suction valve unloader
(Fig. 43/1).
3. Unfasten and remove the fastening screws (Fig. 43/2) and keep
them safe.
4. Remove the suction valve unloader (Fig. 43/1), seals

(Fig. 43/3+5, optional) and spacer (Fig. 43/4, optional) from the
centring device in the suction valve cover (Fig. 43/6).
5. Check that all the parts of the suction valve unloader (Fig. 43/1)
are free from damage.
Fig. 43: Replacing the suction valve

unloader (example illustration)
Have a damaged suction valve unloader replaced before re-

installation.
Replace damaged suction valve covers.
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Installing the suction valve unload- NOTICE! Risk of material damage due to use of damaged compo-
er nents!
der.
If damaged or faulty components are installed, considerable mat e-
may be caused.
6. Insert the seal (Fig. 44/5, optional) and spacer (Fig. 44/4, option-
al) into the centring device in the suction valve cover (Fig. 44/6).
7. Insert the seal (Fig. 44/3, optional) and suction valve unloader
(Fig. 44/1, optional) into the centring device in the spacer
(Fig. 44/4).
8. Fit the fastening screws (Fig. 44/2) and tighten them with a torque
wrench. Adhere to the stipulated torque value when doing
so  Chapter 12.5 „Bolted joints“, page 151.
9. Connect all lines on the suction valve unloader as per flow dia-
gram provided by the plant manufacturer.
Fig. 44: Replacing the suction valve

unloader (example illustration)
8.4.10 Disassembling and assembling the crosshead-piston rod connection
Disassembling the crosshead- Personnel:  Specialist staff
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piston rod connection

 Safety goggles
 Safety gloves
 Safety boots
Adhere to the operating instructions provided by the manufacturer

of the hydraulic tightening device.
Within the scope of work the crosshead-piston rod connection has to

be unfastened and disassembled and then reassembled. When doing
so, always proceed as follows:

vers!
3. Determine the size of the hydraulic tightening device re-

quired Chapter 12.5 „Bolted joints “, page 151.
NOTICE! Risk of material damage from incorrectly unfastening the
crosshead-piston rod connection!
- First unfasten the 4 fastening screws on opposite sides. Then
shift the pump elements and unfasten the remaining fastening
screws.
If the stipulated sequence for disassembly of a crosshead-piston
rod connection with 6 fastening screws is not adhered to, material
damage to the connection elements may be caused.
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Fig. 45: Fitting the support sleeve
4. Place the support sleeve (Fig. 45/2) for the hydraulic tightening
device on the fastening flange (Fig. 45/1) (Fig. 45/arrow).
Fig. 46: Screwing on the pump elements
5. Screw the pump elements (Fig. 46/3) onto the fastening screws
(Fig. 46/1) (Fig. 46/arrow).
6. Connect high-pressure hoses on the hydraulic tightening device
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to the connections on the pump elements (Fig. 46/2).
7. Connect the other end of the high-pressure hoses to the distribu-

tion block.
Fig. 47: Hand lever pump
8. Connect the high-pressure hose on the distribution block

(Fig. 47/1) to the connection (Fig. 47/2) for the hand lever pump
on the hydraulic tightening device.
9. Open the pressure relief valve (Fig. 47/3).
10. Actuate the pump's hand lever (Fig. 48/2) with ten strokes with
the pressure relief valve open (Fig. 48/arrow).
11. Close the pressure relief valve (Fig. 48/1) again.
12. Pressurise the pump elements with the nominal oil pressure.
Refer to the table for the nominal pressure for the crosshead-
piston rod connection Chapter 12.5 „Bolted joints“, page 151.
13. Insert the pin through the opening in the support sleeve and into
the location hole of the round nuts.
14. Unfasten the round nuts half a turn with the pin.
WARNING! Risk of injury from uncontrolled pressure equalisa-

tion!
Before starting work on the hydraulic tightening device:
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- Always make sure that pressure cannot be relieved unintention-

ally.
The hydraulic tightening device carries hydraulic oil under high
pressure. If the pressure relief valve is opened too quickly, serious
injuries may be caused. If handled incorrectly the high pressure
may be expelled in an uncontrolled manner and cause serious inj u-
ries.
15. Carefully and slowly relieve the pressure via the pressure relief
valve.
16. Disconnect the high-pressure hoses from the pump elements.
Fig. 49: Removing the pumps
17. Unscrew the pump elements (Fig. 49/2) from the fastening
screws and remove them together with the support sleeves
(Fig. 49/3).
18. Unscrew the fastening nuts (Fig. 49/1) by hand and keep them
safe.
 The crosshead-piston rod connection is unfastened.
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Fig. 50: Disassembling the crosshead-piston rod connection
19. Carefully pull the piston rod (Fig. 50/5) out of the counter bore on
the crosshead (Fig. 50/1).
20. Push back the fastening flange (Fig. 50/4) so that the two-piece
clamping ring (Fig. 50/2) is exposed.
21. Remove the O-ring (Fig. 50/3) and the two-piece clamping ring
(Fig. 50/2).
22. Check that all the removed components are in technically perfect
conditions.
Replace faulty or damaged components with new ones before re-

installation.
23. Transport the fastening flange (Fig. 50/4) using lifting gear which
us engineered for the weight of the fastening flange.
 The crosshead-piston rod connection has been disassembled.
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Assembling the crosshead-piston Personnel:  Specialist staff

rod connection
 Safety goggles
 Safety gloves
 Safety boots
Adhere to the operating instructions provided by the manufacturer

of the hydraulic tightening device.

vers!

2. Determine the size of the hydraulic tightening device re-
quired Chapter 12.5 „Bolted joints“, page 151.
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Fig. 51: Assembling the crosshead-piston rod connection
3. Guide the fastening flange (Fig. 51/4) over the end of the piston
rod (Fig. 51/7).
4. Fasten the two-piece clamping ring (Fig. 51/2) using the O-ring
(Fig. 51/3) on the piston rod (Fig. 51/7).
5. Remove the protective cone (if fitted) from the piston rod
(Fig. 51/7).
NOTICE! Risk of material damage due to incorrect assembly!
- Make sure that the shim is correctly fastened to the end of the
piston rod.
- Make sure that the fastening screw seals off flush with the shim.
- Do not under any circumstances mix up the shims on multiple-
crank compressors.
- Make sure that the eccentric sleeve is positioned in the location
hole on the crosshead.
Incorrect or faulty assembly of the crosshead-piston rod connection
can cause considerable material damage to the compressor and its
components.
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6. Fit the shim.
7. Position the piston rod (Fig. 51/7) in front of the crosshead

(Fig. 51/1) and carefully insert it into the counter bore on the
crosshead.
8. Push the fastening flange (Fig. 51/4) over the fastening screws
(Fig. 51/5) against the two-piece clamping ring (Fig. 51/2).
9. Screw on the fastening nuts (Fig. 51/6) by hand.
10. Align the fastening flange (Fig. 51/4) parallel to the face of the
crosshead.
11. Tighten the fastening nuts (Fig. 51/6) by hand.
NOTICE! Risk of material damage from incorrectly assembling the

crosshead-piston rod connection.
- First tighten the 4 fastening screws on opposite sides. Then
shift the pump elements and tighten the remaining fastening
screws.
If the stipulated sequence for assembly of a crosshead-piston rod
connection with 6 fastening screws is not adhered to, material
damage to the connection elements may be caused.
Fig. 52: Screwing on the pump elements
12. Screw the pump elements (Fig. 52/3) with support sleeves onto
the fastening screws (Fig. 52/1) (Fig. 52/arrow).
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13. Connect the high-pressure hoses on the hydraulic tightening de-

vice to the connections on the pump elements (Fig. 52/2).
14. Connect the other end of the high-pressure hoses to the distribu-
tion block.
15. Connect the high-pressure hose (Fig. 53/1) on the distribution

block to the connection (Fig. 53/2) for the hand lever pump.
16. Open the pressure relief valve (Fig. 53/3).
17. Actuate the pump's hand lever (Fig. 54/2) with ten strokes with
the pressure relief valve (Fig. 54/1) open (Fig. 54/arrow).
18. Close the pressure relief valve (Fig. 54/1) again.
19. Pressurise the pump elements with the nominal oil pressure.
Refer to the table for the nominal pressure for the crosshead-
piston rod connection Chapter 12.5 „Bolted joints“, page 151.
20. Insert the pin through the opening in the support sleeve and into
the location hole of the fastening nuts.
21. Use the pin to tighten the fastening screws by hand.
WARNING! Risk of injury from uncontrolled pressure equalisa-

tion!
Before starting work on the hydraulic tightening device:
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- Always make sure that pressure cannot be relieved unintention-

ally.
The hydraulic tightening device carries hydraulic oil under high
pressure. If the pressure relief valve is opened too quickly, serious
injuries may be caused. If handled incorrectly the high pressure
may be expelled in an uncontrolled manner and cause serious inj u-
ries.
22. Carefully and slowly relieve the pressure via the pressure relief
valve (Fig. 54/1).
Fig. 55: Removing the pumps
23. Disconnect the high-pressure hoses from the pump elements

(Fig. 55/2).
24. Unscrew the pump elements (Fig. 55/2) from the fastening
screws (Fig. 55/1) (Fig. 55/arrow) and remove them together with
the support sleeves (Fig. 55/3).
8.4.11 Measuring and setting the rod runout

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 Safety goggles
 Safety gloves
 Safety boots
Special tool:  Pin-type face wrench
You can use the eccentric sleeve to set the rod runouts as necessary.
The eccentric sleeve is situated in the mount on the crosshead for the
threaded rod.
Measuring the rod runout
Fig. 56: Rod runout, measuring
1. Fasten the threaded flange (Fig. 56/2) to the crosshead

(Fig. 56/1) with the fastening screws (Fig. 56/3) by hand.
2. Slowly rotate the reciprocating compressor once by hand or using

the device and measure the fluctuations of the straight running
with a measuring gauge (Fig. 56/4) during a stroke of the
reciprocating compressor.
3. Compare the determined values with the nominal val-

ue Chapter 12.3.1 „Reciprocating compressor machine data“,
page 141.
If there is a deviation which is outside of the tolerance range, the

rod runout will need to be et.
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Setting the rod runout
Fig. 57: Rod runout, setting
4. Unfasten the fastening screws (Fig. 57/3) on the threaded flange

5. Unfasten the retaining (Fig. 57/6) on the eccentric sleeve

(Fig. 57/4).
6. Insert the pin-type face wrench (Fig. 57/1) in the eccentric sleeve
(Fig. 57/4).
7. Turn the eccentric sleeve (Fig. 57/4) with the pin-type face
wrench (Fig. 57/1).
Turning the eccentric sleeves by 2° (1° for each eccentric sleeve)

causes a change in length of 0.01 mm (0.0003937 inches).
8. Tighten the retaining screws (Fig. 57/6) on the fastening screws

(Fig. 57/3) by hand.
9. Measure the rod runout again and compare the results with the
nominal value Chapter 12.3.1 „Reciprocating compressor ma-
chine data“, page 141.
10. Keep repeating steps 4. to 6. until the nominal value for rod
runout is achieved.
11. Tighten the fastening screws (Fig. 57/3) with the hydraulic tight-
ening device. Adhere to the stipulated pump pressure in the pro-
cess Chapter 12.5 „Bolted joints“, page 151.
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8.4.12 Grinding the sealing surfaces


 Safety goggles
 Safety gloves
 Safety boots
Special tool:  Grinding tools
Damage to sealing surfaces on the valve covers or the cylinders has

to be ground out.
1. Clean the sealing surface you wish to grind of soiling, grease and
oil.
2. Apply grinding paste to the damaged sealing surfaces.
3. Apply the grinding tool to the sealing surface and grind with an
alternating rotating movement.
The grinding tool is not part of the scope of delivery. It can be pro-
duced from a cast iron sleeve, for instance.
4. Check the contact pattern. To do so die-spot the sealing surface.
5. Keep repeating steps 2. to 4. until there is a contact ring of at

least 1.0 mm (0.03937 inches) in width.
6. Clean the grinding paste from the sealing surfaces.
 The sealing surface is functional again.
8.5 Actions after maintenance has been completed

After completing the maintenance work and before switching on the
machine, carry out the following steps:
1. Check that all previously loosened threaded connections are

tight.
2. Check that all previously removed protective devices and covers

have been replaced properly.
3. Check that all tools, materials and other equipment used have
been removed from the work area.
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4. Clean the work area and remove any substances which may
have escaped, such as liquids, processing material or similar.
5. Ensure that all the machine's safety devices are completely func-
tional.
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9 Faults
The following section describes possible causes of faults and the work
to remedy them.
In case of faults that occur more than once, abbreviate the mainte-
nance intervals according to the actual utilisation.
In case of faults that cannot be remedied using the following instruc-
tions, contact the manufacturer, see contact data on page 2.
9.1 Safety
Electrical system
DANGER Danger to life from electric power!

- Switch off the power supply before starting work and make
sure that it cannot be switched on again.
Contact with live parts may prove fatal. When switched on, electric
components may be subject to uncontrolled movements and may
cause grave injury.
Securing to prevent restart

WARNING Danger to life from an unauthorised restart!
- Switch off all power supplies before starting work and make
sure they cannot be switched on again.
In the event of an unauthorised restart of the power supply while
tracking down and rectifying a fault, there is a danger of serious
injuries or death for persons in the danger zone.
Improperly executed
troubleshooting work
WARNING Danger of injury from improper troubleshooting!

- Ensure sufficient assembly space before starting work.
- Pay attention to orderliness and cleanliness in the assembly
location! Loosely stacked or scattered components and tools
could cause accidents.
- If components have been removed, pay attention to correct as-
sembly, refit all fixing elements and comply with bolt tightening
torques.
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- Before the restart, ensure that

- all troubleshooting work has been carried out and completed
in accordance with the information and instructions in this
manual.
- no persons are in the danger zone.
- all covers and safety devices are installed and functioning
properly.
Improperly executed troubleshooting work may result in serious
injury and significant damage to property.
Moving parts
WARNING Danger of injury from moving parts!

- Before carrying out any troubleshooting work on moving parts,
shut down the machine and take precautions to prevent restart-
ing. Wait until all parts have stopped moving.
- When in the danger zone, wear close-fitting protective work
clothing with low tear strength.
Rotating parts and/or parts moving in linear fashion may caus e se-
rious injuries.
Behaviour in the event of faults The following applies in principle:
1. Immediately initiate an emergency stop in the event of faults po s-

ing an immediate danger to people or property.
2. Ascertain the cause of the fault.
3. If fault rectification requires work in the danger zone, shut down

the machine and secure to prevent restarting.
Immediately notify those responsible at the place of use about the
fault.
4. Depending on the nature of the fault, have it rectified by autho r-

ised specialised personnel or rectify it you rself.
The fault table below provides information about who is authorised

to rectify the fault.
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9.2 Fault table
Fault description Cause Remedy Personnel
Oil pressure too low The oil pump is faulty. Check that the oil pump is Service staff
functional.
 Have faulty oil pump
replaced with a new
one.
The oil system has a Check that the oil system Specialist staff
leak. is working.
 Repair any leaks.
 Replace any faulty
components of the oil
system.
The oil heater is switched  Switch on the oil Specialist staff

off or faulty. heater.
 In case of a fault have
the oil heater replaced
by NEAC After Sales
Service staff.
The oil level is too low. Check the oil level. Specialist staff
 If the oil level is too
low, top up the
oil  Chapter 8.4.2
„Checking the oil level
in the drive unit“,
page 85.
Incorrect oil viscosity. Drain the oil and top up Specialist staff
with oil of the correct
viscosity Chapter 8.4.3
„Replacing the drive unit
oil“, page 86.
The crankpin bearing play Check the crankpin bear- Service staff
is not correct. ing play.
 Have faulty crankpin
bearings replaced by
NEAC After Sales
Service staff.
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The main bearing play is Check the main bearing Service staff
not correct. play.
 Have faulty main
NEAC After Sales
Service staff.
Knocking sounds The valves are not cor- Check that the valve fas- Specialist staff
rectly fastened. tenings are firmly in
place.
 Tighten the fastening
screws on the valve
cover.
 Tighten the pressure
screws on the valve
cover.
Condensation or lubricant Check for condensation Specialist staff

has collected in the cylin- or lubricant build-up in the
ders. cylinder.
 Drain the
condensation or
lubricant build-up.
The piston is not fastened Check the piston fas- Specialist staff
correctly. tening.
 Tighten the fastening
screws on the piston.
The crosshead pin is not Check the crosshead pin Service staff
fastened correctly. fastening.
 Have the fastening
screws on the
crosshead pin
tightened.
The connecting rod is not Check the connecting rod Service staff
fastened correctly. fastening.
 Have the fastening
screws on the
connecting rod
tightened by NEAC
After Sales Service
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staff.
The crankpin bearing play Have the crankpin bear- Service staff
is not correct. ing play checked.
 Have faulty crankpin
NEAC After Sales
Service staff.
The main bearing play is Have the shaft journal Service staff
not correct. bearing play checked.
 Have faulty main
NEAC After Sales
Service staff.
The coupling is faulty. Have the coupling Service staff

checked to determine
whether it is functional.
 In case of a fault have
the coupling replaced
by NEAC After Sales
Service staff.
Vibrations The console fastening is Check the console fas- Specialist staff
loose. tening.
 Tighten loosened
console fastening.
The compressor fas- Check the compressor Specialist staff

tening is loose. fastening.
 Tighten loosened
compressor fastening.
The machine's natural Have the machine's natu- Service staff

frequency is too high. ral frequency measured.
 Adapt the supports of
the reciprocating
compressor to the
natural frequency.
 Equip the
reciprocating
compressor with
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additional supports to
compensate for the
natural frequency.
The natural frequency of Have the natural frequen- Service staff

the floor, building or scaf- cy of the floor, building or
fold is too high. scaffold measured.
 Adapt the supports of
the reciprocating
compressor to the
frequency values.
Equip the
reciprocating
compressor with
additional supports to
compensate for the
frequency values.
The gas temperature is too The valves on the suction Check whether the valves Specialist staff
high. side or pressure side of are functional.
the cylinder are faulty.  Replace faulty
components of the
valves Chapter 8.4.8
„Replace the valves“,
page 101.
The valve seat or the Check whether the valve Specialist staff
valve supports in the seats are functional.
cylinder are damaged.  Regrind damaged
valve
seats Chapter 8.4.1
2 „Grinding the sealing
surfaces“, page 124.
Intermediate pressure shift The valves on the suction Check whether the valves Specialist staff
side or pressure side of on the suction side or
the cylinder are faulty. pressure side of the cyl-
inder are functional.
 Replace faulty
valves Chapter 8.4.8
page 101.
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The valve seats in the Check the valve seats. Specialist staff
cylinder are damaged.  Regrind damaged
valve
page 101.
The piston rings are Check whether the piston Specialist staff
damaged. rings are functional.
 Replace faulty piston
rings Chapter 8.4.7
„Replacing the piston
rings and guide rings“,
page 98.
Delivery rate too low The valves on the suction Check whether the valves Specialist staff
side or pressure side of on the suction side or
the cylinder are faulty. pressure side of the cyl-
inder are functional.
 Replace faulty
valves  Chapter 8.4.8
page 101.
Valve seats in the cylin- Check the valve seat. Specialist staff
der damaged.  Regrind damaged
valve
2 „Grinding the sealing
surfaces“, page 124.
The piston rings are Check whether the piston Specialist staff
damaged. rings are functional.
 Replace faulty piston
rings Chapter 8.4.7
„Replacing the piston
rings and guide rings“,
page 98.
The Pressure packing is Check whether the Pres- Specialist staff

faulty. sure packing is functional.
 Replace the Pressure
packing if it is
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faulty Chapter 8.4.6
„Replace the pressure
packing“, page 94.
The valves are not cor- Check the valve fasten- Specialist staff
rectly fastened. ings.
 Re-tighten the valve
fastenings.
The pressing force of the Check the pressure Specialist staff

valves is too low. screws.
 Re-tighten the
pressure screws.
The suction valve un- Check whether the suc- Specialist staff
loader is not set correctly. tion valve unloaders are
fully functional.
 Reset the suction
valve unloaders.
 Replace faulty suction
valve
unloaders Chapter 8
.4.9 „Replacing the
suction valve
unloader“, page 109.
9.3 Work to remedy faults

9.3.1 Tasks before starting to remedy faults
1. Bring the reciprocating compressor a nd oil pump to a stand-

2. Secure the drive motor to prevent it from being switched back

on

equalisation!
any work.
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sor.
9.3.2 Work on the oil system

 Chemical resistant saf ty gloves
Carry out work on the oil system as per the steps for checking the
oil system Chapter 8.4.1 „Checking the oil systems for leaks“,
page 81.
Selecting lubricating oil Refer to the table of lubricants for the suitable type of lubricating oil.
Topping up lubricating oil

Top up the lubricating oil as per the steps for changing the
oil Chapter 8.4.3 „Replacing the drive unit oil“, page 86.
9.3.3 Work on valves
Tightening the fastening screws on Personnel:  Specialist staff

the valve cover
 Safety gloves
1. Tighten all nuts on the valve fastening screws with a torque

wrench Chapter 12.5 „Bolted joints“, page 151.
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Tightening the pressure screws on Personnel:  Spe ialist staff

the valve cover
 Safety gloves
1. Unfasten and remove all cap nuts and keep them safe.
2. Remove all seals and check them for damage.
Have damaged sea s replaced before re-installation.
3. Tighten all pressure screws in the valve cover with a torque

wrench  Chapter 12.5 „Bolted joints“, page 151.
4. Fit the sea s and cap nuts.
5. Tighten cap nuts with a torque wrench  Chapter 12.5 „Bolted

9.3.4 Draining the condensation or lubricant build-up

 Chemical resistant safety gloves
 Safety goggles
1. Place a condensation and lubricating oil resistant container un-

derneath the condensation drain.
2. Unfasten and remove the condensation drain screw in the cylin-

der and keep it saf e.
 The condensation or lubricant build-up flows out of the cylin-
der.
3. Dispose of the condensation and lubricating oil build-up in an

environmentally friendly manner in accordance with the laws and
regulations valid for the installation location of the compressor.
4. Remove the seal and check for damage.
Have damaged seals replaced before re-installation.
5. Fit the seal and tighten the condensation drain screw.
9.3.5 Tightening the piston fastenings
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 Safety gloves
 Safety boots
The operating instructions for using the SUPERBOLT® tightening

system are included in the appendix of these operating instructions.
Without turning device 1. Manually turn the reciprocating compressor so that the piston for
the respective stage is in the top dead center  Chapter 6.5
„Rotating the reciprocating compressor“, page 70.
With turning device 2. Rotate the compressor using the turning device so that the piston
for the respective stage is in the top dead center.
3. Unfasten the fastening screws on the cylinder cover, remove the
nuts and keep them safe.
4. Attach the cylinder cover to the crane with suitable lifting gear.
5. Unfasten the cylinder cover with the jacking screws and remove
it.
6. Tighten the pressure screws on the SUPERBOLT® tightening

system in accordance with the operating instructions with a
torque socket wrench Chapter 12.5 „Bolted joints“, page 151.
9.4 Start-up following fault rectification

After rectifying the fault, the following steps should be performed to
restart the system:
1. Reset the emergency stop devices.
2. Acknowledge the fault at the controller.
3. Ensure that no persons are in the danger zone.
4. Start up in accordance with the instructions in the "Operation"

chapter.
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10 Disassembly and disposal

Once the machine has reached the end of its useful life, it must be
disassembled and disposed of appropriately.
Disassembly is performed by NEAC After Sales staff only.
WARNING Risk of fatal injury due to incorrect disassembly!

- Disassembly must only be performed by NEAC After Sales staff.
- Consult NEAC After Sales staff even when changing location at
a later date.
- Do not perform disassembly or change location arbitrarily.
Errors made when disassembling can cause potentially fatal situa-
tions or considerable material damage.
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11 Spare parts
11.1 Safety
Incorrect spare parts
WARNING Risk of injury from use of unsuitable spare parts!
- Only use original NEAC After Sales spare parts or spare parts
approved by the NEAC After Sales department.
- Contact the NEAC After Sales department with any questions.
The use of incorrect or faulty spare parts can cause hazards to staff
and damage, malfunctions or complete failure.
WARNING Risk of injury from use of unsuitable spare parts!

- Only use original NEAC After Sales spare parts or spare parts
approved by the NEAC After Sales department.
- Contact the NEAC After Sales department with any questions.
- Only store spare parts in dry, clean places which are free from
oil and grease.
The use of incorrect or faulty spare parts which have not been BAM
tested for ignition capability and have not been approved for opera-
tion with oxygen may cause fires. This can cause serious or even
fatal injuries as well as considerable material damage.
11.2 Spare parts

Spare parts can be purchased from the NEAC After Sales depart-
ment, see page 2 for address. The list of spare parts is included in the
appendix.
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12 Technical data
12.1 Dimensional sheet
Fig. 58: Dimensions of the reciprocating compressor
Data Value Unit
Width x 380 cm
Height y 180 cm
Length z 620 cm
12.2 Requirements for the location for installation

Foundation A foundation is required to erect the plant. It must be supplied by the
user. The user must make sure that the substructure matches the
stipulations in the plant manufacturer's foundation diagram.
The machine's foundation must meet the following requirements:
 It must have a sufficient supporting area with sufficient load
bearing capacity.
 It must have a non-slip surface.
 It must be flat.
Erection conditions When erecting the machine, adhere to the following:

 Make sure that it is stable.
 Escape routes and rescue apparatus must be freely accessible.
 The safety of personnel must be ensured.
 There must be sufficient illumination.
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 All parts of the machine must be easily accessible and there must
be sufficient space for installation, maintenance and measures for
dealing with faults.
Space requirement for erection The user must make sure that the foundation matches the stipulations
in for space requirement:
Fig. 59: Required machine space for operation, maintenance and servicing
Item Value Unit

Space between hall wall and compressor section "a" > 210 cm
Space between hall wall and compressor section "b" > 220 cm
Space between hall wall and installation openings "c" > 200 cm
Space between hall wall and installation openings "d" > 200 cm
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12.3 General information

12.3.1 Reciprocating compressor machine data
Type: ⃞ vertical ☒horizontal ⃞ V-type
Cylinder lubrication: ☒non-lube ⃞ lube
Compressor throws: ⃞1 ⃞2 ⃞3 ☒4
Frame design: ☒atmospheric ⃞ explosion-proof
Compressor speed: 514 1/min Compressor power: 916 kW
Drive system: ☒directly coupled ⃞ gear unit ⃞ belt drive
Type of driver: ☒induction motor ⃞ synchr. motor ⃞ steam turbine
⃞ gas turbine ⃞ engine ⃞ other
Driver speed: 514 1/min Driver power: 1014 kW
Coupling ☒Low speed ⃞ High speed
between compressor and driver or between drive and gear

gear
Manufacturer: STROMAG AG
Model: High-flexible disc coupling
Type: PVP 66611 R-24"
API 671 applies: ☒Yes ⃞ No ☒Yes ⃞ No
Capacity control ⃞ fixed volume pocket ☒suction valve unloader
⃞ bypass ⃞ HydroCOM®
Action: ⃞ direct (air-to-unload) ☒reverse (air-to-load/fail-safe)
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for: ☒part load ☒start-up only ☒both

condition
Number of steps: ⃞1 ⃞3 ⃞5 ☒other: four
⃞ stepless
Distance piece: ⃞ type A ⃞ type B ⃞ type C ☒type D
Covers: ☒solid metal ⃞ screen ⃞ louvered
Cylinder compartment: ☒vented to atmosphere ⃞ purged at __ [kg/cm²]
⃞ pressurised __ [kg/cm²] ⃞ with safety valve
Frame compartment: ⃞ vented to __ ☒purged at 1,7 [kg/cm²]
⃞ pressurised __ [kg/cm²] ⃞ with safety valve
Distance piece MAWP: 2.04 [kg/cm²]
Cylinder
Service / Item No. Llenado de

Amoniaco
Stage 1 2
Cylinders per stage 2 2
Single or double acting (SA or DA) DA DA
Bore [mm] 735 398
Stroke [mm] 225 225
Cylinder liner Yes Yes
Liner nominal thickness [mm] 12.5 12.5
Cylinder design clearance, average [%] 16.3 16.5
Piston rings per cylinder 3 4
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Service / Item No. Llenado de

Amoniaco
Stage 1 2
Guide rings per cylinder 3 3
Number of valves per cylinder (suc- 4/4 4/4

tion/discharge)
Type of valves Ring Ring
Valve lift (suction/discharge) [mm] 2.0 / 1.8 2.0 / 1.6
Rod diameter [mm] 80.0 80.0
Rod runout
– Vertical [mm] 0.11 0.08
– Horizontal [mm] 0.035 0.035
Piston clearance (head end/crank end) [mm] 11,0 / 6,5 / 5,0

8,5
Max. allowable working pressure [kg/cm²] 10.2 16.3
Max. allowable working temperature [°C] 150 150
Hydrostatic test pressure [kg/cm²] 15.3 24.5
Helium test pressure [kg/cm²] 10.2 16.3
Inlet flange
– Size / rating 12"-150# 8"-150#
– Facing FF-SMF FF-SMF
Outlet flange
– Size / rating 12"-150# 8"-150#
– Facing FF-SMF FF-SMF
Cooling water inlet, outlet 1"NPT 1"NPT
Indicator tap connection 1/2"NPT 1/2"NPT
Lubrication connection - -
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12.3.2 Component weights
Component Value Unit

Compressor, total 30000 kg
Frame 9000 kg
Fylwheel 1200 kg
Coupling 230 kg
Cylinder 1st stage 3800 kg
Cylinder 2nd stage 2800 kg
Cylinder cover 1st stage 395 kg
Cylinder cover 2nd stage 135 kg
Piston with piston rod 1st stage 415 kg
Piston with piston rod 2nd stage 230 kg
12.4 Operating conditions

12.4.1 Process gas data
Service or Item no. Llenado de

Amoniaco
Stage 1 2
Normal or alt Normal Normal

H2 O 18.016 0,5 0,5
Ammonia 17.031 99.5 99.5
Total [%] 100 100
Calculated molar weight [kg/kmol] 17.03 17.03
Dew point [°C]
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12.4.2 Operating data
Service or Item no. Llenado de Llenado de

Amoniaco Amoniaco
Stage 1 2 1 2
Normal or alt Normal Normal Normal Normal

Molecular weight [kg/kmol] 17.03 17.03 17.03 17.03
Capacity
% Capacity 100% 100% 50%A 50%A
Valve operation - - CE/HE-S CE-S/HE

CE-S/HE CE/HE-S
Mass flow [kg/h] 5284 6864 2642 3430
Volume flow [m³/h] 6954 9034 3477 4515
Inlet conditions at cylinder flange
Pressure [kg/cm²] 1.02 4.16 1.02 4.16
Temperature [°C] -32,9 -1,1 -32,9 -1,1
Outlet conditions at cylinder flange
Pressure [kg/cm²] 4.32 14.17 4.32 14.17
Temperature [°C] 79.7 98,3 79.7 98.3
Power
Power per stage [kW] 432 444 289 261
Total @ compressor shaft [kW] 916 550
Service or Item no. Llenado de Llenado de

Amoniaco Amoniaco
Stage 1 2 1 2
Normal or alt Normal Normal Normal Normal
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Molecular weight [kg/kmol] 17.03 17.03 17.03 17.03
Capacity
% Capacity 50%B 50%B 75%A 75%A
Pockets / valve operation CE- S/HE CE/HE-S CE/HE-S CE/HE

CE/HE-S CE-S/HE CE/HE CE/HE- S
Mass flow [kg/h] 2642 3430 3982 5125
Volume flow [m³/h] 3477 4515 5241 6745
Pressure [kg/cm²] 1.02 4.16 1.02 4.16
Temperature [°C] -32,9 -1,1 -32,9 -1,1
Pressure [kg/cm²] 4.32 14.17 4.32 14.17
Temperature [°C] 79.7 98,3 79.7 98,3
Power
Power per stage [kW] 289 261 363 351
Total @ compressor shaft [kW] 550 714

Amoniaco
Stage 1 2

Molecular weight [kg/kmol] 17.03 17.03
Capacity
% Capacity 75%B 75%B
Pockets / valve operation CE/HE CE/HE-S

CE/HE-S CE/HE
Mass flow [kg/h] 3982 5125
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Amoniaco
Stage 1 2

Molecular weight [kg/kmol] 17.03 17.03
Volume flow [m³/h] 5241 6745
Pressure [kg/cm²] 1.02 4.16
Temperature [°C] -32,9 -1,1
Pressure [kg/cm²] 4.32 14.17
Temperature [°C] 79.7 98,3
Power
Power per stage [kW] 363 351
Total @ compressor shaft [kW] 714
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12.4.3 Utilities
Frame lube oil system
☒Oil rate 5.75 m³/h ☒Oil pressure 3.06 kg/cm²
☒Oil viscosity ISO VG 150 ☒Oil temperature min 20 °C

max 50
☒Sump volume 0.64 m³
Cooling system
⃞ Cooling water ⃞ Glycol mixture ☒Other: oil
Forced Thermosy- Standpipe Flow Pressure Inlet Outlet

cooling phon [m³/h] [kg/cm²] temp. temp.
[°C] [°C]
☒Cylinder 1st stage ☒ ⃞ ⃞ 3.3 3.1 40 Inlet+°5K
☒Cylinder 2nd stage ☒ ⃞ ⃞ 3.4 3.1 40 Inlet+5°K
☒Pressure packing, total ☒ ⃞ ⃞ 0.5 N/A N/A Inlet+5°K
Purge and buffer gas system
Buffer gas Flow Pressure Purge gas Flow Pressure

[m³/h] [kg/cm²] [m³/h] [kg/cm²]
⃞ Inboard distance piece ⃞ Inboard distance piece
⃞ Outboard distance piece ☒Outboard distance piece 1.2 Flare +

(0,3-0,5)
/ interm. part. packing
☒Pressure packing 2.0 <1.43 ⃞ Pressure packing
Instrument air system
Flow Pressure
[m³/h] [kg/cm²]
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☒Diaphragm cylinder 3.06
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12.5 Bolted joints
The specified tightening torque values for screws apply for lubricat-
ed threads and nut contact areas.
Bolted joint Thread Torque Pump pressure Support Pump

[Nm] [bar] sleeve element
Frame anchor bolt M42 1400 - - -
Frame to distance piece M24 440 - - -
Console to distance piece M20 160 - - -
Console to foundation M24 185 - - -
Crosshead - piston rod M36 - 1150 H3/1-3 Z3/1
Eccentric bushing M8 25 - - -
Flywheel clamping set M14 190
Oil wiper packing M10 30 - - -
Intermediate partition M10 40 - - -

packing
Coupling M18 290 - - -
Stage 1
Cylinder to distance piece M24 440 - - -
Cylinder head M20 150 - - -
Valve cover M24 260 - - -
– Cap nut M20 40 - - -
– Allen set screw M20 70 - - -
Suction valve unloader M12 85 - - -
SUPERBOLT jackbolts HEX/SW9 72 - - -

(piston to piston rod)
Pressure packing M20 300 - - -
Inlet & outlet flange 7/8"UNC 200 - - -
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Bolted joint Thread Torque Pump pressure Support Pump

[Nm] [bar] sleeve element
Stage 2
Cylinder to distance piece M24 440 - - -
Cylinder head M16 65 - - -
Valve cover M20 155 - - -
– Cap nut M20 40 - - -
– Allen set screw M20 70 - - -
Suction valve unloader M12 85 - - -
SUPERBOLTjackbolts HEX/SW9 72 - - -
(piston to piston rod)
Pressure packing M20 300 - - -
Inlet & outlet flange 3/4"UNC 160 - - -
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12.6 Clearances and wear limits for drive unit parts

Main bearing
Nominal clearance [mm] Wear limit [mm]

Radial: 0.164 – 0.252 0.353
Axial: 0.336 – 0.571 0.740
Crankpin bearing

Radial: 0.164 – 0.252 0.353
Axial: 0.336 – 0.571 0.740
Crosshead pin bushing

Radial: 0.078 – 0.144 0.190
Crosshead

Radial: 0.200 – 0.322 0.450
Oil wiper packing
Gap [mm] Wear limit [mm]

3x 1.00 0.00
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12.7 Dimensions and wear limits for compressor sections

Cylinder liner bore
Nominal dimension [mm] Wear limit [mm]

735.00 (1st stage) 736.00
398.00 (2nd stage) 398.50
Piston rod diameter
Nominal dimension [mm] Wear limit [mm]

80.00 79.60
Piston ring
Radial thickness [mm] Wear limit [mm]

17.00 (1st stage) 10.20
17.00 (2nd stage) 10.20
Guide ring
Radial thickness [mm] Wear limit [mm]

12.00 (1st stage) 10.25
8.00 (2nd stage) 6.55
Pressure packing, sealing element
Gap [mm] Wear limit [mm]

3x 3.00 0.00
12.8 Emissions
Data Value Unit
Noise emission 85 dB(A)
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12.9 Nameplate
The nameplate is situated on the crank housing and contains the fol-
lowing information:
Fig. 60: Nameplate
1 Manufacturer
2 Serial-number
3 Year of manufacture
4 Compressor type
5 Capacity [Nm³/h]
6 Suction pressure [kg/cm²]
7 Final pressure [kg/cm²]
8 Speed [1/min]
9 Stroke [mm]
10 Rated power [kW]
11 Compressor mass [kg]
12.10 Cylinder plate

The cylinder plate is situated on the respective compressor section
and contains the following information:
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NEA USA 291007 / Ser. No. 108399
Fig. 61: Cylinder plate
1 Cylinder serial number

2 Operating pressure [kg/cm²]
3 Design pressure and temperature [kg/cm² / °C]
4 Hydrostatic test pressure [kg/cm²]
5 Piston clearance [mm]
6 Cylinder design clearance [Vol.-%]
7 Stroke [mm]
8 Nominal diameter [mm]
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13 Index
disassembling............................................. 100
A
Customer service ............................................... 9
Accident............................................................28 Cylinder .................................................... 44, 130
B Grinding the sealing surfaces ...................... 112

Bearing Cylinder cooling ............................................... 45
Crankpin bearing ...........................................38 Cylinder inner diameter
Main bearing .................................................36 Tolerances ................................................. 140
Bolted joints ....................................................137 Cylinder plate................................................. 141
C D
Cage.................................................................41 Danger areas ................................................... 50

Capacity control ..............................................129 Delivery rate................................................... 135
Checking the oil level ........................................76 Dimensional sheet.......................................... 127
Compressor ......................................................44 Dimensions .................................................... 127
Compressor data ............................................129 Discharge valves
Compressor section..........................................34 replacing....................................................... 94

Connecting rod .................................................38 Draining condensation.................................... 122
Contact person .................................................. 9 Drive unit ....................................................33, 35
Coolant.............................................................45 Checking the oil level .................................... 76
Cooling .............................................................45 Replacing the oil ........................................... 77
Corrosion..........................................................56 Replacing the oil wiper packing ..................... 78

Coupling .........................................................129 E
Crank housing...................................................35
Electric power .................................................. 13
Crankpin bearing ..............................................38
Emergency....................................................... 62
Tolerances ..................................................139 Emergency stop............................................... 62
Crankshaft........................................................36 Environmental protection
Crosshead ........................................................39
Cleaning liquids ............................................ 30
Tolerances ..................................................139
Coolants ....................................................... 30
Crosshead liner.................................................35 Cooling water - frost protection ..................... 30
Crosshead pin bushing Lubricants ..................................................... 30
Tolerances ..................................................139 Packaging material ....................................... 57
Crosshead-piston rod connection
Process chemicals ........................................ 30
assembling ..................................................106
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Erection ..........................................................127 Activities before ............................................ 72

Erection conditions .........................................127 Maintenance schedule ..................................... 71
F N
Fastening points ............................................... 55 Nameplate ......................................................140
Fault table.......................................................116
O
Fire...................................................................28
Oil inspection glass .......................................... 76
First aid ............................................................28
Oil pressure
Foundation .....................................................127
checking....................................................... 72
G Oil pump
Gas analysis ...................................................135 checking....................................................... 73
Gas data.........................................................132 Oil wiper packing ............................................. 41
Grinding..........................................................112 replacing ...................................................... 78
Guide ring......................................................... 47 Tolerances ..................................................139
replacing .......................................................88 Operating data ................................................135
Tolerances ..................................................140 Outboard distance piece ...........................42, 130
Overview ........................................................... 8
H
External view ................................................ 31
Hazards ............................................................13
Internal view ................................................. 32
I
P
Inspection at delivery ........................................54
Packaging.............................................51, 56, 66
Intermediate partition packing ...........................43
Packaging material .......................................... 57
replacing .......................................................82
Piston .............................................................. 46
L Piston ring
Leakage ...........................................................73 replacing ...................................................... 88
Loads ............................................................... 51 Tolerances ..................................................140
Location for installation ...................................127 Piston rod ........................................................ 46
Lubricating oil Measuring and setting the straight running...110
draining.......................................................122 Piston rod diameter
Selecting type .............................................122 Tolerances ..................................................140
topping up ...................................................122 Power .............................................................135
Preservation ............................................... 56, 65
M
Pressure packing ............................................. 47
Main bearing..................................................... 36
replacing ...................................................... 85
Tolerances ..................................................139
Tolerances ..................................................140
Maintenance
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NEA USA 291007 / Ser. No. 108399
Process gas data............................................132 Space requirement......................................... 128

Proper use........................................................12 Staff ................................................................. 19
Protective equipment ........................................22 Start-up............................................................ 60
Storage .......................................................51, 57
Q
Substructure .................................................. 127
Qualification......................................................19
Suction valve unloader..................................... 49
R replacing....................................................... 98
Relief elements.................................................26 Suction valves
Remaining risks ................................................13 replacing....................................................... 91
Remedying faults............................................121 Superbolt® connection..................................... 46
Oil system ...................................................121 Switching off .................................................... 61
Piston fastenings .........................................123 Switching on .................................................... 60
Valves .........................................................122 Symbols
Removal from service .......................................65 in the instructions.......................................... 10
Replacing the oil ...............................................77
T
Rescue measures.............................................62
Tolerances ..............................................139, 140
Rod runout......................................................110
Transportation.............................................51, 54
Rotating............................................................62
Rotating the reciprocating compressor ..............62 U
Use.................................................................. 12
S
User................................................................. 29
Safety
General .........................................................10 V
Safety devices ..................................................26 Valve cover
Seal Grinding the sealing surfaces ...................... 112
Replace the Intermediate partition packing ....82 Tightening the fastening screws .................. 122
Replace the Pressure packing .......................85 Tightening the pressure screws .................. 122
Sealing ring.......................................................46 Valves.............................................................. 48
Sealing surfaces replacing..................................................91, 94
grinding .......................................................112 Suction valve unloader.................................. 49
Service .............................................................. 9 Venting ............................................................ 26
Short description...............................................33
W
Signs ................................................................24
Warranty terms .................................................. 9
Cylinder plate ..............................................141
Weight ........................................................... 132
Nameplate...................................................140
Working areas.................................................. 50
2010-08-31 159
Appendix
14 Appendix
160 2010-08-31
Appendix
Table of content:
A1 Declaration of conformity
A2 General arrangement drawing
A3 Exploded drawing:
A3.1 Motion work
A3.2 Distance piece
A3.3 Motion work internals

st
A3.4 Cylinder 1 stage
nd
A3.5 Cylinder 2 stage
A4 List of spare parts
A5 Oil wiper packing:
A5.1 Manual
A5.2 Drawing and part list
A5.3 Buffer gas unit, manual
A5.4 Buffer gas unit , drawing and part list
A6 Crankcase relief device:
A6.1 Manual
A7 Intermediate partition packing:
A7.1 Manual
A8 Pressure packing:
A8.1 Manual
st
A8.2 Drawing and part list, pressure packing 1 stage
nd
A8.3 Drawing and part list, pressure packing 2 stage
A9 Suction valve:
2010-08-31 161
Appendix
A9.1 Manual
st
A9.2 Drawing and part list, suction valve 1 stage
nd
A9.3 Drawing and part list, suction valve 2 stage
A10 Suction valve unloader:
A11 Discharge valve:
A11.1 Manual
st
A11.2 Drawing and part list, discharge valve 1 stage
nd
A11.3 Drawing and part list, discharge valve 2 stage
A12 Piston to rod assembly drawing:

st
A12.1 Piston to rod assembly 1 stage
nd
A12.2 Piston to rod assembly 2 stage
A12.3 SUPERBOLT® Pre-Tensioning System, manual
A12.4 SUPERBOLT® Pre-Tensioning System, drawing
A13 Flywheel:
A13.1 Drawing
A13.2 Flywheel locking system, manual
A14 Coupling:
A14.1 Manual
A14.2 Drawing
A15 Special tools:
A15.1 Hand Lever Pump
A15.2 Distributer with pressure hose
A15.3 Bolt tensioning device
A16 Lube oil system:
162 2010-08-31
Appendix
A16.1 Table of lubricants, drive unit
A16.2 Mechanical oil pump, manual
A16.3 Mechanical oil pump, drawing and part list
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2010-08-31 165
2010-08-31
Instrucciones de montaje
y funcionamiento
Compresor alternativo
Tipo 1+1TVL190
¡Lea las instrucciones antes de realizar cualquier

operación!
Form: ZT028e/03
Fabricante:
NEUMAN & ESSER GmbH & Co. KG Maschinenfabrik
Werkstraße
Teléfono: +49 (0) 2451/ 481-01
Fax: +49 (0) 2451/ 481-100
Email: info@neuman-esser.de
Internet: www.neuman-esser.de
Servicio Post-Venta:
The OEM Company
NEAC Compressor Service GmbH & Co.
Werkstraße
Teléfono: +49 (0) 2451 / 481-03
Teléfono: +49 (0) 171 / 42 58 595
Fax: +49 (0) 2451 / 481-300
Email: info@neac.de
Email: 24-h-service@neac.de
Internet: www.neac.de
Instrucciones de instalación y funcionamiento (traducción del original)

Neum-13035-DE, en_GB
© NEUMAN & ESSER GmbH & Co. KG 2010
2 2010-08-31
Compresor alternativo Tipo 1+1TVL190
Instrucciones complementarias
Estas instrucciones le permiten usar el compresor alternativo 1+1TVL

190 de forma segura y eficiente. Estas instrucciones son parte de la
máquina y deben mantenerse siempre muy cerca y al alcance del
personal. Los empleados deben leerlas detenidamente y entenderlas
antes de iniciar cualquier acción. Además de estas instrucciones,
deben leerse las instrucciones de los componentes instalados, que
están incluidas en el apéndice.
Seguir toda la información de seguridad y las instrucciones especifi-

cadas en estas instrucciones es un requisito básico para asegurar la
seguridad en el trabajo. También son aplicables los reglamentos loca-
les para la prevención de accidentes y las normas generales de segu-
ridad en la zona de operaciones de la máquina. Las ilustraciones de
estas instrucciones están dirigidas a la comprensión y pueden variar
respecto al diseño actual de la máquina. No se aceptan quejas en
relación a las diferencias.
Restricciones de responsabilidad
Toda la información y las instrucciones incluidas en este manual han
sido compiladas teniendo en cuenta los estándares aplicables y los
reglamentos, la tecnología de última generación, y nuestro propio
saber hacer, junto a años de experiencia. El fabricante no se hace
cargo de ninguna responsabilidad por daños causados por:
 Falta de fidelidad a las estipulaciones de este manual

 Uso inapropiado
 Uso por parte de empleados sin formación
 Conversiones arbitrarias o cambios técnicos no aprobados por el
fabricante
 Uso de piezas de recambio no aprobadas
Deben cumplirse las obligaciones presentes en el contrato de entre-

ga, los términos y condiciones generales, las condiciones de entrega
del fabricante y las provisiones legales en el momento de la ejecución
del contrato.
Copyright
2010-08-31 3
Instrucciones complementarias
Estas instrucciones están protegidas por copyright.

Estas instrucciones no deben ponerse a disposición de terceros, re-
producirse de ningún modo, -ni siquiera parcialmente- y su contenido
no puede ser utilizado y/o comunicado sin permiso por escrito de
NEUMAN & ESSER GmbH & Co. KG Maschinenfabrik ("fabricante”),
excepto para uso interno. Cualquier infracción llevará al infractor a
pago de indemnización. El fabricante se reserva el derecho a imponer
derechos adicionales.
El fabricante tiene el copyright.

© NEUMAN & ESSER GmbH & Co. KG Maschinenfabrik
Werkstraße
52531 Übach-Palenberg, Alemania
4 2010-08-31
NEA USA 291007 / No. Ser. 108399
Tabla de contenidos
1.1 Condiciones de la garantía ..........................................9
1.2 Servicio de atención al cliente ....................................10
2 Seguridad...........................................................................11
2.1 Explicación de los símbolos .......................................11
2.2 Uso adecuado ...........................................................12
2.3 Peligros básicos ........................................................13
2.3.1 Peligros generales en el lugar de trabajo.....13
2.3.2 Peligros a causa de energías eléctricas ......13
2.3.3 Peligros mecánicos.....................................14
2.3.4 Peligros a causa de las energías hidráulicas15
2.3.5 Peligros debidos a los gases presionados...15
2.3.6 Peligros a causa de las altas o bajas
temperaturas ..............................................16
2.3.7 Peligro de incendio .....................................18
2.3.8 Peligros de explosión..................................19
2.3.9 Peligros a causa de sustancias químicas ....19
2.4 Requisitos de los empleados .....................................20
2.4.1 Cualificaciones............................................20
2.4.2 Personas no autorizadas ............................22
2.4.3 Formación ..................................................23
2.5 Ropa y equipamiento de seguridad personal..............23
2.6 Señales .....................................................................25
2.6.1 Señales de acciones obligatorias ................26
2.6.2 Señales de prohibición................................26
2.6.3 Señales de advertencia...............................27
2.7 Mecanismos de seguridad .........................................27
2.8 Asegurar la máquina para prevenir que vuelva a
encenderse................................................................29
2.9 Comportamiento en caso de incendio o accidentes....30
2.10 Responsabilidad del usuario ......................................31
2.11 Protección medioambiental........................................32
3 Construcción y función.....................................................35
3.1 Vista general .............................................................35
3.2 Breve descripción ......................................................36
3.3 Descripción de montaje .............................................39
3.3.1 Unidad de accionamiento............................39
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NEA USA 291007 / No. Ser. 108399
3.3.2 Sección del compresor ...............................50

3.4 Zonas de trabajo y zonas de peligro ..........................56
4 Transporte, embalaje y almacenamiento ......................... 57

4.1 Notas de seguridad para el transporte .......................57
4.2 Símbolos en el embalaje ...........................................59
4.3 Inspección de transporte ...........................................60
4.4 Transporte.................................................................61
4.5 Embalaje ...................................................................64
4.6 Almacenamiento........................................................65
5 Instalación y puesta en marcha inicial .............................66
6 Funcionamiento.................................................................67
6.1 Seguridad..................................................................67
6.2 Encendido .................................................................68
6.3 Apagado....................................................................68
6.4 Paro en situaciones de emergencia ...........................69
6.5 Rotación del compresor alternativo............................70
7 Retirada del servicio a largo plazo ...................................73

7.1 Conservación ............................................................73
7.2 Nueva puesta en marcha tras un tiempo de interrupción
..................................................................................74
8 Mantenimiento ...................................................................77
8.1 Seguridad..................................................................77
8.2 Programa de mantenimiento......................................81
8.3 Preparación para los trabajos de mantenimiento........83
8.4 Trabajo de mantenimiento .........................................83
8.4.1 Revisión de fugas en el sistema de lubricación
...................................................................83
8.4.2 Comprobación del nivel de aceite en la unidad
de accionamiento........................................88
8.4.3 Reponer el aceite de la unidad de
accionamiento ............................................89
8.4.4 Sustitución de la junta del colector de aceite91
8.4.5 Sustitución de la junta de separación
intermedia...................................................95
8.4.6 Sustitución del empaque de presión............98
8.4.7 Sustitución de los segmentos de pistón y
anillos guía ............................................... 103
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NEA USA 291007 / No. Ser. 108399
8.4.8 Sustitución de las válvulas ........................106

8.4.8.1 Sustitución de las válvulas de
succión ......................................106
8.4.8.2 Sustitución de las válvulas de
descarga ....................................111
8.4.9 Sustitución del descargador de la válvula de
succión .....................................................115
8.4.10 Desmontaje y montaje de conexión vástago
del pistón - cruceta....................................118
8.4.11 Medición y ajuste del descentramiento de la
barra.........................................................129
8.4.12 Rectificación de las superficies de
estanqueidad ............................................131
8.5 Acciones tras completar el mantenimiento ...............132
9 Averías .............................................................................133
9.1 Seguridad ................................................................133
9.2 Tabla de averías ......................................................136
9.3 Trabajo para solucionar averías ...............................143
9.3.1 Tareas antes de solucionar las averías .....143
9.3.2 Trabajo sobre el sistema de lubricación ....143
9.3.3 Trabajo en las válvulas .............................144
9.3.4 Drenaje de la condensación o la acumulación
de lubricante .............................................145
9.3.5 Fijación de los ajustes del pistón ...............145
9.4 Puesta en marcha tras la rectificación de la avería...146
10 Desmontaje y eliminación...............................................147
11 Piezas de recambio .........................................................148

11.1 Seguridad ................................................................148
11.2 Piezas de recambio .................................................148
12 Datos técnicos.................................................................149
12.1 Hoja dimensional .....................................................149
12.2 Requisitos para el lugar de instalación .....................149
12.3 Información general .................................................151
12.3.1 Datos de la máquina compresor alternativo151
12.3.2 Peso de los componentes .........................155
12.4 Condiciones de funcionamiento ...............................155
12.4.1 Datos gas de proceso ...............................155
12.4.2 Datos de funcionamiento ..........................156
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NEA USA 291007 / No. Ser. 108399
12.4.3 Utilidades ................................................. 159

12.5 Juntas empernadas ................................................. 161
12.6 Juegos y límites de desgaste para las piezas de la
unidad de accionamiento .........................................164
12.7 Dimensiones y límites de desgaste para las secciones
del compresor.......................................................... 165
12.8 Emisiones................................................................ 165
12.9 Placa de identificación ............................................. 166
12.10 Placa del cilindro ..................................................... 166
13 Índice ............................................................................... 168
14 Apéndice.......................................................................... 171
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NEA USA 291007 / No. Ser. 108399
Vista general
Fig. 1: Vista previa
1 Sección del compresor 3 Volante

2 Unidad de accionamiento
Breve descripción El compresor alternativo comprende la unidad de accionamiento y la

sección del compresor y funciona mediante un motor eléctrico. Se usa
para comprimir gases de proceso y mezclas de gas de proceso. El
compresor alternativo y los montajes individuales están descritos
detalladamente en un apartado posterior Apartado Error! Refer-
ence source not found. “Breve descripción” en la página 34.
Utilice el compresor alternativo siempre de acuerdo con su uso apro-
piado para garantizar un funcionamiento adecuado y libre de averías.
1.1 Condiciones de la garantía

Las condiciones de la garantía están incluidas en los Términos y
Condiciones del fabricante.
2010-08-31 9
NEA USA 291007 / No. Ser. 108399
1.2 Servicio de atención al cliente

Nuestro departamento de atención al cliente está disponible para
proveer información técnica.
Véase página 2 para los datos de contacto.
Además, nuestros empleados siempre están interesados en obtener
nueva información y adquirir experiencia de la aplicación práctica.
Dicha información y experiencia puede ayudar a mejorar nuestros
productos.
10 2010-08-31
NEA USA 291007 / No. Ser. 108399
2 Seguridad
Esta sección aporta una vista previa de todos los aspectos de seguri-
dad importantes para la protección de las personas así como para un
funcionamiento seguro libre de averías. En las secciones sobre las
fases de la vida individual se encuentran instrucciones de seguridad
adicionales relacionadas con el funcionamiento.
2.1 Explicación de los símbolos

Instrucciones de seguridad Las instrucciones de seguridad están marcadas con símbolos en es-
tas instrucciones. Las instrucciones de seguridad siempre aparecen
introducidas por palabras de aviso que expresan la extensión del
peligro.
PELIGRO La combinación de un símbolo y una palabra de aviso indica una

situación de peligro inminente que podría provocar la muerte o da-
ños graves si no se evita.
ADVERTENCIA Esta combinación de símbolo y palabra de aviso indica una posible

situación de peligro que podría causar la muerte o daños graves si
no se evita.
PRECAUCIÓN Esta combinación de símbolo y palabra de aviso indica una posible

situación de peligro que podría provocar daños leves si no se evita.
AVISO Esta combinación de símbolo y palabra de aviso indica una posible

situación de peligro que podría causar daños en la propiedad o el
medio ambiente si no se evita.
Consejos y recomendaciones
Este símbolo destaca consejos útiles y recomendaciones así como
información designada a asegurar un funcionamiento sin complica-
ciones y eficiente.
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Marcas adicionales Para enfatizar las instrucciones de funcionamiento, resultados, listas,

referencias y otros elementos se utilizan las siguientes marcas en
este manual de instrucciones:
Marca Explicación
 Resultados de los pasos del funcionamiento
Referencias a secciones de estas instruc-

ciones y otros documentos relevantes
Listado sin secuencia fija
[Botones] Elementos de funcionamientos (p.ej. boto-

nes, interruptores), elementos de visualiza-
ción (p.ej. lámparas de señalización)
"Pantalla" Elementos de pantalla (p.ej. botones, pro-

gramación de las claves de funcionamiento)
2.2 Uso adecuado

La máquina está diseñada y pensada solo para el uso adecuado aquí
descrito.
El compresor alternativo 107967 tipo 1+1 TZL 190 se usa exclusi-

vamente para comprimir gases de proceso de acuerdo con los
datos del gas de proceso especificados en los datos técnicos
 Apartado Error! Reference source not found. “Datos del gas
de proceso” en la página 141.
Está diseñado para ser instalado en una planta.
El uso adecuado también incluye la adherencia a todas las estipula-

ciones presentes en este manual.
Cualquier tipo de uso que vaya más allá del uso adecuado o cualquier
otro tipo de uso diferente se considera uso inadecuado.
ADVERTENCIA Peligro por uso inadecuado.

- No use el compresor alternativo en áreas potencialmente ex-
plosivas.
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- No comprima gases de proceso no listados en las especifica-

ciones del cliente.
- Nunca instale el compresor alternativo en plantas que no sean
del fabricante.
El uso indebido del compresor alternativo puede ocasionar situa-
ciones de peligro.
No se aceptarán reclamaciones por cualquier tipo de daño provocado

por un uso inadecuado.
2.3 Peligros básicos

La siguiente sección describe los riesgos existentes que pueden apa-
recer incluso cuando se maneja la máquina de forma adecuada.
Con el fin de reducir los riesgos de lesiones personales y daños en la
propiedad y evitar situaciones de peligro, se debe cumplir con las
instrucciones de seguridad listadas aquí y las instrucciones de segu-
ridad en las otras secciones de este manual.
2.3.1 Peligros generales en el lugar de trabajo
Ruido
ADVERTENCIA ¡Peligro de lesiones auditivas!
- Lleve siempre un protector contra el ruido mientras esté traba-
jando
- No esté en la zona de peligro más de lo necesario.
Los niveles de ruido que se producen en el lugar de trabajo pue-
den provocar graves lesiones auditivas.
2.3.2 Peligros a causa de energías eléctricas
Energía eléctrica
PELIGRO ¡Peligro de vida debido a la energía eléctrica!
- Cuente con electricistas cualificados para llevar a cabo todo el
trabajo desarrollado en el equipamiento eléctrico.
- En el caso de existir peligro de aislamiento corte el suministro
de energía inmediatamente y proceda con las reparaciones.
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- Antes de trabajar sobre componentes vivos de sistemas y equi-

pamiento eléctrico desactive dichos componentes y asegúrelos
en este estado mientras realiza los trabajos. En tal caso cíñase
a las siguientes normas de seguridad:
- Desconecte.
- Asegure para evitar reinicios.
- Verifique que se han desactivado los componentes.
- Circuito de tierra y cortocircuito.
- Cubra o proteja los componentes vivos adyacentes.
- Nunca derive ni desactive ningún fusible. Cumpla con la especi-
ficación correcta de amperaje cuando reemplace los fusibles.
- Mantenga la humedad lejos de los componentes vivos. Podría
provocar corto circuitos.
Existe un riesgo inmediato de una descarga eléctrica mortal si se
tocan los componentes vivos. Los daños por el aislamiento de los
componentes individuales pueden ser de funestas consecuencias.
2.3.3 Peligros mecánicos
Piezas móviles
ADVERTENCIA ¡Riesgo de lesiones a causa de las piezas móviles!
- No toque ni manipule las piezas móviles mientras el funciona-
miento esté en activo.
- Nunca abra las cubiertas en funcionamiento.
- Tenga presente el tiempo del margen de recorrido: antes de
abrir las cubiertas asegúrese de que ninguna de las piezas si-
gue en movimiento.
- Vista ropa de trabajo ajustada y apretada con baja resistencia al
desgarro cuando esté trabajando en la zona de peligro de la
máquina.
Las piezas móviles pueden causar lesiones graves.
Vibraciones
ADVERTENCIA ¡Peligro de lesiones a causa de las fuertes vibraciones!
- No desconecte los amortiguadores de vibraciones.
- Manténgase lejos de la zona de vibraciones durante el funcio-
namiento.
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A largo plazo, las fuertes vibraciones pueden derivar en lesiones

importantes y perjuicios crónicos para la salud. La fuente de vibra-
ción se desacopla del medioambiente por un amortiguador de vi-
braciones.
Bordes afilados y ángulos puntia-

gudos
PRECAUCIÓN ¡Peligro de lesiones por los bordes afilados y ángulos puntiagudos!
- Proceda con precaución cuando trabaje en la proximidad de
bordes afilados y ángulos puntiagudos.
- En caso de duda, lleve guantes de seguridad.
Los bordes afilados y los ángulos puntiagudos pueden causar
rasguños y cortes en la piel.
2.3.4 Peligros a causa de las energías hidráulicas
Neblina de aceite
PRECAUCIÓN ¡Peligro de daños a causa de la neblina de aceite!
- Cuando trabaje sobre el sistema de lubricación, y en el caso de
que se produzca una neblina de aceite, use un respirador y ga-
fas protectoras, y asegúrese de que se abastece de aire fresco.
Las altas temperaturas o la pulverización mecánica pueden pro-
ducir una neblina de aceite. Las neblinas de aceite pueden irritar
los ojos y las vías respiratorias.
2.3.5 Peligros debidos a los gases presionados
Componentes presionados
ADVERTENCIA ¡Peligro de muerte por los componentes presionados!
Antes de iniciar el trabajo en estos componentes:
- Los component es presionados deben presentarse sin presión
antes de iniciar el trabajo sobre ellos. Las energías residuales
también deben estar descargadas.
- Asegúrese siempre de que el líquido no puede escaparse acci-
dentalmente.
- Los componentes defectuosos sujetos a presión durante el fun-
cionamiento deben ser reemplazados inmediatamente por per-
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sonal especializado apropiado.

Si se manejan de forma inapropiada, los componentes presiona-
dos pueden moverse de un modo incontrolado provocando daños
más graves. Si se manejan de forma inadecuada o defectuosa,
pueden desprender líquido bajo altas temperaturas, causando le-
siones graves o la muerte.
2.3.6 Peligros a causa de las altas o bajas temperaturas
Superficies calientes
ADVERTENCIA ¡Peligro de daños por las superficies calientes!
- Vista siempre ropa de trabajo protectora resistente al calor y
guantes protectores como regla general cuando trabaje cerca
de superficies calientes.
- Antes de llevar a cabo cualquier tipo de trabajo, asegúrese de
que las superficies se han enfriado a temperatura ambiente.
Las superficies pueden calentarse mucho durante el funciona-
miento. El contacto de las superficies calientes con la piel pro-
voca quemaduras graves en la piel.
Superficies frías
ADVERTENCIA ¡Riesgo de lesiones por las superficies frías!

- Cuando lleve a cabo algún tipo de trabajo cerca de superficies
extremadamente frías debe vestir ropa protectora profesional y
guantes de protección.
- Antes de iniciar cualquier trabajo asegúrese de que todas las
superficies se han calentado a temperatura ambiente.
Las superficies de componentes con refrigerantes pueden enfriar-
se hasta temperaturas muy bajas durante el funcionamiento. Si la
piel entra en contacto con superficies frías, la piel sufrirá graves
quemaduras.
Consumibles calientes
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ADVERTENCIA ¡Peligro de lesiones por consumibles calientes!

guantes protectores como regla general cuando lleve a cabo
cualquier tipo de trabajo con consumibles.
- Compruebe siempre si los consumibles están calientes antes
de trabajar con ellos. Pueden enfriarse si es necesario.
Los consumibles pueden alcanzar altas temperaturas durante el
funcionamiento. El contacto de la piel con consumibles calientes
provoca graves quemaduras en la piel.
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2.3.7 Peligro de incendio
Prevención y protección de incen-

dios
ADVERTENCIA ¡Peligro de lesiones a causa de un equipo de extinción de incen-
dios limitado o inapropiado!
- Cerciórese de que los extintores disponibles son aquellos apro-
piados a la clase de fuego en cuestión.
- Compruebe la funcionalidad de los extintores cada dos años.
- Rellene los extintores tras cada activación.
- Utilice únicamente propulsores de extintor y recambios confor-
me a los modelos reconocidos especificados en el aparato ex-
tintor.
- En el caso de usarlo, observe las instrucciones de funciona-
miento y seguridad del aparato extintor.
- En el caso de usarlo, observe la función de la variación de tem-
peraturas.
En caso de incendio, si el extintor no se encuentra operativo, o no
es adecuado a la clase de fuego específica, podrían producirse
lesiones graves o la muerte, así como daños importantes en la
propiedad.
Sustancias altamente inflamables

ADVERTENCIA ¡Peligro mortal en caso de incendio a causa de las sustancias al-
tamente inflamables!
- No fume alrededor de la zona de peligro. No trate con llamas

abiertas, fuego ni fuentes de ignición de ningún tipo.
- Asegúrese de la disponibilidad de agentes de extinción ade-
cuados (cubierta protectora de llamas, extintor).
- Informe inmediatamente de sustancias sospechosas, líquidos o
gases a la persona al cargo.
- Cese el trabajo inmediatamente en caso de incendio. Abandone
la zona de peligro hasta que se haya dado luz verde y notifíque-
lo a la brigada de incendios.
Las sustancias altamente inflamables, líquidos o gases pueden
derivar en incendios, provocando lesiones graves o mortales.
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2.3.8 Peligros de explosión
Protección ante explosiones

ADVERTENCIA ¡Riesgo de explosiones!
- Observe y siga las medidas válidas de organización local de
protección ante explosiones.
- Es obligatorio seguir los intervalos de mantenimiento estipula-
dos. Es particularmente importante proceder con precaución
con los siguientes componentes:
- Cierres
- Sistema lubrificante
- Es obligatorio adherirse a los pasos de acción estipulados.
- Mantenga todo tipo de fuentes de ignición adicionales tales co-
mo cigarrillos o fuego, lejos del área potencialmente de explo-
sión.
- Asegúrese de que el compresor alternativo se ha conectado a
tierra durante la instalación.
Si hay algún tipo de fuentes de ignición, como chispas, llama abier-
ta, y superficies calientes, en las áreas potencialmente explosivas
existe un riesgo de explosión.
2.3.9 Peligros a causa de sustancias químicas
Gas de proceso tóxico

ADVERTENCIA ¡Riesgo de lesiones mortales por el gas de proceso tóxico!
- Manténgase fiel a la hoja de datos de seguridad del fabricante.
- Cuando trate con gas de proceso vista siempre ropa protectora,
guantes protectores resistentes a las sustancias químicas y ga-
fas protectoras.
- Monte o almacene depósitos únicamente en lugares muy bien
ventilados.
- Acordone la zona ante riesgos por la dirección del viento.
- No inhale gas de proceso. Cuando trabaje con gas de proceso,
asegúrese siempre de que puede proveerse de aire fresco.
Tras una inhalación trate inmediatamente a la persona afectada
con un aparato respiratorio autónomo, estire a la persona hacia
un lado en una posición estable donde haya aire fresco y man-
téngala abrigada. Consulte a un doctor inmediatamente.
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- Quítele de inmediato cualquier prenda de ropa, zapatos o calce-

tines húmedos.
- Evite el contacto de la piel con gas de proceso. En caso de con-
tacto con la piel, lave la parte afectada de la piel con una canti-
dad copiosa de agua y manténgala bajo agua corriente al me-
nos durante 15 minutos.
- En caso de contacto con los ojos, aclárese los ojos con agua
durante 15 minutos. Al hacerlo, tírese un chorro de agua directa
a los ojos. Consulte a un doctor inmediatamente.
- Disipe cualquier gas de proceso expulsado con un chorro de
agua pulverizada y retenga el agua para la extinción contami-
nada. Al hacerlo, lleve siempre un equipo de oxígeno y vista un
conjunto de protección química.
- Tenga el equipo de oxígeno disponible para emergencias.
- Cuando trabaje con gas de proceso, no coma, ni beba, ni fume.
Si el gas de proceso tóxico entra en contacto con la piel puede
provocar graves quemaduras químicas en la piel. En caso de inha-
larlo o tragarlo puede provocar quemaduras químicas en las vías
respiratorias o intoxicación grave.
2.4 Requisitos de los empleados

2.4.1 Cualificaciones
Las diferentes tareas descritas en este manual de instrucciones re-

quieren diferentes cualificaciones del personal al que se le confían las
tareas.
ADVERTENCIA ¡Riesgo en caso de personal no suficientemente cualificado!

- Todos los trabajos deben ser llevados a cabo por personal con
las cualificaciones apropiadas.
- Mantenga al personal que no esté suficientemente cualificado
lejos de las zonas de trabajo.
El personal que no está suficientemente cualificado no es capaz de
calcular los riesgos que supone utilizar la máquina y puede provo-
car un riesgo de lesiones graves o mortales a otros y a él mismo.
El equipo de empleados debe estar formado por personal de quien se

espera que realice todo trabajo de forma fiable. No se permite contar
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con personal cuyas reacciones estén afectadas a consecuencia de

las drogas, el alcohol o alguna medicación.
Estas instrucciones se refieren a las siguientes cualificaciones del

personal para varias tareas:
Especialista en gas
El especialista en gas está cualificado para las tareas que se le asig-
nan y está familiarizado con las regulaciones y los estándares rele-
vantes.
El especialista en gas está capacitado para llevar a cabo trabajos en
plantas de gas e identificar y prevenir posibles peligros independien-
temente, gracias a su especialización con muchos años de experien-
cia.
Electricista cualificado
El electricista cualificado está capacitado para llevar a cabo trabajos
en equipamiento eléctrico e identificar y prevenir posibles peligros
independientemente, gracias a su s aber hacer, años de experiencia y
conocimiento de las regulaciones y estándares aplicables.
Debe contar con una certificación de su especialización que demues-
tre su capacidad para desarrollar tareas en equipamientos eléctricos.
El electricista cualificado debe seguir las regulaciones válidas legales
para la prevención de accidentes.
El electricista cualificado con una cualificación de protección de ex-
plosiones adicional está capacitado para llevar a cabo tareas en
equipamientos eléctricos e identificar y prevenir posibles peligros
independientemente gracias a su saber hacer y sus muchos años de
experiencia. Está familiarizado con las regulaciones y los estándares
relevantes.
Personal de servicio
Determinadas tareas puede llevarlas a cabo únicamente el personal
de servicio del NEAC, el departamento del Servicio Post-Venta. Los
otros miembros del personal no están autorizados para llevar a cabo
el trabajo designado como tal en estas instrucciones. Para tener el
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trabajo a punto cuando de necesita, contacte el NEAC, el departa-

mento del Servicio Post-Venta. Véase dirección en la página 2.
Personal especializado
El personal especializado está capacitado para llevar a cabo las ta-
reas asignadas e identificar y prevenir posibles peligros independien-
temente, debido a su cualificada especialización, su saber hacer,
muchos años de experiencia y conocimiento de las regulaciones y los
estándares válidos.
El personal especializado para áreas potencialmente explosivas está
capacitado para llevar a cabo tareas en plantas o componentes en la
zona potencialmente explosiva gracias a su especialización cualifica-
da, su saber hacer, muchos años de experiencia y conocimiento de
las regulaciones y los estándares válidos. El especialista de las zonas
potencialmente explosivas puede identificar y prevenir posibles peli-
gros independientemente.
Usuario
El usuario utiliza y opera la máquina para el propósito deseado sin un
conocimiento anterior.
Personal especializado con formación (compresores de oxígeno)

El personal especializado con formación está capacitado para realizar
las tareas que se le asignan e identificar y prevenir posibles peligros
gracias a sus muchos años de saber hacer y experiencia y conoci-
miento de las regulaciones vigentes.
Además ha asistido a un curso de formación provisto por el usuario
en el que se le ha instruido sobre peligros especiales asociados a
compresores de oxígeno.
2.4.2 Personas no autorizadas
ADVERTENCIA ¡Riesgo mortal para las personas no autorizadas debido a los peli-
gros en la zona de trabajo y de peligro!
- Las personas no autorizadas deben mantenerse lejos de la zo-
na de trabajo y de peligro.
- En caso de duda, diríjase a las personas en cuestión y pídales
que abandonen la zona de trabajo y de peligro.
- Cese el trabajo mientras haya personas no autorizadas en la
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zona de trabajo y de peligro.

Las personas no autorizadas que no siguen los requisitos aquí
descritos no estarán familiarizadas con los peligros en la zona de
trabajo y de peligro. Por lo tanto, las personas no autorizadas co-
rren el riesgo de sufrir daños graves o mortales.
2.4.3 Formación
El propietario debe formar al personal periódicamente. La ejecución

de una formación está pensada para mejorar la trazabilidad.

 Fecha de la formación
 Nombre de la persona formada
 Contenido de la formación
 Nombre del instructor
 Firmas de la persona formada y del instructor
2.5 Ropa y equipamiento de seguridad personal

El equipamiento de protección personal sirve para proteger a las per-
sonas de peligros y garantizar su seguridad y salud en el trabajo.
El personal debe llevar el equipamiento de protección personal mien-
tras está trabajando en y con la máquina al que se hace específica
referencia en este manual según las diferentes secciones.
Descripción del equipamiento de El equipamiento de protección personal se explica a continuación:

protección personal
Guantes de seguridad resistentes a las sustancias químicas
Los guantes de seguridad resistentes a las sustancias químicas tie-
nen la finalidad de proteger las manos de las agresiones por sustan-
cias químicas.
Protección auditiva
La protección auditiva ofrece protección contra lesiones auditivas
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Guantes de protección con resistencia al calor con protección en

el brazo
Los guantes de protección protegen las manos y los antebrazos del
contacto con en calor en case de tocar componentes a altas tempera-
turas.
Protección de respiración ligera

La protección de respiración ligera se usa para proteger del polvo
nocivo.
Ropa protectora
La ropa protectora son prendas ajustadas y apretadas y con baja
resistencia al desgarre, con mangas ajustadas y sin partes que so-
bresalgan. Estas prendas principalmente evitan ser atrapado al mover
piezas de la máquina. No se permite llevar anillos, cadenas, brazale-
tes ni ningún tipo de joyería.
Casco protector
El casco protector ofrece protección contra caídas de piezas y mate-
riales.
Botas de seguridad
Las botas de seguridad pretenden proteger del peligro de resbalones
o golpes con herramientas pesadas.
Guantes protectores
Los guantes protectores están pensados para proteger las manos de
la fricción, abrasión, cortes o heridas más profundas y el contacto
directo con las superficies calientes.
Gafas protectoras
Las gafas protectoras tienen la finalidad de proteger los ojos de es-
combros en el aire y chorros líquidos.
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2.6 Señales
Las siguientes señales y señales de instrucción están fijadas en la
zona de trabajo. Estos símbolos y señales de instrucción se refieren a
las inmediaciones del lugar donde están fijadas.
ADVERTENCIA ¡Peligro por señalización ilegible!

- Mantenga todas las advertencias, instrucciones de funciona-
miento y seguridad que están fijadas al aparato en condiciones
de legibilidad.
- Remplace señales o adhesivos dañados inmediatamente.
Con el paso del tiempo los adhesivos y las señales pueden ensu-
ciarse o quedar ilegibles, de manera que no se pueden reconocer
los peligros y no se pueden seguir las instrucciones de funciona-
miento necesarias. En consecuencia, aparece el peligro de que se
produzcan daños.
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2.6.1 Señales de acciones obligatorias
Adhesión a las instrucciones

No utilice la máquina designada hasta que no haya leído las instruc-
ciones.
2.6.2 Señales de prohibición
Prohibido comer y beber

En la zona de trabajo se emplean sustancias peligrosas que son per-
judiciales para la salud. No consuma ni guarde bebidas, comida ni
estimulantes.
Prohibido encender fuego y fumar
No pueden introducirse ni generarse los siguientes tipos de fuentes

de ignición:
 Llamas y gases calientes (p.ej. velas, cerillas, gotas de
soldaduras, chispas, carbón vegetal o tabaco ardiente)
 Chispas generadas mecánicamente (p.ej. chispas de piedra, y
metal, generadas por rectificación, cortes abrasivos o golpes de
martillo)
 Chispas generadas eléctrica o electroestáticamente (p.ej. por el
problema de una avería en caso de altos voltajes, fricción e n
piezas de plástico)
No acercarse
Peligros de roturas, cortes, agarre, devanado, o captura. Los puntos
de peligro podrían no ser visibles.
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Prohibido soldar
Está prohibido soldar en las zonas de trabajo señalizadas ya que el
proceso térmico podría derivar en un peligro de incendio aparente u
oculto.
Prohibido el acceso no autorizado

Solo pueden acceder a la zona de peligro las personas autorizadas
por el propietario.
2.6.3 Señales de advertencia
Piezas móviles de la máquina

Los trabajos de mantenimiento en las máquinas abiertas solo pueden
llevarlos a cabo técnicos formados especialmente. Existe un peligro
de lesiones mientras la máquina está en movimiento.
Superficie caliente
Las superficies calientes tales como las piezas, contenedores o mate-
riales calientes de la máquina, así como los líquidos calientes no
siempre se pueden detectar. No los toque nunca sin guantes de pro-
tección.
2.7 Mecanismos de seguridad
ADVERTENCIA ¡Peligro de muerte a causa de mecanismos de seguridad en mal

estado!
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- Compruebe que todos los mecanismos de seguridad funcionan

adecuadamente y están instalados correctamente antes de ini-
ciar el trabajo.
- Nunca desactive o derive mecanismos de seguridad.
- Asegúrese de que todos los mecanismos de seguridad son ac-
cesibles.
Si los mecanismos de seguridad no funcionan o están desactiva-
dos existe un peligro de lesiones graves o mortales.
Vista general Las siguientes cifras muestran donde se encuentran los mecanismos
de seguridad:
Fig. 2: Dispositivos de seguridad
1 Racor de conexión de purga para distanciador 3 Racor de conexión de purga para distanciador
interior exterior
2 Válvula de escape
Elementos de ventilación Las zonas cerradas del alojamiento están provistas de elementos de
ventilación que previenen de que la presión excesiva, la deflagración
o las pulsaciones disruptivas dentro del alojamiento provoquen daños
a piezas de la máquina durante el funcionamiento.
Esto incluye:
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 Respiraderos (Fig. 21+3) que previenen las pulsaciones

disruptivas provocadas por los movimientos de la cruceta.
 Las válvulas de descarga (Fig. 2/2) se usan como dispositivos
limitadores de presión en las zonas presurizadas.
Se requiere integrar el concepto La máquina está destinada para su uso dentro de un sistema. No
cuenta con un controlador propio, ni una función de PARO DE
de paro de emergencia
EMERGENCIA autónoma.
Antes de poner en marcha la máquina, instale los dispositivos de paro
de emergencia para la máquina e intégrelos dentro de la cadena de
seguridad del controlador del sistema.
Conecte los dispositivos de paro de emergencia de manera que no se
produzca ningún tipo de daño a personas ni propiedades si el abaste-
cimiento energético se interrumpe o reactiva.
Los dispositivos de paro de emergencia deben estar siempre fácil-
mente accesibles.
2.8 Asegurar la máquina para prevenir que vuelva a encenderse

ADVERTENCIA ¡Riesgos de lesiones mortales si la máquina vuelve a encenderse
sin autorización o de modo incontrolado!
- Antes de volver a encender la máquina, asegúrese de que to-
dos los dispositivos de seguridad están instalados y funcionan
perfectamente y no existen riesgos para los empleados.
- Siga fielmente siempre la secuencia descrita a continuación
para asegurarse de que no vuelva a encenderse la máquina.
Si se enciende la máquina sin autorización o de modo incontrolado
pueden producirse lesiones graves o incluso mortales.
Asegurar la máquina para prevenir 1. Apague el suministro de energía.

que vuelva a encenderse
2. Informe a los responsables de los trabajos en la zona de peligro.
3. Adjunte una señal en la máquina para indicar que se está llevan-

do a cabo un trabajo en la zona de peligro y que est á prohibido
encenderla. La señal debe contener la siguiente información:
 Apagado el:
 Apagado a las:
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 Apagado por:
 Nota: ¡No encender!
 Nota: No encender hasta haber comprobado y haberse
asegurado de que no existe ningún peligro para el personal.
4. Una vez se haya completado el trabajo, asegúrese de que no
existen riesgos para los empleados.
5. Asegúrese de que todos los dispositivos de protección y seguri-

dad están instalados y funcionan en su totalidad.
¡ADVERTENCIA! ¡Riesgo de lesiones mortales si la máqui-

na vuelve a encenderse sin autorización!
- Antes de volver a conectar el suministro de energía, asegúrese
de que no existe ningún peligro para los empleados.
Si el suministro de energía se conecta sin autorización o de modo
incontrolado, el personal que se halle en la zona de peligro podría
sufrir consecuencias mortales.
6. Quite la señal.
2.9 Comportamiento en caso de incendio o accidentes

Medidas preventivas  ¡Esté preparado en todo momento para incen dios o accidentes!
 Tenga el equipamiento de primeros auxilios (kit de primeros
auxilios, mantas, etc.) y los dispositivos para la extinción del fuego
operativos y siempre a punto.
 Haga que el personal esté familiarizado con el equipamiento de
accidentes así como el de rescate y primeros auxilios.
 Mantenga las vías de acceso libres para los vehículos de rescate.
Pasos en caso de incendio o  Solicite inmediatamente un paro de emergencia hacienda uso de

los dispositivos para el PARO DE EMERGENCIA.
accidentes
 Siempre que no ponga su vida en peligro rescate al personal que
se encuentre en la zona de peligro.
 Si es necesario, practique primeros auxilios.
 Avise a los bomberos y/o a los servicios médicos de emergencia.
 En caso de incendio: siempre sin poner su propia vida en peligro,
intente acabar con el fuego utilizando el equipamiento para la
extinción del fuego hasta que lleguen los servicios de bomberos.
 Notifique a la persona en cargo del lugar de instalación de la
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máquina.
 Mantenga las zonas de acceso libres para los vehículos de
rescate.
 Dirija a los vehículos de rescate hacia el lugar.
2.10 Responsabilidad del usuario

Propietario El término 'propietario' se refiere a la persona que opera la máquina
con fines comerciales, o quien entrega la máquina a un tercero para
su uso/ aplicación, y quien sostiene la responsabilidad legal del pro-
ducto para proteger al usuario, el personal o las terceras partes du-
rante el funcionamiento.
Nominación de una parte El usuario tiene la obligación de nominar a una parte responsable
para garantizar un funcionamiento seguro de la máquina y la coordi-
responsable
nación de todo el trabajo de ésta.
Obligaciones del usuario La máquina es de uso comercial. El usuario de la máquina, por lo

tanto, está sujeto a las obligaciones legales de seguridad y sanidad
en el trabajo.
Además de las notas de seguridad de estas instrucciones, se debe
cumplir también con las regulaciones de seguridad, de prevención de
accidentes y de protección del medio ambiente vigentes para la zona
de acción de la máquina.
En concreto se aplica lo siguiente:

 El usuario debe mantenerse informado de las regulaciones de
seguridad y sanidad en el trabajo y en una valoración de riesgos
debe identificar los peligros que pueden producirse como resultado
de las condiciones laborales especiales en el lugar de uso de la
máquina. Estas deben ser aplicadas en las instrucciones de
manejo de la máquina.
 Durante todo el periodo de uso de la máquina el usuario debe
comprobar si las instrucciones de manejo compiladas concuerdan
con las regulaciones actuales y actualizar las instrucciones de
manejo si fuera necesario.
 El usuario debe organizar y definir claramente las
responsabilidades de instalación, funcionamiento, mantenimiento y
resolución de fallos y limpieza.
 El usuario debe asegurarse de que todos los empleados que están
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en contacto con la máquina han leído y entendido las

instrucciones. Además debe contar con un equipo preparado e
informarlos de los peligros regularmente.
 El usuario debe contar con un equipo con la ropa y el
equipamiento de seguridad personal requeridos y comunicarles las
instrucciones vinculantes que les obligan a llevar ropa y
equipamiento de seguridad personal.
El usuario también es responsable de garantizar que la máquina esté
en perfectas condiciones técnicas en todo momento. Se aplica lo
siguiente:
 El usuario debe, por lo tanto, garantizar que se cumplen los
intervalos de mantenimiento descritos en este manual.
 El usuario debe controlar todos los dispositivos de seguridad
regularmente para asegurarse de que están completos y funcionan
correctamente.
2.11 Protección medioambiental

AVISO ¡Peligro medioambiental por el manejo indebido de materiales que
pueden dañar el medioambiente!
- Preste atención a las anotaciones a continuación sobre el ma-
nejo de materiales que pueden dañar el medioambiente y su
eliminación.
- Si accidentalmente se liberan materiales que pueden dañar el
medioambiente, tome las medidas adecuadas. En caso de du-
da, informe a la autoridad local responsable sobre las repercu-
siones y pregunte cuáles son las medidas que deberían llevarse
a cabo.
En caso de un incorrecto manejo de los materiales que pueden
dañar el medioambiente, especialmente en cuanto a una elimina-
ción inapropiada, puede haber consecuencias significativas en el
medioambiente.
Los materiales utilizados que pueden dañar el medioambiente

son los siguientes:
Refrigerantes Cuando se liberan, los refrigerantes desarrollan unos productos de

descomposición peligrosos para el medio ambiente. Se requiere el
máximo cuidado y precaución al manejar refrigerantes. Observe
siempre la información de seguridad proporcionada por el fabricante.
Asegúrese de que el personal que trabaja con refrigerantes está in-
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formado de los peligros potenciales y está formado para tratar refrige-

rantes con seguridad.
Agua de refrigeración – contra he- El agua de refrigeración y la protección de congelación contienen

ladas sustancias tóxicas. No puede permitirse que se liberen al medio am-
biente. Su eliminación debe llevarla a cabo una empresa de residuos
especializada.
Productos químicos de proceso Los productos químicos de proceso usados en la máquina son sus-
tancias peligrosas con unos requisitos de tratamiento de residuos
especiales.
Para garantizar que se eliminan adecuadamente debe tenerse en
cuenta y seguirse los requisitos locales aplicables en los reglamentos,
leyes, regulaciones técnicas, etc., así como en las fichas de datos de
seguridad para las sustancias en cuestión.
Líquidos limpiadores Los líquidos limpiadores que incorporan disolventes contienen sus-
tancias tóxicas. No deben liberarse en el ambiente. Su eliminación
debe llevarla a cabo una empresa de residuos especializada.
Lubricantes Los lubricantes como grasas o aceites contienen sustancias tóxicas.

No deben liberarse en el ambiente. Su eliminación debe llevarla a
cabo una empresa de residuos especializada.
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3 Construcción y función
3.1 Vista general
Vista exterior (ejemplo)
Fig. 3: Vista exterior (ejemplo)
1 Bomba de aceite 9 Boquilla de llenado de aceite

2 Tubo distribuidor del aceite 10 Vidrio de revisión de aceite
3 Válvula de escape 11 Vaciado de aceite
4 Volante 12 Enlace de succión de aceite
5 Virola 13 Conexión del monitor de nivel
6 Conexiones del compresor (especifico para el 14 Conexión del calentador eléctrico
trabajo) 15 Enlace de recuperación de aceite
7 Recubrimiento protector de la biela 16 Aperturas de instalación
8 Perno expansible
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Vista interior (ejemplo)
Fig. 4: Vista interior (ejemplo)
1 Vástago del pistón 10 Consola

2 Válvula de escape 11 Distanciador exterior
3 Respiradero 12 Cruceta
4 Entrada de gas 13 Biela
5 Válvula de aspiración de descarga 14 Cigüeñal
6 Válvula de aspiración 15 Alojamiento del cigüeñal
7 Válvula de descarga 16 Cilindro
8 Tapa de válvula 17 Pistón
9 Salida de gas 18 Culata
3.2 Breve descripción

El compresor alternativo comprende la unidad de accionamiento y la
sección del compresor y funciona mediante un motor eléctrico. Se usa
para comprimir los gases de proceso y las mezclas de gas de proce-
so.
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Unidad de accionamiento
Fig. 5: Montaje de la unidad de accionamiento
La unidad de accionamiento del compresor convierte el movimiento

rotatorio del cigüeñal en un movimiento translacional oscilante en la
cruceta y los componentes de corriente abajo (pistón, biela). Esto
facilita la succión y la compresión por el cambio del volumen dentro
de las cámaras de gas del cilindro.
La unidad de accionamiento incluye el cárter del cigüeñal, el distan-
ciador exterior, el cigüeñal, la varilla de conexión, la biela y el apoyo
deslizante.
 Apartado Error! Reference source not found. “Unidad de accio-
namiento” en la página 37.
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Sección del compresor
Fig. 6: Montaje de la sección del compresor
La sección del compresor transporta el gas que comprime de un nivel

de presión bajo a un nivel de presión alto. El medio transportado se
succiona por las válvulas de succión en el lateral de succión de la
sección del compresor. El gas se desplaza mediante un pistón y co-
mo resultado queda comprimido y se expulsa a través de las válvulas
de descarga en el lateral de presión de la sección del compresor.
El compresor incluye el cilindro, el pistón, la biela, las válvulas de
succión y descarga y las cubiertas para tapar las entradas de los ci-
lindros (tapa del cilindro, tapa de la válvula)  Apartado Error! Refer-
ence source not found. “Sección del compresor” en la página 46.
Dependiendo de la extensión del cociente de presión general el gas
se comprime en uno o varios pasos (cilindros). La compresión los
gases de proceso y las mezclas del gas de proceso siempre generan
calor de compresión. Por eso los cilindros se tratan con un refrigeran-
te.
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3.3 Descripción de montaje

3.3.1 Unidad de accionamiento
Alojamiento del ci-

güeñal
Fig. 7: Cárter del cigüeñal
El cárter del cigüeñal (Fig. 7) es una pieza única , alojamiento fundido libre de torsiones.
El diseño del cárter del cigüeñal depende del tipo de compresor y el número de cilin-
dros que tienen que conectarse y por lo tanto difiere de trabajo a trabajo.
Las nervaduras en el cárter del cigüeñal se usan para absorber las fuerzas de la masa
y el gas. Todos los elementos de la máquina que se encuentran el cárter del cigüeñal
son accesibles mediante aperturas de instalación integradas en el cárter del cigüeñal.
Las aperturas de instalación están selladas con recubrimientos.
El cárter del cigüeñal tiene forros de cruceta reemplazables y también sirve como un
depósito de aceite para el sistema de engrase de la unidad de accionamiento.
Los distanciadores interiores son partes integrales del cárter del cigüeñal.
Forros de cruceta
Fig. 8: Forro de cruceta
Los forros de cruceta reemplazables (Fig. 8) realizados por fundición

se encuentran instalados en el cárter del cigüeñal. Está prevista una
superficie mecanizada en el perímetro para instalar un apoyo con un
sensor EXLINE ®.
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Cigüeñal
Fig. 9: Cigüeñal (ejemplo)
El cigüeñal (Fig. 8) está hecho de acero forjado. Los puntos de apoyo

del cigüeñal están localizados en el alojamiento del cigüeñal. Las
perforaciones inclinadas en las muñequillas garantizan que el lubrifi-
cante llegue hasta los respectivos puntos de apoyo. El cigüeñal está
sellado hacia el lado de propulsión por un anillo de lubrificación que
está permanentemente unido al eje y un colector de aceite fijado al
alojamiento del cigüeñal.
Un pequeño cierre en la parte final exterior del colector de aceite pro-
tege de la penetración de polvo o ambiente corrosivo.
Cojinete principal Todos los cojinetes principales se combinan formando un canal de

cojinetes que sostiene el cigüeñal. Son de un diseño trimaterial. Los
cojinetes principales comprenden un encofrado metálico, bronce anti-
fricción y una capa galvánica de metal blanco. Los cojinetes principa-
les son un cojinete flotante o de diseño fijo. El cojinete fijo se usa para
asegurar el cigüeñal en la dirección axial.
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Fig. 10: Cojinete principal (ejemplo)
1 Tuerca y perno expansible

2 Cubierta del bloque de apoyo
3 Concha de cojinete principal
4 Alojamiento del cigüeñal
5 Soporte del cojinete
Las conchas del cojinete principal (Fig. 10/3) se encuentran en el
soporte del cojinete (Fig. 10/5) en el alojamiento del cigüeñal. La tapa
del soporte del cojinete de acero inoxidable extraíble permite instalar
y quitar las conchas del cojinete. La junta del cojinete se posiciona de
manera que quede fuera de la zona de carga y no interrumpa en la
formación de la capa de lubricación hidrodinámica.
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Cojinete del pie de biela
Fig. 11: Cojinete del pie de biela (ejemplo)
1 Cigüeñal
2 Concha del cojinete del pie de biela
3 Tornillo de biela
4 Muñequilla
6 Biela
7 Tuerca de biela
Las conchas de los cojinetes del pie de biela (Fig. 11/2+5) se encuen-
tran en la parte baja de la cabeza del cigüeñal (Fig. 11/6) y están
asegurados con tornillos de biela (Fig. 11/3).
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Biela
Fig. 12: Biela (ejemplo)
1 Cigüeñal
3 Tapa de la biela
4 Tornillo de biela
6 Cabeza de la biela
7 Cruceta buje del perno
8 Ojo de biela
9 Perforación longitudinal
10 Tuerca de biela
La biela está hecha de acero forjado. Convierte el movimiento rotato-
rio del cigüeñal (Fig. 12/1) en un movimiento recto y lo transmite a la
cruceta.
Mediante la perforación longitudinal el aceite llega a la cruceta buje
del perno (Fig. 12/9) en el eje de la biela. El suministro de aceite en el
cojinete del pie de biela (Fig. 12/5+2) está por lo tanto asegurado. La
cabeza de la biela (Fig. 12/6) y la tapa de la biela (Fig. 12/3) cierran el
cojinete del pie de biela (Fig. 12/5+2) con el cigüeñal (Fig. 12/1) y
están aseguradas con tornillos de biela (Fig. 12/4). El ojo de biela
(Fig. 12/8) sirve para fijar la cruceta buje del perno.
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Cruceta
Fig. 13: Cruceta (ejemplo)
1 Tuerca redonda
2 Perno de cruceta
3 Corona de fijación
4 Junta de unión, dos piezas
5 Manguito excéntrico (opcional)
6 Manguito cónico de sujeción
7 Disco de presión
8 Cruceta
9 Pasador de cruceta
10 Aro tórico
La cruceta (Fig. 13/8) consiste en una fundición de acero tratada con
metal antifricción. Es la unión entre la biela y el vástago del pistón.
Las superficies de rodadura de la cruceta están aplanadas en los
laterales para reducir la pulsación durante la carrera por el alojamien-
to del cigüeñal. La guía de cruceta en el alojamiento del cigüeñal está
equipada con dos conexiones lubricantes externas.
Barrenos de lubricación, situados a lo largo y transversalmente sumi-
nistran aceite constantemente a la superficie de rodadura de la cruce-
ta durante toda la carrera. La cruceta está conectada a la biela por la
cruceta buje del perno, que está presionada dentro del ojo de la biela
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y el pasador de cruceta (Fig. 13/9) que está insertado a través. Un

manguito cónico de sujeción (Fig. 13/6) insertado en la cruceta
(Fig. 13/8) a ambos lados asegura el pasador de la cruceta
(Fig. 13/9). Los discos de presión enroscados (Fig. 13/7) evitan que el
manguito cónico de sujeción (Fig. 13/6) se suelte.
Conexión vástago del pistón - cru- El vástago del pistón está ajustado a la cruceta (Fig. 13/8) con una
ceta conexión abrazadera. Esta conexión comprende una corona de fija-
ción (Fig. 13/3), dos piezas de juntas de unión (Fig. 13/4), los pernos
de la cruceta (Fig. 13/2) y tuercas redondas (Fig. 13/1). El aro tórico
(Fig. 13/10) funciona únicamente como una ayuda para la instalación.
Los pernos de la cruceta (Fig. 13/2) empujan el vástago del pistón
hacia la cruceta. Entre la cruceta y el vástago del pistón hay una cu-
ña. Esto asegura que la junta del pistón está segura en el punto
muerto superior e inferior durante la carrera una vez que el vástago
del pistón se ha reinstalado en la cruceta después de haber sido reti-
rado.
Un manguito excéntrico (Fig. 13/5) permite el ajuste del descentra-
miento de la barra.
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Junta colector de aceite
Fig. 14: Junta colector de aceite
1 Tapa
2 Aro tórico
3 Piezas internas
4 Caja
5 Alojamiento
La junta del colector de aceite se encuentra justo encima de la cruce-
ta. Asegura que el aceite de la unidad de accionamiento no entre en
la sección del compresor con el vástago de pistón durante el recorri-
do.
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Fig. 15: Caja y piezas internas
1 Cámara
2 Anillo de sellado
3 Cámara
4 Anillo rascador
La junta del colector de aceite cuenta con un anillo de sellado
(Fig. 15/2) y dos anillos rascadores (Fig. 15/4+5). Todos los anillos
son construcciones de piezas múltiples están equipadas con labios
encarados hacia la unidad de accionamiento. Muelles tubulares pre-
sionan los anillos en el vástago del pistón. Perforaciones y canales en
las cámaras de anillo permiten que el aceite vuelva a la unidad de
accionamiento.
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Distanciadores exteriores
Fig. 16: Distanciador exterior (ejemplo)
1 Distanciador exterior
2 Junta de separación intermedia
3 Consola
De acuerdo con la especificación del trabajo y los requisitos API se
instala un distanciador tipo D (largo/corto dos-compartimentos). El
distanciador exterior (Fig. 16/1) conecta el alojamiento del cigüeñal
con el cilindro, mientras que el distanciador interno es una parte inte-
gral del alojamiento del cigüeñal.
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Junta de separación intermedia
Fig. 17: Junta de separación intermedia
1 Alojamiento
2 Tapa
3 Elemento de sellado
4 Cámara
5 Aro tórico
6 Anillo laberíntico
7 Tapa
El gas de transporte entra en la cámara del lado del cilindro directa-
mente en la junta de separación intermedia. Un anillo laberíntico
(Fig. 17/6) provoca una determinada corriente de gas de transporte
en el lateral del cilindro. El gas de transporte sale de la cámara lateral
del cilindro del distanciador exterior y se dirige al conducto de gas de
combustión.
La cámara lateral del cigüeñal está sellada con dos elementos de
sellado (Fig. 17/2) que están presionados hacia el vástago del pistón
mediante muelles helicoidales.
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3.3.2 Sección del compresor
Cilindro
Fig. 18: Cilindro (ejemplo)
1 Descargadores de la válvula de succión

2 Cámara de succión
3 Entrada de gas
4 Pistón con pistón and aros de soporte
5 Empaque de presión
6 Cámara de presión
7 Salida de gas
8 Camisa del cilindro
9 Unidad válvula de descarga
10 Tapa de la válvula
11 Tapa del cilindro
12 Cámara de trabajo
13 Unidad válvula de succión
La construcción de los cilindros está adaptada a las condiciones de
trabajo y al medio que ha de ser comprimido. Succionan el gas de
proceso que se está comprimiendo mediante la entrada de gas
(Fig. 18/5) en el lado de succión. El proceso gas entra en la cámara
de trabajo de los cilindros por medio de los cilindros de succión
(Fig. 18/2). El ritmo de entrada del gas de proceso puede ser regula-
do por medio de los descargadores de la válvula de succión
(Fig. 18/3) de las válvulas de succión.
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En las camisas del cilindro (Fig. 18/10) los pistones (Fig. 18/6) com-
primen el gas a la presión requerida con movimientos de carrera. La
sobrepresión generada en la cámara de trabajo (Fig. 18/1) de la ca-
misa del cilindro (Fig. 18/10) hace que las válvulas de descarga
(Fig. 18/11) abran el lado de presión y dirijan el gas de proceso com-
primido a las cámaras de gas del lado de presión (Fig. 18/8). El gas
de proceso comprimido se suministra al sistema de oleoductos de la
planta (Fig. 18/9) a través de la salida de gas.
Las salidas de gas (Fig. 18/9) están situadas en la parte más baja de
los cilindros.
Un indicador está instalado en la zona de presión y las válvulas de
succión (Fig. 18/2+11) de los cilindros. Cuando se conecta el disposi-
tivo adecuado se registran los diagramas indicadores. Todos los cilin-
dros del compresor de pistón están equipados con tapas de la válvula
(Fig. 18/12) y tapas de cilindro (Fig. 18/13). Están asentados con los
cilindros en las superficies de sellado y están selladas metálicamente.
Además, las tapas del cilindro están ajustadas con una junta redonda
(aro tórico). La apertura de los cilindros en el lateral de la unidad de
accionamiento está sellada con el empaque de presión (Fig. 18/7).
Refrigeración del cilindro Los cilindros tienen cámaras y canales de refrigeración. El sistema de
refrigeración está diseñado de manera que el calor generado por
fricción en los segmentos del pistón y el calor de compresión se disi-
pe.
El sistema de refrigeración debe estar libre de burbujas de aire para
que se pueda disipar el calor. Los cilindros que no tienen ventilación
propia tienen los respectivos respiraderos. El sistema de refrigeración
tiene que ventilarse antes de cada puesta en marcha y después de
que el líquido de refrigeración se haya agotado. El líquido refrigerante
en el cilindro no debe llegar a una temperatura de más de 10K, como
máximo. Todos los componentes del sistema de refrigeración del
cilindro están diseñados para una presión del refrigerante máxima de
10 bar (g).
Tenga en cuenta los siguientes aspectos de seguridad relativos al
sistema de refrigeración del cilindro:
 Si falla el sistema de refrigeración del cilindro, el cilindro sufrirá un
sobrecalentamiento. Esto puede derivarse en un aumento del
desgaste y en daños graves en el cilindro y los componentes
instalados.
 La temperatura de entrada del líquido refrigerante al entrar en el
sistema de refrigeración del cilindro debe ser al menos de 5 K por
encima de la entrada de gas en el cilindro. De lo contrario el punto
de rocío puede descender por debajo del mínimo y provocar
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condensación de los componentes del gas, lo cual podría causar

daños graves al compresor.
 Si la máquina está instalada en exteriores y el compresor está
paralizado, existe el riesgo de que se congele y eso provoque la
destrucción del cilindro. El líquido refrigerante debe utilizarse como
medida preventiva contra la congelación, de acuerdo con las
temperaturas esperadas.
La calidad del refrigerante es una condición para su efectividad. Re-

comendamos las siguientes calidades de agua:
 Intervalo de dureza: hasta un máx. de 178.57 ppm (10 °dH)
-6
 Contenido de hierro: hasta un máx. de 6.243 * 10 lb/ft³ (0.1 mg/l)
 Evite minerales disueltos, dióxido de carbono, cloro y oxígeno.
Si no se siguen estas recomendaciones, existe el riesgo de que se
salgan piezas y la transferencia de calor sea peor. Existe por tanto un
peligro de corrosión.
Vástago del pistón
Fig. 19: Vástago del pistón (ejemplo)
1 Vástago del pistón

2 Anillo de sellado
3 Anillo guía
4 Superbolt®
5 Sección de pistón superior
6 Sección de pistón inferior
El vástago del pistón (Fig. 19/1) es la conexión entre la cruceta y el
pistón (Fig. 19/5+6).
Se fija a la cruceta con una brida de fijación. Para prevenir que el
aceite de la unidad de accionamiento entre en los cilindros del com-
presor de pistón, un deflector de aceite pasa por el vástago del pistón
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en el distanciador exterior.
Pistón El pistón (Fig. 19/5+6) transforma la carrera con la ayuda del vástago
del pistón (Fig. 19/1) y comprime el gas de proceso dentro del cilin-
dro. Los pistones pueden tener un diseño de pistón hueco de dos
piezas o de un material sólido dependiendo del tamaño, la forma del
anillo y el material.
El pistón se fija al vástago del pistón con una conexión Superbolt®

(Fig. 19/4).
Los pistones huecos tienen orificios de ventilación que garantizan la
ventilación mientras el compresor de pistón realiza el proceso flus-
hing. Los orificios están situados en la cara en la base del pistón o en
la base de la ranura del anillo guía. El pistón y el vástago del pistón
forman una unidad única y sólo pueden instalarse o desinstalarse
como un todo.
Anillo de sellado Los anillos de sellado (Fig. 19/2) se usan para sellar el pistón y la
camisa del pistón. La presión del gas los presiona hacia la pared de la
camisa del pistón. El diseño, el material y la cantidad de anillos de
sellado que se emplean depende del tipo de gas y la presión diferen-
cial en el pistón.
Anillos guía Los anillos guía (Fig. 19/3) no cumplen una función de sellado. Se
usan para guiar el pistón y el vástago del pistón y son más anchos
que los anillos de sellado. Las ranuras de escape de los anillos guía
evitan que los anillos guía sean presionados contra la camisa del
pistón.
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Empaque de presión
Fig. 20: Empaque de presión (ejemplo)
1 Tirante
2 Aro tórico
3 Enfriamiento de la zona media (opcional)
4 Elemento de sellado
5 Conexión de la sonda de temperatura (opcional)
6 fuga de elemento de cierre
El empaque de presión (Fig. 20) sella la cámara de trabajo del cilindro
del distanciador exterior, p.ej.la cámara de la unidad de accionamien-
to. Sus cámaras cuentan con diferentes anillos de sellado o pares de
anillos de sellado de politetrafluoretileno (PTFE) según la aplicación
específica. Las diferentes cámaras del anillo están unidas por un ti-
rante para formar una unidad única.
Si la presión diferencial del sellado lo requiere se añaden anillos de

soporte a los pares de anillos de sellado. Evitan que los anillos de
sellado de PTFE se deslicen o se peguen.
Válvulas Las válvulas de la sección del compresor son válvulas de placa auto-
máticas. La presión de gas hace que se abran y se cierren. Los mue-
lles de válvula integrados tienen un efecto estabilizante para la aper-
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tura y el cierre. Los tornillos de presión en las tapas de la válvula em-

pujan las válvulas hacia el listón de sellado en el cilindro del compre-
sor alternativo con recipientes de presión.
Las válvulas y las cubiertas de la válvula sellan metálicamente sin
necesidad de un sello adicional. Los muelles de tensión aseguran las
válvulas y los recipientes de presión en el cilindro del compresor al-
ternativo para prevenir que se caigan durante la instalación.
Descargador de la válvula de
succión
1 Indicador de posición
2 Alojamiento
3 Tornillos de ajuste
4 Empujador de válvula
El cilindro del compresor alternativo está equipado con descargado-
res en el lado de succión para controlar la velocidad de descarga del
gas de proceso que se comprime. Cuando las válvulas de succión se
mantienen abiertas, el gas de proceso succionado retrocede a la tu-
bería de aspiración.
El control graduado mantiene la válvula de succión abierta durante
todo el recorrido del pistón de modo que toda la descarga retroceda.
Este proceso de mantener abierta la válvula se puede usar para el
100 %, 50 % o 0 % de la velocidad de descarga.
El control variable continuo (o control de la presión dinámica) usa
pinzas para mantener abierta la válvula de succión durante parte del
recorrido del pistón, de manera que únicamente una parte de la
transmisión retroceda hacia la tubería de aspiración.
Fig. 21: Descargador de la válvula de

succión
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3.4 Zonas de trabajo y zonas de peligro
Fig. 22: Zonas de trabajo y zonas de peligro
1 Zona de peligro 2 Zona de trabajo
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4 Transporte, embalaje y almacenamiento
Este dispositivo debe ser instalado y puesto en funcionamiento

únicamente por el ingeniero de planta del fabricante o por perso-
nas autorizadas por el fabricante. Sin embargo, es posible que el
equipo de trabajo del usuario tenga que manipular los paquetes
durante la instalación y uso posterior. Es obligatorio seguir las indi-
caciones listadas a continuación.
4.1 Notas de seguridad para el transporte

Materiales en suspensión
ADVERTENCIA ¡Peligro de lesiones mortales a causa de materiales en suspen-
sión!
- Nunca camine bajo materiales en suspensión ni camine dentro
de las zonas de rotación.
- Mueva cargas únicamente bajo supervisión.
- Utilice montacargas probados y mecanismos elevadores con
una capacidad suficiente para soportar la carga.
- No utilice sistemas de carga sometidos a abrasión como cuer-
das o correas.
- No sitúe sistemas de carga como cuerdas o correas contra can-
tos o esquinas afilados y no las anude ni enrolle.
- Quite la carga cuando abandone el lugar de trabajo.
Durante las operaciones de propulsión, las cargas pueden balan-
cearse y caer. Esto podría derivar en lesiones graves o la muerte.
Centro de gravedad excéntrico

ADVERTENCIA ¡Peligro de lesiones por caídas o inclinación de paquetes!
- Observe las marcas y especificaciones en los paquetes relati-
vas al centro de gravedad.
- Al realizar transportes con grúa, ligue el gancho de la grúa de
manera que esté sobre el centro de gravedad del paquete.
- Deslice el paquete con cuidado y preste atención a las inclina-
ciones. Cambie la posición de sujeción si es necesario.
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Los paquetes pueden tener un centro de gravedad excéntrico.

Una sujeción inadecuada puede hacer que el paquete se mueva y
se caiga. La inclinación o la caída de paquetes podrían causar
lesiones graves.
Unidad de transporte giratoria

ADVERTENCIA ¡Peligro de lesiones a causa de unidades de transporte giratorias!
- Durante el transporte, asegúrese de que ninguna persona,
ningún objeto ni ningún obstáculo se halla dentro de la zona de
la unidad de transporte giratorio.
Cuando realice el transporte con una grúa, la unidad de transporte
puede ser giratoria y causar graves lesiones y provocar daños sus-
tanciales en las instalaciones.
Transporte no autorizado
AVISO ¡Peligro en las instalaciones por el uso de un transporte no autori-
zado o conducido por personal sin formación!
- Las descargas de las unidades de transporte de entregas y
transporte in-house deben realizarlas personal formado bajo la
dirección de empleados del fabricante.
- Se prohíbe cualquier tipo de transporte no autorizado o ayuda
en la retirada de transporte.
- No mueva paquetes sin autorización.
Las unidades de transporte pueden caer o volcar cuando el tras-
porte lo realiza personal no preparado y con transporte no auto-
rizado. Esto puede ocasionar un nivel significativo de daños en
las instalaciones.
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4.2 Símbolos en el embalaje

Los siguientes símbolos aparecen en el embalaje. Fíjese siempre en
los símbolos cuando realice un transporte.
Arriba
Las flechas de la señal indican la parte de arriba del embalaje. Deben
estar siempre señalando hacia arriba, de lo contrario podría dañarse
el contenido.
Protección anti humedad

Proteja los embalajes de la humedad y manténgalos secos.
Sujetar aquí
Los aparatos para impulsar (cadena o correa de elevación) solo pue-
den sujetarse a sitios donde esté presente este símbolo.
Centro de gravedad
Marca el centro de gravedad de los embalajes.
Observe en qué lugar se encuentra el centro de gravedad cuando
transporte o eleve materiales.
Peso, carga sujeta
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Indica el peso de los embalajes.

Manipule el embalaje marcado de acuerdo con su peso.
Carga que se puede apilar

Señala los paquetes que se pueden apilar parcialmente.
No exceda el máximo de capacidad de sujeción de carga especifica-
do en el símbolo con el fin de evitar que se dañe o rompa el conteni-
do.
No dañar los embalajes herméticos

El embalaje es hermético. Dañar la capa de barrera puede provocar
que el contenido quede inutilizable.
No agujerear. Utilice objetos afilados para abrirlo.
4.3 Inspección de transporte

Al recibirlo, inspeccione la entrega inmediatamente para comprobar
que está completo y no ha sufrido daños por el transporte.
En el caso de observar aparentes daños por el transporte externa-
mente, proceda de la siguiente manera:
 No acepte la entrega, o acéptela si está sujeto a reservas.
 Anote la extensión de los daños en la documentación del
transporte o la nota de entrega del proveedor.
 Inicie el proceso de reclamación.
Realice una reclamación sobre todos los defectos que observe in-
mediatamente después de detectarlos. Las reclamaciones de
compensaciones por daños solo son válidas dentro de la fecha lí-
mite de reclamación aplicable.
Protección ante explosiones

ADVERTENCIA ¡Pérdida de la protección ante explosiones tras daños por el trans-
porte!
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- En el caso de que aparentemente existan daños por el trans-

porte en la máquina, contacte con el fabricante.
Los daños ocasionados por el transporte pueden provocar la pér-
dida de la protección ante explosiones. No observar estas instruc-
ciones puede derivar en la pérdida de la protección ante explosio-
nes.
4.4 Transporte
ADVERTENCIA ¡Riesgo de lesiones mortales a causa de un transporte incorrecto!

- Sujete únicamente component es individuales del compresor
alternativo con las garras para transporte.
- No utilice nunca las garras de unión para transportar el compre-
sor alternativo completo.
Las garras de unión designadas en la Fig. 23 están previstas para
el transporte de component es individuales. Si se transporta el
compresor completo mediante las garras de unión podrían romper-
se y el compresor alternativo podría caer. Dicha situación puede
ocasionar situaciones de consecuencias funestas, graves lesiones
y causar considerables daños materiales.
El compresor alternativo incluye los siguientes componentes:

 Sección del compresor
 Distanciador exterior
 Alojamiento del cigüeñal
Puntos de ajuste para los compo- Los siguientes puntos de ajuste están provistos para el transporte de
nentes componentes individuales:
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Fig. 23: Puntos de sujeción para los componentes
1 Garras para transporte en la sección del 4 Garras para transporte en la sección del
compresor compresor
2 Garras para transporte en el distanciador exterior 5 Garras para transporte en el alojamiento del
3 Garras para transporte en el distanciador exterior cigüeñal
Puntos de sujeción para el com- El compresor alternativo cuenta con los siguientes puntos de sujeción
presor alternativo completo para transportarlo en su totalidad:
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Fig. 24: Puntos de sujeción para el compresor alternativo completo
Sujeción Equipamiento de protección:  Casco protector

 Botas de seguridad
Los componentes se pueden transportar mediante una grúa directa-

mente según las siguientes condiciones:
 La grúa y el equipo de elevación son apropiados para el peso de
las cargas.
 El operador debe estar autorizado para manejar la grúa.
1. Fije las cuerdas, cinturones o arnés multipunto como en Fig. 23.
2. Asegúrese de que los paquetes cuelgan de forma recta. Tenga

en cuenta que pueden tener el centro de gravedad descentrado.
3. Inicie el transporte.
4.5 Embalaje
Información en el embalaje
AVISO ¡Riesgo de daños materiales a causa de una falta de conservación!
- No extraiga el embalaje hasta justo antes de iniciar la instala-
ción.
Los embalajes individuales deben conservarse para proteger los
componentes de la corrosión. Si se quita el embalaje con anticipa-
ción, la protección anticorrosión podría perderse y en consecuen-
cia, los componentes pueden resultar dañados
Los embalajes individuales están preparados para garantizar las con-

diciones de transporte esperadas y los períodos de almacenamiento
de forma adecuada. El embalaje protege los componentes individua-
les de daños durante el transporte, corrosión u otros daños hasta el
momento de la instalación.
 No destruya el embalaje y no lo quite hasta inmediatamente antes
de la instalación.
AVISO ¡Riesgo de daños materiales a causa de un manejo inadecuado de

componentes desempaquetados!
- Instale inmediatamente los componentes desempaquetados en
el lugar de instalación.
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Los componentes que no estén empaquetados para la entrega po-

drían resultar inutilizables por la corrosión y podrían ocasionar da-
ños materiales.
Como manipular los materiales de

embalaje
AVISO ¡Riesgo de daños medioambientales debido a una eliminación in-
debida!
- Elimine los materiales de embalaje de un modo respetuoso con
el medio ambiente.
- Cíñase a las regulaciones locales para la eliminación de resi-
duos. Contrate una empresa de residuos especializada si es
necesario.
Los materiales de embalaje son valiosas materias primas y en mu-
chos casos pueden reutilizarse o tratarse y reciclarse. Una elimina-
ción incorrecta de los materiales de embalaje puede causar peligros
para el medio ambiente.
Elimine los materiales de embalaje de acuerdo con las regulaciones

locales y nacionales vigentes.
4.6 Almacenamiento
Almacenamiento de los paquetes Almacene los paquetes de acuerdo con las siguientes condiciones:
 No utilice almacenes exteriores.
 Almacene en un lugar seco y libre de polvo.
 No los exponga a ningún medio abrasivo.
 Protéjalos de la luz solar.
 Evite el amortiguamiento mecánico.
 Temperatura de almacenamiento: 15 a 35 °C.
 Humedad relativa del aire: máx. 60 %.
 Cuando almacene revise regularmente las condiciones generales
de todas las partes. Aplique de nuevo o sustituya la conservación
si es necesario Apartado Error! Reference source not found.
“Retirada del servicio a largo plazo” en la página 67.
En algunos casos los embalajes pueden mostrar más instrucciones

relativas al almacenamiento que las que aparecen listadas aquí.
Siga estas instrucciones, como corresponde.
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Instalación y puesta en marcha inicial
La instalación y la puesta en marcha inicial solo pueden llevarla a

cabo empleados del fabricante o personas autorizadas por el fabri-
cante.
ADVERTENCIA ¡Peligro mortal en el caso de una instalación o puesta en marcha

inadecuada!
- La instalación o puesta en marcha solo la pueden llevar a cabo
empleados del fabricante o personas autorizadas por el fabri-
cante.
- Consulte al fabricante en caso de cambios de localización pos-
teriores.
- Absténgase de realizar la instalación o un cambio de localiza-
ción sin autorización.
Los errores producidos durante la instalación o la puesta en mar-
cha inicial pueden ocasionar consecuencias fatales y provocar da-
ños significativos en la propiedad.
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5 Funcionamiento
5.1 Seguridad
Funcionamiento inadecuado
ADVERTENCIA ¡Peligro de lesiones por un funcionamiento inadecuado!
- Lleve a cabo todos los pasos para el funcionamiento de acuer-
do con la información y los avisos que se encuentran en este
manual.
- Preste atención a los siguientes puntos antes de iniciar la acti-
vidad:
- Asegúrese de que todas las tapas y los mecanismos de se-
guridad están instalados y funcionan adecuadamente.
- Asegúrese de que nadie se encuentra en la zona de peligro.
- Nunca haga caso omiso de las normas de seguridad durante el
proceso de trabajo.
Un funcionamiento indebido puede provocar lesiones graves y da-
ños materiales significativos.
Piezas móviles
ADVERTENCIA ¡Riesgo de lesiones a causa de las piezas móviles!
- No alcance o toque las piezas móviles mientras el trabajo está
en progreso.
- Nunca abra las tapas en funcionamiento.
- Sea consciente del tiempo de margen: Antes de abrir las tapas
asegúrese de que ninguna de las piezas está todavía en movi-
miento.
- Vista ropa de trabajo ajustada y apretada con baja resistencia al
desgarre cuando esté en la zona de peligro de la máquina.
Las piezas móviles pueden provocar lesiones graves.
Funcionamiento
La máquina funciona totalmente de forma automática. No es nece-
sario operarla mientras está en funcionamiento. La máquina (así
como toda la planta) está monitorizada por el sistema de control
superior.
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5.2 Encendido
Personal:  Personal especializado
Equipamiento protector:  Protección auditiva

 Casco protector
 Ropa protectora
 Guantes de seguridad
Para un funcionamiento seguro y libre de fallos es necesario llevar a

cabo las siguientes tareas, independientemente de si el compresor
alternativo se controla mediante un sistema máster control o si los
componentes individuales son operados manualmente.
Además de las tareas aquí especificadas debe cumplirse también

con las regulaciones de funcionamiento del usuario y el ingeniero
de la planta.
1. Encienda la lubricación del cilindro y lubrique el cilindro hasta

que el aceite sea expulsado por todas las conexiones atornilla-
das del cilindro de los tubos de lubricación (solo si está provista
la lubricación del cilindro).
2. Encienda la bomba de engrase para la lubricación de la unidad

de accionamiento.
3. Encienda el aprovisionamiento de agua de refrigeración.

4. Encienda el mando del compresor alternativo.
5. Realice el trabajo de mantenimiento diario  en la página 71.
5.3 Apagado
Equipamiento protector:  Protección auditiva

 Casco protector
 Ropa protectora
Para un funcionamiento seguro y libre de fallos es necesario llevar a
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cabo las siguientes tareas, independientemente de si el compresor

alternativo se controla mediante un sistema máster control o si los
componentes individuales son operados manualmente.
Además de las tareas aquí especificadas debe cumplirse también

con las regulaciones de funcionamiento del usuario y el ingeniero
de la planta.
1. Apague el mando del compresor alternativo y asegúrelo para

evitar que vuelva a encenderse.
2. Apague la lubricación del cilindro (si provista).
3. Apague la bomba de engrase para la lubricación de la unidad de

accionamiento.
4. Apague el aprovisionamiento de agua de refrigeración.
5.4 Paro en situaciones de emergencia

En situaciones de peligro se debe parar el movimiento de los compo-
nentes lo antes posible y desconectar el suministro de energía.
Paro en situaciones de emergencia En una situación de emergencia proceda como se explica a continua-
ción:
1. Realice inmediatamente el paro de emergencia en el mecanismo

de paro de emergencia.
2. Siempre que no arriesgue su propia vida saque a las personas

presentes en la zona de peligro.
3. En caso necesario realice primeros auxilios.
4. Alerte al cuerpo de bomberos y/o equipo de rescate.
5. Informe a los responsables del lugar de implementación.
6. Apague la máquina y protéjala para que no vuelva a activarse de

nuevo.
7. Mantenga los accesos libres para los vehículos de rescate.

8. Dé indicaciones a los vehículos de rescate.
Después de las medidas de 9. Dependiendo de la gravedad de la situación de emergencia, in-

socorro forme a los entes públicos pertinentes.
10. Asigne personal especializado para resolver el malfuncionamien-
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to.
¡ADVERTENCIA! ¡Existe peligro de muerte si se reinicia sin
autorización o de forma no controlada!
- Antes de reiniciar asegúrese de que todos los mecanismos de
seguridad están montados y funcionan correctamente y que no
existe peligro para el personal.
Encender el suministro eléctrico de forma no controlada o no auto-
rizada puede provocar lesiones graves o mortales.
11. Antes de reiniciar la máquina, revise y asegúrese de que todos

los mecanismos de seguridad están instalados y funcionan.
5.5 Rotación del compresor alternativo

Equipamiento protector:  Ropa protectora

 Protección auditiva
 Casco protector
Preparación 1. Apague el compresor alternativo y asegúrelo para que no vuelva

a activarse Apartado Error! Reference source not found.
“Apagado” en la página 63.
Rotación 2. Abra la tapa de la capucha de protección en el volante.
3. Inserte el dispositivo para el torneado en la perforación del perí-

metro del volante. Se encuentra en el borde superior de la aper-
tura de la capucha de protección.
¡ADVERTENCIA! ¡Riesgo de lesiones si no se procede
apropiadamente!
- Asegúrese de que el dispositivo para el torneado se introduce
hasta el fondo de la perforación.
Si procede indebidamente, puede provocar lesiones graves y da-
ños materiales.
4. Gire manualmente el volante.
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5. Extraiga el dispositivo para el torneado de la perforación e i nsér-

telo en la perforación que está ahora en el borde superior de la
apertura.
Giro con torno neumático 6. Haga girar el compresor alternativo como se estipula en las ins-
trucciones de funcionamiento para el torno neumático.
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6 Retirada del servicio a largo plazo

En el caso de una retirada del servicio a largo plazo (p.ej. más de 3
meses) deben seguirse unas medidas de conservación determinadas.
Esto depende del tiempo que se prolongue la parada, dónde está
montada la máquina (en una sala o en exteriores) y el tipo de medio
comprimido.
Contacte el NEAC el departamento del Servicio Post-Venta antes

de planear una retirada del servicio a largo plazo para informarse
de cuáles son las medidas necesarias a seguir. Véase página 2
para la dirección.
6.1 Conservación
Conservación Personal:  Personal especializado
 Electricista cualificado
 Especialista en gas
Equipamiento pro-  Guantes de seguridad resistentes a las

tector: sustancias químicas
 Guantes protectores resistentes al calor con
protección para los brazos.
¡ADVERTENCIA! ¡Riesgo de lesiones debido a una falta de

cualificación!
- Únicamente el personal designado para las áreas individuales
puede llevar a cabo estas tareas.
- En caso de duda consulte con el NEAC el departamento del
Servicio Post-Venta
Si la retirada del servicio la realiza personal con una cualificación
insuficiente existe el riesgo de que se produzcan lesiones.
¡AVISO! ¡Riesgo de daños materiales a causa de una conserva-

ción incorrecta!
- Solo abra las tapas de las aperturas de instalación y/o otras
tapas si es necesario.
- Después de abrir tapas en las aperturas de instalación u otras
tapas, vuelva a ponerlas. Selle las cámaras de manera que
queden herméticas.
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- Sustituya el embalaje dañado.

Una conservación incorrecta o que el embalaje designado para la
conservación se encuentre dañado puede provocar daños corrosi-
vos en los componentes del compresor alternativo.
Lleve a cabo la siguiente preparación para conservar el compresor

alternativo.
1. Desconecte la máquina Apartado Error! Reference source

not found. “Apagado” en la página 63.
2. Despresurice e inactive todas las partes presurizadas de la má-

quina.
3. Haga que un electricista especializado desconecte todos los

componentes eléctricos de la corriente eléctrica y asegúrelos
para evitar que se vuelvan a activar.
4. Haga que un especialista en gas se asegure de que no hay resi-

duos de gas en el conjunto del compresor alternativo.
5. Implemente medidas de conservación según las indicaciones del

NEAC, el departamento del Servicio Post-Venta.
Embalaje dañado Personal:  Personal especializado
Si el embalaje está dañado la protección anticorrosiva podría estar en

peligro. Por ese motivo, el embalaje dañado debe reemplazarse ur-
gentemente.
1. Abra y quite el embalaje dañado.

2. Compruebe las partes del compresor de daños por corrosión.
3. Cambie el desecante.
4. Embale de nuevo las piezas del compresor alternativo indivi-

dualmente con film de polietileno.
5. Extraiga el aire del interior del embalaje.
6.2 Nueva puesta en marcha tras un tiempo de interrupción

AVISO ¡Riesgo de daños materiales a causa de componentes corroídos!
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- No realice una nueva puesta en marcha sin autorización.

- Haga que el NEAC, el departamento del Servicio Post-Venta
inspeccione los componentes y realice la puesta en marcha.
Véase página 2 para la dirección.
Debido a que existen diferentes posibilidades de conservación, las
medidas que han de ser implementadas en el momento de prepa-
rar la puesta en marcha también difieren. Si las dichas medidas no
se llevan a cabo apropiadamente, o existen componentes corroí-
dos, existe el riesgo de que se produzcan daños en los componen-
tes o un fallo total tras la puesta en marcha.
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7 Mantenimiento
7.1 Seguridad
Sistema eléctrico
PELIGRO ¡Peligro de vida por el suministro eléctrico!
- Desconecte el suministro eléctrico antes de iniciar el trabajo y
asegúrese de que no puede activarse de nuevo.
El contacto con las partes activas puede ser fatal. Cuando están
activados, los componentes eléctricos pueden estar sujetos a mo-
vimientos incontrolados y pueden causar lesiones graves.
Asegurar para prevenir una

reactivación
ADVERTENCIA ¡Peligro de vida por una reactivación no autorizada!!
- Desconecte el suministro eléctrico antes de empezar el trabajo
y asegúrese de que no puede reactivarse.
En el caso de reactivar el suministro eléctrico durante el manteni-
miento existe el peligro de que se produzcan lesiones graves o in-
cluso mueran personas que se hallen dentro de la
zona de peligro.
Componentes presurizados,
salida de gas
WARNING ¡Riesgo de lesiones mortales debido a los componentes presuriza-
dos!
Antes de empezar a trabajar sobre estos componentes:
- Despresurice. Descargue toda la energía residual.
- Limpie todos los componentes despresurizados con gas inerte.
- Asegúrese de que el gas de proceso, gas de transporte o fugas
no se pueden expulsar involuntariamente.
- Haga que el equipo especialista apropiado reemplace los com-
ponentes defectuosos que han sido presurizados durante la
operación inmediatamente.
Los componentes del compresor alternativo generan gas de
proceso a alta presión durante la operación. Abrir las tapas en
el área del cilindro durante la operación y el distanciador exte-
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rior sin realizar primero compensación de la presión puede oc a-

sionar lesiones graves. Un uso inapropiado o un fallo pueden
provocar que gas de proceso, gas de transporte o fugas salgan
expulsados a altas presiones y pueden provocar lesiones gra-
ves, intoxicación o incluso la muerte.
Gas residual
ADVERTENCIA ¡Riesgo de intoxicación por el almacenamiento de gas residual!
- No inicie ningún trabajo sobre piezas extraídas de la máquina
hasta que se hayan ventilado por al menos 30 minutos.
- Asegúrese de que no hay personal en la zona de peligro.
Cuando realice trabajos de mantenimiento existe el riesgo de que
en las diferentes piezas y componentes todavía haya residuos tó-
xicos de gas de proceso, gas de transporte o fuga. La expulsión no
controlada de estos gases de proceso puede causar situaciones y
lesiones altamente funestas.
Piezas móviles
ADVERTENCIA ¡Peligro de lesiones por las piezas móviles!

- Antes de llevar a cabo cualquier trabajo de mantenimiento so-
bre piezas móviles, apague la máquina y tome precauciones
para evitar que se reactive. Espere hasta que todas las piezas
hayan dejado de moverse.
- Cuando se encuentre en la zona de peligro, vista ropa de traba-
jo ajustada con baja resistencia al desgarro.
Las piezas rotatorias y/o las piezas que se mueven secuencial-
mente pueden provocar lesiones graves.
Trabajo de mantenimiento realiza-

do en modo inadecuado
ADVERTENCIA ¡Riesgo de lesiones si el trabajo de mantenimiento se realiza de
modo inadecuado!
- Antes de empezar a trabajar, asegúrese de que tiene suficiente
espacio para la instalación.
- Mantenga la zona de instalación limpia y ordenada. Los com-
ponentes y las herramientas sueltos sobre el suelo o unos en-
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cima de los otros son una fuente de accidentes potencial.

- Si tienen que impulsarse o transportarse los componentes para
poder realizar el trabajo de mantenimiento, siga las instruccio-
nes para el transporte de este manual  Apartado 4.4 “Trans-
porte” en la página 57:
- Utilice únicamente herramientas de levantamiento, camiones
industriales y equipamiento de ajuste con dimensiones sufi-
cientes y una capacidad de soporte de carga adecuada.
- Utilice los puntos de sujeción y garras para transporte de-
signados por el fabricante.
- Asegúrese de que no hay personal en las inmediaciones de
la zona de peligro cuando los componentes de la planta es-
tén en movimiento.
- Si se han extraído los componentes, asegúrese de que están
instalados correctamente, reinstale todos los elementos de
ajuste y cíñase a los valores de par para tornillos.
- Haga lo siguiente antes de realizar de nuevo la puesta en mar-
cha:
- Asegúrese que todos los trabajos de mantenimiento se han
llevado a cabo y completado de acuerdo con las estipulacio-
nes de estas instrucciones.
- Asegúrese de que no hay personas en la zona de peligro.
- Asegúrese que todas las tapas y dispositivos de seguridad
están instalados y funcionan perfectamente.
Si procede de forma inadecuada, podría causar graves lesion es y
daños materiales considerables.
Dispositivo de ajuste hidráulico

ADVERTENCIA ¡Riesgo de lesiones mortales a causa del desgaste en los elemen-
tos de la bomba!
- Es necesario que el fabricante del dispositivo de ajuste hidráu-
lico le reemplace todos los elementos de la bomba por elemen-
tos nuevos después de 500 presurizaciones o como máximo a
los 10 años.
Si los tornillos se atornillan y desatornillan muchas veces con el
dispositivo hidráulico tensor, los componentes del dispositivo de
bloqueo podrían desgastarse. Como consecuencia, los compone n-
tes no quedan bien atornillados y pueden producirse accidentes y
lesiones graves.
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Consumibles calientes
ADVERTENCIA ¡Peligro de lesiones por los consumibles calientes!
guantes protectores como regla general cuando lleve a cabo
cualquier tipo de trabajo con consumibles.
- Compruebe siempre si los consumibles están calientes antes
de trabajar con ellos. Pueden enfriarse si es necesario.
Los consumibles pueden alcanzar altas temperaturas durante el
funcionamiento. El contacto de la piel con consumibles calientes
provoca graves quemaduras en la piel.
Superficies calientes
ADVERTENCIA ¡Peligro de lesiones a causa de las superficies calientes!
guantes protectores como regla general cuando trabaje cerca
de superficies calientes.
- Antes de llevar a cabo cualquier tipo de trabajo, asegúrese de
que las superficies se han enfriado a temperatura ambiente
Las superficies pueden calentarse mucho durante el funcionamien-
to. El contacto de las superficies calientes con la piel provoca
quemaduras graves en la piel.
Superficies frías
ADVERTENCIA ¡Peligro de lesiones a causa de las superficies frías!

- Cuando lleve a cabo algún tipo de trabajo cerca de superficies
extremadamente frías debe vestir ropa de protección profesio-
nal y guantes de protección.
- Antes de iniciar cualquier trabajo asegúrese de que todas las
superficies se han calentado a temperatura ambiente.
Las superficies de componentes con refrigerantes pueden enfriar-
se hasta temperaturas muy bajas durante el funcionamiento. Si la
piel entra en contacto con superficies frías, la piel sufrirá graves
quemaduras.
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Protección del medio ambiente Tenga en cuenta las siguientes instrucciones para la protección del
medio ambiente cuando realice trabajos de mantenimiento:
 Con respecto a todos los puntos de lubricación provistos de
lubricante manualmente, retire cualquier exceso de grasa, grasa
usada o sobrante y elimínela de acuerdo con las regulaciones
locales vigentes.
 Meta los repuestos de aceite en los contenedores adecuados y
elimínelos de acuerdo con las regulaciones locales vigentes.
7.2 Programa de mantenimiento

En las secciones a continuación se describen las tareas de manteni-
miento necesarias para un funcionamiento de la máquina óptimo y sin
problemas.
Si se detecta un aumento del desgaste durante las inspecciones re-
gulares, entonces reduzca los intervalos de mantenimiento necesa-
rios a las indicaciones actuales de desgaste. Contacte con el fabri-
cante (véase dirección en la página 2), si tiene consultas relativas a
los intervalos y las tareas de mantenimiento.
Intervalo Trabajo de mantenimiento Personal
Cada 24 ho- Revisar fugas en el sistema de lubricación Usuario

ras operati-  Apartado Error! Reference source not found. “Revi- Personal especializado
vas sión de fugas en el sistema de lubricación” en la pági- Personal de servicio
na 77
Comprobar el nivel de aceite en la unidad de acciona- Usuario

miento
 Apartado Error! Reference source not found. “Com-
probación del nivel de aceite en la unidad de acciona-
miento” en la página 81
Cada 24.000 Inspeccionar el cigüeñal Personal de servicio

horas opera-
tivas o cada Inspeccionar el controlador de las bombas de aceite Personal de servicio
48 meses
Inspeccionar las conexiones por tornillos Personal de servicio
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Intervalo Trabajo de mantenimiento Personal
Inspeccionar el cojinete principal Personal de servicio
Inspeccionar el cojinete del pie de biela Personal de servicio
Inspeccionar la cruceta buje del perno Personal de servicio
Cada 8000 Reponer el aceite de la unidad de accionamiento Personal especializado

horas opera-  Apartado 7.4.3 “Reponer del aceite de la unidad de
tivas accionamiento” en la página 82
o cada 24
meses Sustituir la junta del colector de aceite Personal especializado
 Apartado Error! Reference source not found. “Susti-
tución de la junta del colector de aceite” en la página 83
Sustituir la junta de separación intermedia Personal especializado

tución de la junta de separación intermedia” en la pági-
na 87
Reemplazar el empaque de presión Personal especializado

tuir el empaque de presión” en la página 90
Sustituir los segmentos del pistón, inspeccionar la bisela y Personal especializado

las superficies y las superficies de rodadura del cilindro.
 Apartado 7.4.7 “Sustitución de los segmentos del pistón
y los anillos guía” en la página 94
Reemplazar las válvulas Personal especializado

tución de las válvulas” “ en la página 97
Reemplazar el descargador de la válvula de suc- Personal especializado

ción Apartado Error! Reference source not found.
“Sustitución del descargador de la válvula de succión” en
la página 105
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7.3 Preparación para los trabajos de mantenimiento

Antes de poder llevar a cabo determinadas tareas de mantenimiento,

el compresor alternativo tiene que encontrarse en un estado de segu-
ridad. Las respectivas partes de estas instrucciones atienden direc-
tamente a este requisito.
1. El compresor alternativo y la bomba de aceite tienen que perma-

necer quietos  Apartado Error! Reference source not found.
2. Asegure el motor de accionamiento para evitar que vuelva a acti-

varse.
¡ADVERTENCIA! ¡Riesgo de lesiones mortales a causa de una
ecualización de presión no controlada!
- Despresurice el compresor alternativo antes de llevar a cabo
algún trabajo.
- Descargue toda energía residual.
- Cuando comprima gases tóxicos o explosivos, inertice los
componentes del compresor alternativo.
El compresor alternativo soporta gas de proceso a altas temperatu-
ras durante su funcionamiento. Si las tapas de las aperturas de
instalación se destapan antes de que se haya producido la ecuali-
zación de la presión, pueden causarse lesiones graves.
3. Despresurice todos los componentes del compresor alternativo
7.4 Trabajo de mantenimiento

7.4.1 Revisión de fugas en el sistema de lubricación
Revisar la presión del aceite Personal:  Usuario

 Gafas de seguridad
 Casco protector
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1. Compruebe todos los oleoductos del sistema de lubricación y las

conexiones exteriores del compresor a causa de las fugas.
2. Compruebe la presión del aceite en el indicador de presión de

aceite del compresor.
Si la presión del aceite es demasiado baja, deberá comprobarse el

aceite para confirmar que está en buen estado.
Revisión de la bomba de aceite Personal:  Personal especializado

 Casco protector
1. Apague el compresor alternativo  Apartado Error! Reference

source not found. “Apagado” en la página 63 y asegure el man-
do del motor para evitar que vuelva a activarse.
2. Despresurice todos los componentes del compresor alternativo.
3. Compruebe que la bomba de aceite esté en buen estado.
¡ADVERTENCIA! ¡Riesgo de explosión a causa de lubrica-

ciones mal realizadas!
- Si la bomba de aceite está en mal estado, cámbiela ur-
gentemente por otra nueva.
Si la bomba de aceite está en mal estado, existe un riesgo de
explosión por una lubricación incorrecta.
Revisión de los conductos en el Personal:  Personal especializado

sistema de lubricación externo
 Casco protector
En caso de escapes en los conductos del sistema de lubricación ex-
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terno, tome las siguientes medidas:
1. Coloque un contenedor de recogida bajo el escape .
2. Extraiga el aceite mediante el vaciado de aceite y acumúlelo.
3. Elimine el aceite de un modo respetuoso con el medio ambiente.
4. Compruebe todas las conexiones y bridas de unión.
5. Si se tienen que cambiar componentes del sistema de lubrica-

ción, desconecte la bomba de aceite.
6. Sustituya los componentes en mal estado.
7. Ajuste todas las conexiones por tornillo.
Revisión del sistema de lubricación Personal:  Personal especializado

en el interior del compresor alter-
nativo.
 Protector respiratorio
 Casco protector
¡PRECAUCIÓN! ¡Riesgo de lesiones por neblinas de aceite!

- Cuando trabaje en el sistema de lubricación y en el caso de
que se produzcan neblinas de aceite, lleve siempre protección
respiratoria y para la vista y asegúrese de que hay entrada de
aire fresco.
Las altas temperaturas o la nebulización mecánica pueden generar
neblinas de aceite. Las neblinas de aceite pueden irritar los ojos y
las vías respiratorias.
1. Afloje las tuercas que ajustan las tapas de las aperturas de insta-
lación.
¡ADVERTENCIA! ¡Riesgo de lesiones por la caída de las cu-
biertas de la apertura de instalación!
- Las tapas en las aperturas de instalación se tienen que instalar
y retirar con la ayuda de una segunda persona siempre que sea
posible. Si es necesario, utilice las herramientas adecuadas.
(p.ej. una grúa).
- Cuando realice el trabajo, lleve siempre la ropa y el equipa-
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miento de seguridad personal estipulado.

Las tapas de las aperturas de instalación pueden ser pesadas. En
caso de caerse, pueden provocar lesiones graves.
2. Retire las tapas de las aperturas de instalación de los tornillos de

ajuste.
3. Encienda la bomba de aceite.
4. Revise visualmente los componentes del sistema de lubricación

dentro del compresor alternativo para comprobar si hay fugas.
¡ADVERTENCIA! ¡Riesgo de explosión a causa de una
lubricación incorrecta!
- Sustituya los componentes en mal estado por otros nue-
vos.
En caso de fuga, existe un riesgo de explosión a causa de la
lubricación inadecuada.
Sustitución de los componentes 1. Desactive la bomba de aceite.

del sistema de lubricación
2. Sustituya los componentes dañados del sistema de lubricación
por otros nuevos.
3. Reactive la bomba de aceite para comprobar si existen fugas en

el sistema de lubricación.
4. Asegúrese de que no se producen más fugas.
5. Desactive la bomba de aceite.

¡ADVERTENCIA! ¡Riesgo de lesiones por la caída de las
tapas de la apertura de instalación!
- Las tapas en las aperturas de instalación se tienen que instalar
y retirar con la ayuda de una segunda persona siempre que sea
posible. Si es necesario, utilice las herramientas adecuadas.
(p.ej. una grúa).
Las tapas de las aperturas de instalación pueden ser pesadas.
En caso de caerse, pueden provocar lesiones graves.
6. Vuelva a colocar las tapas en las aperturas de instalación.
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7. Encienda la bomba de aceite.
8. Deje que la bomba de aceite funcione con el compresor alternati-

vo apagado durante 30 minutos.
 El aceite se distribuye por todos los puntos de lubricación.
9. Encienda el compresor alternativo Apartado Error! Reference

source not found. "Encendido” en la página 63.
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7.4.2 Comprobación del nivel de aceite en la unidad de accionamiento
Personal:  Usuario

 Casco protector
¡ADVERTENCIA! ¡Riesgo de lesiones si el nivel de aceite en la
unidad de accionamiento es demasiado bajo!
Asegúrese de que el nivel de aceite se encuentra siempre en-
tre las marcas de mínimo y máximo del nivel de aceite.
Si los cojinetes del compresor alternativo se calientan porque el
nivel de aceite es demasiado bajo, existe un riesgo de explosión.
¡AVISO! ¡Riesgo de daños materiales si el nivel de aceite en la

unidad de accionamiento es demasiado bajo!
- Asegúrese de que el compresor alternativo no está funcionando
con un nivel de aceite demasiado bajo. Si el nivel es demasiado
bajo, desconecte el compresor alternativo inmediatamente.
- Llene de aceite la unidad de accionamiento hasta el tope me-
diante la boquilla de llenado de aceite según los pasos descri-
tos en este manual.
Si el nivel de aceite en la unidad de accionamiento es demasiado
bajo, los cojinetes y otras piezas flotantes de la unidad de accio-
namiento recibirán una cantidad de aceite dentro de la unidad de
accionamiento demasiado baja. Esto puede provocar daños consi-
derables en los componentes.
1. Lea el nivel de aceite en el vidrio de inspección de aceite del

alojamiento del cigüeñal mientras el compresor alternativo está
en funcionamiento.
Fig. 25: Comprobación del nivel de aceite
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Si el nivel de aceite no se encuentra entre las marcas "H"

(Fig. 25/1) y "L" (Fig. 25/2), reponga de aceite hasta el tope.
 Apartado 7.4.3 “Reponer el aceite de la unidad de accionamien-
to” en la página 82.
7.4.3 Reponer el aceite de la unidad de accionamiento

 Casco protector
¡AVISO! ¡Riesgo de daños medioambientales a causa de escapes
de aceite en la unidad de accionamiento!
- Tenga siempre suficiente cantidad de aglomerante de aceite al
alcance.
- Si se producen escapes de aceite en la unidad de accionamien-
to, informe a los servicios de bomberos urgentemente.
Los escapes de aceite en la unidad de accionamiento durante el
cambio de aceite contaminan el medio ambiente.
1. Prepare los trabajos de mantenimiento  Apartado Error! Refer-

ence source not found. “Preparación para el trabajo de mante-
nimiento” en la página 76.
No es necesario despresurizar el compresor alternativo.
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Vaciar el aceite de la unidad de

accionamiento
Fig. 26: Unidad de accionamiento
2. Coloque un contenedor de recogida bajo la apertura del vaciado

de aceite (Fig. 26/3) del alojamiento del cigüeñal.
Observe el volumen mínimo del contenedor  Apartado Error!

Reference source not found. „Error! Reference source not
found.“ en la página Error! Bookmark not defined..
3. Quite la pestaña y el cierre del vaciado de aceite y guárdelos de

forma segura.
 El aceite de la unidad de accionamiento cae dentro del conte-

nedor de recogida.
Reponer el aceite de la unidad de 4. Ponga el cierre y la pestaña a la apertura del vaciado de aceite
accionamiento (Fig. 26/3).
5. Revise el vidrio de inspección de aceite (Fig. 26/2) de daños o

escapes.
6. Quite el tapón de la boquilla de llenado de aceite (Fig. 26/1).
¡ADVERTENCIA! ¡Riesgo de explosión por una lubricación in-
suficiente!
- Reponga con suficiente aceite de manera que el nivel se sitúe
entre las marcas de mínimo y máximo.
Si no se rellena con la cantidad de aceite suficiente, existe un ries-
go de explosión, a causa de una lubricación inadecuada.
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7. Rellene de aceite la unidad de accionamiento hasta que el nivel

en el vidrio de inspección de aceite alcance la marca "H"
(Fig. 27/1).
8. Vuelva a colocar el tapón en la boquilla de llenado de aceite.

(Fig. 26/1).
Fig. 27: Vidrio de inspección de aceite
7.4.4 Sustitución de la junta del colector de aceite

 Casco protector
Herramienta especial:  Cono protector
Para cambiar la junta del colector de aceite el vástago del pistón tiene
que desajustarse de la cruceta y retirarse.
1. Preparación para el trabajo de mantenimiento  Apartado Error!

Reference source not found. “Preparación para el trabajo de
mantenimiento” en la página 76.
Sustitución de la junta del colector ¡ADVERTENCIA! ¡Riesgo de lesiones por la caída de cubiertas
de aceite de las aperturas de instalación!
- Las cubiertas de las aperturas de instalación se tienen que ins-
talar y retirar, a ser posible, con la ayuda de otra persona. Si es
necesario, utilice las herramientas adecuadas (p.ej. una grúa).
Las tapas de las aperturas de instalación pueden ser muy pesa-
das. Si se caen, pueden producir lesiones graves.
2. Retire las tapas de las aperturas de instalación.
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3. Gire el compresor alternativo manualmente o con un dispositivo

de manera que el pistón quede posicionado en el punto muerto
superior.  Apartado 5.5 “Rotación del compresor alternativo” en
la página 65.
¡ADVERTENCIA! ¡Riesgo de intoxicación en caso de una reti-

rada inadecuada!
- Proceda siempre con cuidado al realizar la retirada.
- Sustituya los componentes o superficies de estanqueidad da-
ñados durante la retirada.
Si las superficies de estanqueidad quedan dañadas, existe un rie-
go de intoxicación a causa de posibles fugas.
4. Desatornille y retire las tuercas de los tornillos de ajuste en la

cubierta del cilindro y déjelas en lugar seguro.
5. Afloje la tapa del cilindro con los tornillos de elevación.
6. Amarre la cubierta del cilindro a la grúa usando mecanismos

elevadores diseñados para el peso de la cubierta del cilindro.
7. Retire la cubierta del cilindro.

8. Desajuste la conexión vástago del pistón – cruceta.
 Apartado 7.4.10 “Desmontaje y montaje conexión vástago del
pistón – cruceta” en la página 107.
9. Extraiga el pistón con la biela de manera que se exponga la junta

del colector de aceite.
10. Desajuste y retire las tuercas de la tapa de ajuste y guárdelas de
forma segura.
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Fig. 28: Sustitución de la junta del colector de aceite
11. Retira la tapa (Fig. 28/1) y el cierre tórico. (Fig. 28/2).
12. Retire las piezas internas de la junta del colector de aceite

(Fig. 28/3), incluyendo la superestructura correspondiente
(Fig. 28/4), al alojamiento (Fig. 28/5).
 Las piezas internas de la junta del colector de aceite se pue-

den reemplazar.
Sustitución de los elementos de NOTICE! ¡Riesgo de daños materiales a causa de una instalación
sellado incorrecta!
- Asegúrese de que los anillos están posicionados adecuada-
mente. (Fig. 29).
- Durante la instalación, asegúrese de que las escobillas en los
anillos de estanquidad señalan a la unidad de accionamiento.
- Asegúrese de que la anilla de ajuste está posicionada correc-
tamente.
Si la junta del colector de aceite no se instala correctamente, no
funcionará de forma adecuada, por lo que existe el riesgo de que
se produzcan daños en el compresor alternativo.
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Fig. 29: Sustitución de los anillos de sellado y anillos raspadores
13. Inserte dos nuevos anillos raspadores (Fig. 29/4+5) en la super-

estructura (Fig. 29/3).
14. Inserte el anillo de sellado (Fig. 29/2) en la cámara (Fig. 29/1).
Instalación de la junta del colector

de aceite
Fig. 30: Junta del colector de aceite, instalación
15. Inserte la superestructura (Fig. 30/4) con las piezas internas

(Fig. 30/3) en el alojamiento (Fig. 30/5).
16. Inserte el aro tórico (Fig. 30/2) dentro de la tapa (Fig. 30/1).
17. Ajuste la tapa (Fig. 30/1).
18. Coloque y apriete las tuercas de la tapa.
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Fig. 31: Colocación del cono de protección
19. Enrosque el cono de protección (Fig. 31/2) hasta la fijación del

vástago (Fig. 31/1).
20. Empuje con cuidado la biela (Fig. 31/1) a través de la nueva junta
del colector de aceite justo hasta antes de la cruceta.
21. Retire el cono protector (Fig. 31/2).
22. Restablezca la conexión vástago del pistón - cruce-

ta  Apartado 7.4.10 “Desmontaje y montaje conexión vástago
del pistón – cruceta” en la página 107.
23. Repare la tapa de instalación con cierres.
24. Ajuste la tapa del cilindro.
25. Ajuste y apriete las tuercas de la cubierta del cilindro.

 Apartado Error! Reference source not found. „Error! Refer-
ence source not found. “ en la página Error! Bookmark not
defined..
7.4.5 Sustitución de la junta de separación intermedia

 Casco protector
Herramientas especiales:  Dispositivo de ajuste hidráulico

 Dispositivo de instalación
 Cono protector
¡AVISO! ¡Riesgo de daños materiales a causa de una reutilización
y una reparación de forma no apropiada de la junta de separación
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intermedia!
- La revisión y la reparación debe llevarla a cabo únicamente el
fabricante.
Si la junta de separación intermedia se reutiliza o repara de forma
incorrecta, se pueden causar daños materiales considerables en el
compresor alternativo y sus componentes.
El NEAC, el departamento del Servicio Post-Venta, decide si la junta

de separación intermedia se puede r eutilizar o reparar.
De no ser así, la junta de separación intermedia debe ser reemplaza-
da. Para hacerlo, la biela tiene que desajustarse de la cruceta y reti-
rar.
1. Prepare el trabajo de mantenimiento  Apartado Error! Refer-

Extracción de la junta de ¡ADVERTENCIA! ¡Riesgo de lesiones por la caída de las

separación intermedia cubiertas de las aperturas de instalación!
- Las cubiertas de las aperturas de instalación deben de ser ins-
taladas y retiradas con la ayuda de otra persona, a ser posible.
Si es necesario, hay que utilizar herramientas adecuadas (p.ej.,
una grúa)
- Cuando realice el trabajo lleve siempre la ropa y el equipamien-
to de seguridad personal estipulado.
Las cubiertas en las aperturas de instalación pueden ser muy pe-
sadas. Si se caen, pueden producir lesiones graves.
2. Retire las cubiertas de las aperturas de instalación.
3. Gire el compresor alternativo manualmente o con la ayuda de un

dispositivo de manera que el pistón quede posicionado en el
punto muerto superior.  Apartado 5.5 “Rotación del compresor
alternativo” en la página 65.
¡ADVERTENCIA! ¡Riesgo de asfixia por fugas de nitrógeno!
- Apague el suministro de nitrógeno y asegúrese de que existe
una entrada suficiente de aire fresco.
- En caso de duda utilice un aparato respiratorio.
Si sale el nitrógeno, existe riesgo de asfixia.
4. Desconecte el conducto de transporte de N2 de la base.
5. Afloje y retire las tuercas de los tornillos de ajuste en la cubierta
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del cilindro y guárdelas de forma segura.
6. Desajuste la cubierta del cilindro con los tornillos de elevación.
7. Amarre la cubierta del cilindro a la grúa utilizando mecanis mos

elevadores diseñados para el peso de la cubierta del cilindro.
9. Desajuste la conexión vástago del pistón – cruceta

10. Retire el pistón con la biela de manera que la fijación del vástago
quede posicionada justo debajo del empaque de presión.
Fig. 32: Eliminación de la junta de separación intermedia
11. Desajuste y retire las tuercas de los tornillos de ajuste (Fig. 32/3)
y guárdelas de forma segura.
12. Quite la junta de separación intermedia (Fig. 32/1) del alojamien-

to (Fig. 32/2).
Instalación de la junta de separa- ¡ADVERTENCIA! ¡Riesgo de lesiones por una instalación inde-
ción intermedia bida!
- Reinserte el aro tórico retirado.
- Asegúrese de que el conducto de salida está conectado ade-
cuadamente.
- Es obligatorio seguir los siguientes pasos.
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En el caso de una instalación incorrecta existe el riesgo de que el

gas de proceso tóxico o nitrógeno entren en la cámara en el lado
de la unidad de accionamiento, lo que podría provocar intoxica-
ción.
13. Inserte la nueva junta de separación intermedia (Fig. 32/1).
14. Coloque y apriete las tuercas de los tornillos de sujeción.

 Apartado Error! Reference source not found. “Juntas em-
pernadas” en la página 145.
15. Conecte el conducto de transporte de N2.
Fig. 33: Ajuste del cono protector
16. Atornille el cono protector (Fig. 33/2) hasta la fijación del vástago
(Fig. 33/1).
17. Empuje delicadamente la biela (Fig. 33/1) a través de la nueva

junta de separación intermedia y junta del colector de aceite has-
ta justo antes de la cruceta.
19. Restablezca la conexión vástago del pistón – cruceta

20. Recoloque la tapa de instalación con sellos.
21. Ajuste la cubierta del cilindro.
22. Ajuste y apriete las tuercas de los tornillos de la cubierta del ci-
lindro Apartado Error! Reference source not found. “Juntas
empernadas” en la página 145.
7.4.6 Sustitución del empaque de presión
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 Casco protector
Herramientas especiales:  Dispositivo de ajuste hidráulico

 Cono protector
¡ADVERTENCIA! ¡Riesgo de lesiones a causa del peso!

- Instale y retire siempre la biela con cuidado y esté atento a
otras piezas que pudieran caer al hacerlo.
- Lleve siempre la ropa y el equipamiento de seguridad personal
necesario.
Dependiendo de la presión, el empaque de presión puede ser muy
largo o comprender diferentes partes conectadas. Puede ser muy
pesado y moverse bajo la influencia de la gravedad, lo cual puede
provocar lesiones graves.
¡AVISO! ¡Riesgo de daños materiales a causa de la reutilización o

reparación del empaque de presión!
- En la reutilización y reparación solo puede trabajar el NEAC, el
departamento del Servicio Post-Venta.
Si el empaque de presión se utiliza de un modo incorrecto, se pue-
den producir daños materiales considerables sobre el compresor
alternativo y sus componentes.
El NEAC, el departamento del Servicio Post-Venta decide si el em-

paque de presión se puede reutilizar o reparar.
De no ser así, el empaque de presión deberá ser sustituido. Para ello,
deberán extraerse el pistón y la biela.

ence source not found.
“Preparación para el trabajo de mantenimiento” e n la página 76.
Retirada del empaque de presión ¡ADVERTENCIA! ¡Riesgo de lesiones por la caída de las tapas
de las aperturas de instalación!
- Las cubiertas de las aperturas de instalación deben de ser ins-
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taladas y retiradas con la ayuda de otra persona, a ser posible.

Si es necesario, hay que utilizar herramientas adecuadas (p.ej,
una grúa).
Las cubiertas en las aperturas de instalación pueden ser muy pe-
sadas. Si se caen, pueden producir lesiones graves.
2. Retire las cubiertas de las aperturas de instalación

punto muerto superior Apartado 5.5 “Rotación del compresor
¡ADVERTENCIA! ¡Riesgo de intoxicación en caso de una reti-

rada inadecuada!
- Proceda siempre con prudencia durante la retirada.
- Sustituya los componentes y las superficies de estanqueidad
que hayan sido dañadas durante la retirada.
Si las superficies de estanqueidad quedan dañadas durante la reti-
rada, existe un riesgo de intoxicación por posibles fugas.

del cilindro y guárdelas de forma segura.
5. Desajuste la tapa del cilindro con los tornillos de elevación.
6. Amarre la cubierta del cilindro a la grúa utilizando mecanismos

de elevación apropiados al peso de la cubierta del cilindro.
7. Retire la tapa del cilindro.
8. Desajuste la conexión vástago del pistón - cruceta

9. Saque el pistón, de manera que la fijación del vástago quede
justo enfrente de la junta del colector de aceite.
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Fig. 34: Cono protector
(Fig. 34/1).
11. Utilice un mecanismo elevador diseñado para el peso para am a-

rrar el pistón con la biela a una grúa  Apartado Error! Refer-
ence source not found. “Pesos de los componentes” en la pá-
gina 141.
12. Retroceda el pist ón con la biela de manera que la fijación del

vástago quede posicionada justo debajo del empaque de pre-
sión.
13. Desconecte todos los tubos de la brida de fijación del empaque

de presión.
Si es necesario, retire también las piezas de los tubos.
Fig. 35: Retirada del empaque de presión
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14. Afloje y quite las tuercas (Fig. 35/1) de los tornillos de ajuste
(Fig. 35/3) y guárdelas de forma segura.
15. Retire el empaque de presión (Fig. 35/2) del cilindro.
Instalación del empaque de presión ¡ADVERTENCIA! ¡Riesgo de lesiones por una instalación inco-
rrecta!
- Reinserte el aro tórico retirado.
- Es obligatorio seguir los siguientes pasos.
En caso de no realizar la instalación correctamente existe el riesgo
de que el proceso gas tóxico o el nitrógeno entren en el distancia-
dor exterior, lo que podría provocar una intoxicación.
16. Inserte el nuevo empaque de presión (Fig. 35/2).
17. Coloque las tuercas (Fig. 35/1) en los tornillos de ajuste

(Fig. 35/3) y ajústelas gradualmente equitativamen-
te Apartado Error! Reference source not found. “Juntas
¡ADVERTENCIA! ¡Riesgo de lesiones por la mezcla de tubos!
- Mueva el empaque de presión hacia su posición original de
modo que las secciones de los tubos prefabricados encajen con
las conexiones en la brida de fijación.
- Compruebe que los tubos están colocados de forma adecuada.
Si confunde los tubos durante la instalación, el gas podría salir ex-

pedido de modo incontrolado y puede causar lesiones graves o
incluso mortales.
18. Recoloque los tubos en la brida de fijación.
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19. Inserte con cuidado el pistón y la biela (Fig. 36/1) en la máquina

con el cono protector (Fig. 36/2) y ajuste.
21. Establezca la conexión vástago del pistón - cruce-

ta  Apartado 7.4.10 “Desmontaje y montaje conexión vástago
22. Instale las tapas de instalación y los sellos.
23. Coloque la tapa del cilindro.
24. Coloque y ajuste las t uercas a los tornillos de la cubierta del ci-
lindro  Apartado Error! Reference source not found. “Juntas
7.4.7 Sustitución de los segmentos de pistón y anillos guía
Personal:  Personal especialista

 Casco protector
Herramienta especial:  Dispositivo de ajuste hidráulico

 Cono protector
Para poder reemplazar los segmentos de pistón y los anillos guía, la

biela y el pistón tienen que ser retirados.
1. Prepare el trabajo de mantenimiento Apartado Error! Refer-

Extracción del pistón y el vástago ¡ADVERTENCIA! ¡Riesgo de lesiones por la caída de las tapas
del pistón de la apertura de instalación!
- Las tapas de las aperturas de instalación deben de ser instala-
das y retiradas con la ayuda de otra persona, a ser posible. Si
es necesario, hay que utilizar herramientas adecuadas (p.ej.,
una grúa).
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Las tapas en las aperturas de instalación pueden ser muy pesa-

das. Si se caen, pueden producir lesiones graves.
2. Retire las cubiertas de las aperturas de instalación

punto muerto superior Apartado 5.5 “Rotación del compresor
¡ADVERTENCIA! ¡Riesgo de intoxicación en si la retirada no se

realiza adecuadamente!
- Proceda siempre con cuidado durante la retirada.
- Sustituya los componentes o superficies de estanqueidad que
hayan quedado dañadas durante la retirada.
Si durante la retirada superficies de estanqueidad quedan dañadas
existe un riesgo de intoxicación a causa de fugas.

del cilindro y guárdelas de formas segura.
5. Suelte la cubierta del cilindro con los tornillos de elevación.
6. Amarre la cubierta del cilindro a la grúa utilizando mecanismos

elevadores apropiados al peso de la cubierta del cilindro.
8. Desajuste la conexión del vástago de pistón - cruce-

ta Apartado 7.4.10 “Desmontaje y montaje conexión vástago
9. Saque el pistón, de manera que la fijación del vástago quede

posicionada justo enfrente de la junta del colector de aceite.
(Fig. 37/1).
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11. Utilice mecanismos elevadores apropiados al peso para amarrar

el pistón con la biela a una grúa  Apartado Error! Reference
source not found. “Pesos de los componentes” en la página
141.
12. Retire el pistón con la biela del compresor alternativo y déjelos
sobre bloques en V adecuados.
13. Limpie la biela.
14. Compruebe que no se hayan producido daños en la biela
En caso de daños contacte con el NEAC, el departamento del Ser-

vicio Post-Venta.
15. Mida el diámetro de la superficie de rodadura.
Determine el diámetro mínimo permitido  Apartado 12.7

“Dimensiones y límites de desgaste para las secciones del
compresor” en la página 147.
16. Compruebe que no se hayan producido daños en la superficie de

rodadura.
En caso de daños contacte con el NEAC, departamento de servicio

postventa.
17. Mida el diámetro de la perforación del cilindro.
Determine el máximo de diámetro permitido Apartado 12.7 “Di-

mensiones y límites de desgaste para las secciones del compre-
sor” en la página 147.
18. Desdoble las ranuras en el pistón y quite los segmentos del pis-
tón de PTFE.
Determine los valores de desgaste permitidos  Apartado 12.7

“Dimensiones y límites de desgaste para las secciones del com-
presor” en la página 147.
¡AVISO! ¡Riesgo de daños materiales a causa de las ranuras del
segmento de pistón que no se ajustan a las dimensiones o no se
han adaptado adecuadamente!
Las inspecciones, adaptaciones y reparaciones solo deben realizar
las el NEAC, el departamento de Servicio Post-Venta.
Las ranuras en los segmentos de pistón pueden provocar daños
considerables al compresor alternativo y sus componentes.
19. Compruebe y limpie las ranuras de los segmentos de pistón. Si

es necesario, consulte con el NEAC, el departamento del Servi-
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cio Post-Venta.
Cambio de los anillos de sellado y 20. Con cuidado desdoble los nuevos anillos guía y de sellado de
anillos guía PTFE, póngalos sobre el pistón y métalos en las ranuras provis-
tas.
Si los segmentos de pistón son demasiado rígidos o demasiado

pequeños de diámetro y por tanto no pueden desdoblarse, calién-
telos en agua caliente.
Instalación del pistón y la biela
21. Inserte cuidadosamente el pistón y la biela (Fig. 38/1) en la má-

quina y enrosque el cono protector (Fig. 38/2).
23. Establezca la conexión vástago del pistón – cruceta

24. Instale las tapas de instalación y las juntas.
25. Coloque la tapa del cilindro.
26. Coloque y ajuste las tuercas a los tornillos de la cubierta del ci-
lindro Apartado Error! Reference source not found. “Juntas
7.4.8 Sustitución de las válvulas

7.4.8.1 Sustitución de las válvulas de succión

 Casco protector
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¡AVISO! ¡Riesgo de daños materiales si se adapta o repara la vál-

vula de modo indebido!
- La adaptación o reparación puede ser realizada únicamente
por el NEAC, el departamento del Servicio Post-Venta.
Si los componentes de las válvulas se adaptan o reparan de modo
inadecuado, se pueden producir daños materiales considerables
sobre el compresor alternativo y sus componentes.

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Eliminación de las válvulas de ¡ADVERTENCIA! ¡Riesgo de intoxicación en caso de una elimi-

succión nación inadecuada!
- Proceda siempre con precaución.
- Sustituya los componentes y superficies de estanqueidad que
hayan sido dañadas durante la eliminación.
Si se dañan superficies de estanqueidad durante la retirada, existe
un riesgo de intoxicación por fugas.
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2. Afloje y retire las tuercas ciegas (Fig. 39/3) y cierres (Fig. 39/2) y
guárdelos en un lugar seguro.
3. Afloje los tornillos de presión (Fig. 39/1) en la tapa de la válvula

de succión (Fig. 39/5).
4. Afloje y retire las tuercas (Fig. 39/4) de los tornillos de la tapa de

la válvula (Fig. 39/9) y guárdelas de forma segura.
¡ADVERTENCIA! ¡Riesgo de lesiones por la caída de compo-
nentes!
- Los componentes deberían instalarse y retirarse con la ayuda
de otra persona, siempre que sea posible. Si es necesario, utili-
ce las herramientas adecuadas (p.ej. una grúa).
Las tapas a de la válvula, las cajas de la válvulas y las propias vál-
vulas pueden ser muy pesadas dependiendo del tamaño. Si se
caen, pueden causar lesiones graves.
5. Retire con cuidado la tapa de la válvula de succión (Fig. 39/5) de

la apertura de la válvula.
6. Compruebe que las superficies de cierre (tapa de la válvula y

cilindro) no hayan sufrido daños.
Fig. 39: Extracción de las válvulas de

succión (Ilustración ejemplo)
Rectifique las superficies de la tapa de la válvula antes de la reins-

talación.
7. Quite el anillo de retención (Fig. 39/6) de la apertura de la válvu-

la.
2010-08-31 109
NEA USA 291007 / No. Ser. 108399
8. Saque la caja de la válvula de succión (Fig. 39/7).
9. Retire la válvula de succión (Fig. 39/8) del asiento de la válvula.
10. Asegúrese de que la válvula, el asiento de la válvula y la caja de

la válvula no hayan sufrido daños.
Si una válvula está dañada, reemplácela antes de la reinstalación.

Rectifique el asiento dañado de una válvula antes de la reinstala-
ción.
Si una caja de la válvula está dañada reemplácela antes de la re-
instalación.
Instalación de válvulas de succión ¡AVISO! ¡Riesgo de daños materiales a causa de componentes

dañados!
- Instale únicamente componentes en buen estado e intactos en
el cilindro.
- Sustituya o repare los componentes dañados.
Si se instalan componentes dañados o en mal estado, se puede
causar un gran daño material al compresor alternativo y a sus
componentes.

nentes!
- Los componentes se deberían instalar y retirar con la ayuda de
otra persona siempre que sea posible. Si es necesario, utilice
las herramientas adecuadas (p.ej una grúa).
- Cuando esté trabajando lleve siempre la ropa y el equipamiento
de seguridad personal estipulado.
Las tapas de la válvula, las cajas de la válvula, y las mismas válvu-
las pueden ser muy pesadas dependiendo del tamaño. Si se caen
pueden provocar lesiones graves.
110 2010-08-31
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11. Inserte la válvula de succión con cuidado (Fig. 40/8) en la aper-

tura de la válvula de succión/el asiento de la válvula en el cilin-
dro.
12. Inserte la caja de la válvula de succión (Fig. 40/7) en la apertura

de la válvula de succión en el cilindro.
13. Inserte el anillo de retención (Fig. 40/6) en la ranura.
14. Ponga con cuidado la tapa de la válvula de succión (Fig. 40/5).
15. Ponga las tuercas (Fig. 40/4) en los tornillos de la tapa de la vál-
vula (Fig. 40/9) y ajústelas con una llave de ajuste. Siga el valor
del par de torsión estipulado al hacerlo  Apartado Error! Ref-
erence source not found. “Juntas empernadas” en la pági-
na 145.
16. Ajuste los tornillos de presión (Fig. 40/1) en la tapa de la válvula

(Fig. 40/5) con una llave de ajuste. Siga el valor del par de ten-
sión “Juntas empernadas” en la página 145.
17. Ponga los cierres (Fig. 40/2) y tuercas ciegas (Fig. 40/3).
18. Ajuste las tuercas ciegas (Fig. 40/3) con una llave de ajuste.
Siga el valor del par de torsión estipulado al hacerlo
 Apartado Error! Reference source not found. “Juntas e m-
19. Compruebe el par de torsión de las tuercas (Fig. 40/4) en los

tornillos de la tapa de la válvula (Fig. 40/9) y ajústelas con una
llave de ajuste si es necesario.

succión (ilustración ejemplo)
7.4.8.2 Sustitución de las válvulas de descarga
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NEA USA 291007 / No. Ser. 108399

 Casco protector
Herramienta especial:  Dispositivo de instalación

¡AVISO! ¡Riesgo de daños materiales a causa de la adaptación o
reparación incorrecta de la válvula!
- La adaptación y la reparación debe realizarla exclusivamente
el NEAC, el departamento de Servicio Post-Venta.
Si los componentes de las válvulas están adaptados o reparados
de un modo inadecuado, se pueden causar daños materiales con-
siderables al compresor alternativo y sus componentes.
Extracción de las válvulas de des- 1. El compresor alternativo y la bomba de aceite tienen que perma-
carga necer parados Apartado Error! Reference source not found.
2. Asegure el motor de accionamiento para evitar que vuelva a acti-

varse.
¡ADVERTENCIA! ¡Riesgo de lesiones mortales debido a una

ecualización de la presión no controlada!
cualquier tarea.
- Descargue cualquier energía residual.
- Cuando comprima gases explosivos o tóxicos, inertice los com-
ponentes del compresor alternativo.
El compresor alternativo contiene gas a alta presión durante su
funcionamiento. Si las tapas de las aperturas de instalación se
abren antes de que se haya ecualizado la presión pueden produ-
cirse lesiones graves.
¡ADVERTENCIA! ¡Riesgo de intoxicación en caso de una

extracción inadecuada!
- Proceda siempre con precaución.
- Sustituya los componentes o superficies de estanqueidad que
hayan sido dañadas durante la extracción.
112 2010-08-31
NEA USA 291007 / No. Ser. 108399
Si durante la extracción resultan dañadas superficies de estan-

queidad, existe riesgo de intoxicación a causa de las fugas.
4. Afloje y retire las tuercas ciegas (Fig. 41/7) y cierres (Fig. 41/8) y
guárdelas de forma segura.
5. Afloje los tornillos de presión (Fig. 41/9) en la tapa de la válvula

de descarga (Fig. 41/5).
6. Afloje y retire las tuercas (Fig. 41/6) de los tornillos de la tapa de

la válvula (Fig. 41/1) y guárdelas de forma segura.
nentes!
- Cuando instale o extraiga la válvula de descarga utilice el dis-
positivo de instalación.
- Los componentes deben instalarse con la ayuda de otra perso-
na siempre que sea posible. Si es necesario, utilice herramien-
tas adecuadas (p.ej. una grúa)
- Lleve siempre la ropa y el equipamiento de seguridad personal
estipulado cuando esté realizando la tarea.
Las tapas de la válvula, las cajas de la válvula, y las propias
válvulas pueden ser muy pesadas dependiendo del tamaño. Si
se caen, pueden provocar lesiones graves.
7. Retire la tapa de la válvula (Fig. 41/5) de la apertura de la válvu-

la.
8. Compruebe que las superficies de estanqueidad de la válvula

(tapa de la válvula y cilindro) no hayan sufrido daños.

descarga
Rectifique las superficies la de tapa de la válvula dañada antes de

la reinstalación.
9. Retire el anillo de retención (Fig. 41/4) de la apertura de la válvu-

la.
10. Quite la caja de la válvula de descarga (Fig. 41/3) y la válvula de

descarga (Fig. 41/2) de la apertura de la válvula.
11. Asegúrese de que la válvula, el asiento de la válvula y la caja de

la válvula no hayan sufrido daños.
2010-08-31 113
NEA USA 291007 / No. Ser. 108399
Si la válvula está dañada remplácela antes de la reinstalación.

Rectifique el asiento dañado de la válvula antes de la reinstalación.
Si la caja de la válvula está dañada remplácela antes de la reinsta-
lación.
Instalación de las válvulas de des- ¡ADVERTENCIA! ¡Riesgo de lesiones por la caída de com-
carga ponentes!
- Cuando instale o retire la válvula utilice siempre el dispositivo
de instalación.
- Los componentes se deberían instalar y retirar con la ayuda de
otra persona siempre que sea posible. Si es necesario, utilice
las herramientas adecuadas (p.ej una grúa).
- Cuando esté trabajando lleve siempre la ropa y el equipamiento
de seguridad personal estipulado.
Las tapas de la válvula, las cajas de la válvula, y las mismas válvu-
las pueden ser muy pesadas dependiendo del tamaño. Si se caen
pueden provocar lesiones graves. .
¡AVISO! ¡Riesgo de daños materiales a causa de componentes

dañados!
el cilindro.
Si se instalan componentes dañados o en mal estado, se pueden
causar daños materiales considerables al compresor alternativo y
sus componentes.
114 2010-08-31
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12. Inserte la válvula de descarga (Fig. 42/2) dentro de la caja de la

válvula de descarg a (Fig. 42/3).
13. Inserte la caja de la válvula de descarga (Fig. 42/3) con la válvula

de descarga (Fig. 42/2) dentro de la apertura de la válvula en el
cilindro.
14. Inserte el anillo de retención (Fig. 42/4) dentro de la ranura de la
apertura de la válvula.
15. Ponga con cuidado la tapa de la válvula de descarga (Fig. 42/5).
16. Ponga las tuercas (Fig. 42/6) en los tornillos de la tapa de la vál-
vula (Fig. 42/1) y ajústelas con una llave de ajuste. Siga el valor
del par de torsión estipulado al hacerlo  Apartado Error! Ref-
erence source not found. “Juntas empernadas” en la pági-
na 145.
17. Ajuste los tornillos de presión (Fig. 42/9) en la tapa de la válvula

(Fig. 42/5) con una llave de ajuste. Siga el valor del par de tor-
sión estipulado al hacerlo  Apartado Error! Reference source
not found. “Juntas empernadas” en la página 145.
18. Ponga los cierres (Fig. 42/8) y las tuercas ciegas (Fig. 42/7).
19. Ajuste las tuercas ciegas (Fig. 42/7) con una llave de ajuste. Siga
el valor del par de torsión estipulado al hacerlo
 Apartado Error! Reference source not found. “Juntas e m-
20. Compruebe el par de tensión de las tuercas (Fig. 42/6) en los

tornillos de la tapa de la válvula (Fig. 42/1) y ajústelas con una
llave de ajuste si es necesario.
Fig. 42: Instalación de las válvulas de
descarga.
7.4.9 Sustitución del descargador de la válvula de succión

 Casco protector
¡AVISO! ¡Riesgo de daños materiales a causa de una adaptación o
2010-08-31 115
NEA USA 291007 / No. Ser. 108399
reparación incorrecta del descargador de la válvula de succión!
- La adaptación y la reparación solo puede llevarla a cabo el

NEAC, el departamento del Servicio Post-Venta.
Si el descargador de la válvula de succión se adapta o repara de
forma incorrecta, pueden producirse daños materiales considera-
bles en el compresor alternativo y sus componentes.

Extracción del descargador de la

válvula de succión
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NEA USA 291007 / No. Ser. 108399
2. Desconect e todos los tubos del descargador de la válvula de

succión (Fig. 43/1).
3. Afloje y retire los tornillos de ajuste (Fig. 43/2) y guárdelos de

forma segura.
4. Retire el descargador de la válvula de succión (Fig. 43/1), los

cierres (Fig. 43/3+5, opcional) y la pieza de separación
(Fig. 43/4, opcional) del dispositivo central en la tapa de la válvu-
la de succión. (Fig. 43/6).
5. Compruebe que las piezas del descargador de la válvula de suc-
ción (Fig. 43/1) no hayan sufrido daños.
Fig. 43: Sustitución del descargador de la

válvula de succión (ilustración ejemplo)
Si el descargador de la válvula de succión está dañado cámbielo

antes de la reinstalación.
Remplace las tapas de las válvulas de succión dañadas.
Instalación del descargador de la ¡AVISO! ¡Riesgo de daños materiales por el uso de componentes
válvula de succión dañados!
el cilindro.
Si se instalan componentes en mal estado se pueden causar da-
ños materiales considerables en el compresor alternativo y sus
componentes.
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6. Inserte el cierre (Fig. 44/5, opcional) y la pieza de separación

(Fig. 44/4, opcional) en el dispositivo central de la tapa de la
válvula de succión (Fig. 44/6).
7. Inserte el cierre (Fig. 44/3, opcional) y el descargador de la válvu-

la de succión (Fig. 44/1, opcional) en el dispositivo central de la
pieza de separación (Fig. 44/4).
8. Coloque los tornillos de ajuste (Fig. 44/2) y ajústelos con una

llave de ajuste. Siga el valor del par de torsión estipulado al ha-
cerlo  Apartado Error! Reference source not found. “Juntas
9. Conecte los tubos del descargador de la válvula de succión se-

gún el diagrama de flujo provisto por el fabricante de la planta.
Fig. 44: Sustitución del descargador de la

válvula de succión (ilustración ejemplo)
7.4.10 Desmontaje y montaje de conexión vástago del pistón - cruceta
Desmontaje conexión vástago del Personal:  Personal especializado

pistón – cruceta
 Casco protector
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Siga las instrucciones de funcionamiento provistas por el fabricante

del dispositivo de ajuste hidráulico.
Para completar el trabajo la conexión vástago del pistón - cruceta

debe desajustarse y desmontarse y después se debe montar de nue-
vo. Al hacerlo, proceda de la siguiente manera:

¡ADVERTENCIA! ¡Riesgo de lesiones por la caída de las
tapas de la apertura de instalación!
- Las tapas de las aperturas de instalación deberían instalarse y
retirarse con la ayuda de otra persona siempre que sea posible. Si
es necesario, utilice herramientas adecuadas (p.ej. una grúa).
- Al realizar el trabajo lleve siempre la ropa y el equipamiento de
seguridad personal estipulado.
Las tapas de las aperturas de instalación pueden ser muy pesa-
das. Si se caen pueden ocasionar lesiones graves.
2. Retire las tapas de las aperturas de instalación.
3. Determine el tamaño del dispositivo de ajuste hidráulico necesa-

rio  Apartado Error! Reference source not found. “Juntas
empernadas”” en la página 145.
¡AVISO! ¡Riesgo de daños materiales por un desajuste inapropiado
de la conexión vástago del pistón – cruceta!
- Primero afloje los 4 tornillos de ajuste a lados opuestos. Luego
mueva los elementos de la bomba y desajuste los tornillos de
ajuste restantes.
Si no se sigue la secuencia estipulada para el desmontaje de la
conexión vástago del pistón - cruceta con 6 tornillos de ajuste,
pueden provocarse daños materiales en los elementos de cone-
xión.
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NEA USA 291007 / No. Ser. 108399
Fig. 45: Ajuste del manguito de soporte
4. Sitúe el manguito de soporte (Fig. 45/2) para el dispositivo de

ajuste hidráulico en la brida de fijación (Fig. 45/1) (Fig. 45/flecha).
Fig. 46: Atornillado de los elementos de la bomba
5. Atornille los elementos de la bomba (Fig. 46/3) con los tornillos

de ajuste (Fig. 46/1) (Fig. 46/flecha).
6. Conecte los tubos flexibles de alta presión del dispositivo de

ajuste hidráulico a las conexiones de los elementos de la bomba
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NEA USA 291007 / No. Ser. 108399
(Fig. 46/2).
7. Conecte el otro lado de los tubos de alta presión al bloque de

distribución.
Fig. 47: Palanca de accionamiento de la bomba
8. Conecte los tubos flexibles de alta presión en el bloque de distri-

bución (Fig. 47/1) a la conexión (Fig. 47/2) de la palanca de ac-
cionamiento de la bomba en el dispositivo de ajuste hidráulico.
9. Abra la válvula de descompresión (Fig. 47/3).
10. Accione la palanca de accionamiento de la bomba (Fig. 48/2) con

diez recorridos con la válvula de descompresión abierta
(Fig. 48/flecha).
11. Cierre la válvula de descompresión (Fig. 48/1) otra vez.
12. Presurice los elementos de la bomba con la presión de aceite

nominal. Diríjase a la tabla de presión nominal para la conexión
vástago del pistón - cruceta  Apartado Error! Reference
source not found. “Juntas empernadas” en la página 145.
13. Inserte el pasador por la apertura en el manguito de soporte y

dentro del agujero de sujeción de las tuercas redondas.
14. Desajuste las tuercas redondas media vuelta con el pasador.
¡ADVERTENCIA! ¡Riesgo de lesiones por una ecualización de

la presión no controlada!
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NEA USA 291007 / No. Ser. 108399
Antes de iniciar el trabajo en el dispositivo de ajuste hidráulico:

- Asegúrese siempre de que la presión no puede liberarse invo-
luntariamente.
- El personal especializado adecuado debe cambiarle inmedia-
tamente cualquier componente en mal estado que se presurice
durante la operación.
El dispositivo de ajuste hidráulico contiene aceite a alta presión.

Si la válvula de descompresión se abre demasiado rápido, se po-
drían provocar lesiones graves. Si se trata de modo incorrecto la
alta presión podría salir expedida de forma incontrolada y provocar
lesiones graves.
15. Libere lentamente y con cuidado la presión por medio de la vál-

vula de descompresión.
16. Desconecte los tubos flexibles de alta presión de los elementos
de la bomba.
Fig. 49: Extracción de las bombas
17. Desatornille los elementos de la bomba (Fig. 49/2) de los tornillos

de ajuste y retírelos con los manguitos de soporte (Fig. 49/3).
18. Desenrosque las tuercas de ajuste (Fig. 49/1) con la mano y

guárdelas de modo seguro.
 La conexión vástago del pistón - cruceta está desajustada.
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NEA USA 291007 / No. Ser. 108399
Fig. 50: Desmontaje de la conexión vástago del pistón – cruceta
19. Saque con cuidado el vástago del pistón (Fig. 50/5) fuera del
agujero escariado en la cruceta (Fig. 50/1).
20. Empuje hacia atrás la brida de fijación (Fig. 50/4) de manera que
se deje al descubierto la junta de unión de dos piezas (Fig. 50/2).
21. Retire el aro tórico (Fig. 50/3) y la junta de unión de dos piezas
(Fig. 50/2).
22. Compruebe que todos los componentes extraídos están en per-

fectas condiciones técnicas.
Sustituya los componentes dañados o en mal estado por otros

nuevos antes de la reinstalación.
23. Transporte la brida de fijación (Fig. 50/4) con un mecanismo ele-

vador apropiado a su peso.
 La conexión vástago del pistón - cruceta está desmontada.
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NEA USA 291007 / No. Ser. 108399
Montaje de la conexión vástago Personal:  Personal especializado
del pistón - cruceta Equipamiento protector:  Ropa protectora

 Casco protector
Siga las instrucciones de funcionamiento proporcionadas por el

fabricante del dispositivo de ajuste hidráulico.
¡ADVERTENCIA! ¡Riesgo de lesiones por la caída de las tapas
de apertura de instalación!
- Las tapas en las aperturas de instalación deben instalarse y
retirarse con la ayuda de una segunda persona siempre que
sea posible. Si es necesario, utilice herramientas adecuadas
(p.ej. una grúa).
- Al realizar este trabajo lleve siempre la ropa y el equipamiento
de seguridad personal estipulados.
Las tapas en las aperturas de instalación pueden ser muy pesa-
das. Si se cayeran, podrían causar lesiones graves.
1. Retire todas las tapas de las aperturas de instalación.

2. Determine el tamaño del dispositivo de ajuste hidráulico necesa-
rio  Apartado Error! Reference source not found. “Juntas
124 2010-08-31
NEA USA 291007 / No. Ser. 108399
Fig. 51: Montaje de la conexión vástago del pistón – cruceta
3. Guíe la brida de fijación (Fig. 51/4) hacia la fijación del vástago

(Fig. 51/7).
4. Ajuste la junta de unión de dos piezas (Fig. 51/2) usando el aro

tórico (Fig. 51/3) en el vástago del pistón (Fig. 51/7).
5. Quite el cono protector (si está puesto) del vástago del pistón
(Fig. 51/7).
¡AVISO! ¡Riesgo de daños materiales a causa de un montaje inco-
rrecto!
- Asegúrese de que la cuña está ajustada correctamente en la
fijación del vástago.
- Asegúrese de que el tornillo de ajuste cierra alineado a la cuña.
- Bajo ningún concepto mezcle las cuñas en compresores múlti-
ples.
- Asegúrese de que el manguito excéntrico está posicionado en
el agujero de sujeción de la cruceta.
Un montaje incorrecto o imperfecto de la conexión vástago del pis-
tón – cruceta puede causar daños materiales al compresor y sus
componentes.
2010-08-31 125
NEA USA 291007 / No. Ser. 108399
6. Ponga la cuña.
7. Posicione el vástago del pistón (Fig. 51/7) enfrente de la cruceta

(Fig. 51/1) e insértelo con cuidado en el agujero escariado de la
cruceta.
8. Empuje la brida de fijación (Fig. 51/4) sobre los tornillos de ajuste

(Fig. 51/5) contra la junta de unión de dos piezas (Fig. 51/2).
9. Enrosque las tuercas de ajuste (Fig. 51/6) con la mano.
10. Alinee la brida de fijación (Fig. 51/4) paralela a la cara de la cru-

ceta.
11. Apriete las tuercas de ajuste (Fig. 51/6) a mano.
¡AVISO! ¡Riesgo de daños materiales por un montaje incorrecto de

la conexión vástago del pistón – cruceta!
- Primero apriete los 4 tornillos a lados opuestos. Luego mueva
los elementos de la bomba y desajuste los tornillos de ajuste
restantes.
Si no se sigue la secuencia estipulada para el montaje de una co-
nexión vástago del pistón - cruceta con 6 tornillos de ajuste, pue-
den provocarse daños materiales en los elementos de conexión.
Fig. 52: Atornillado en los elementos de la bomba.
126 2010-08-31
NEA USA 291007 / No. Ser. 108399
12. Atornille los elementos de la bomba (Fig. 52/3) con manguitos de

soporte en los tornillos de ajuste (Fig. 52/1) (Fig. 52/flecha).
13. Conecte los tubos flexibles de alta presión en el dispositivo de

ajuste hidráulico a las conexiones en los elementos de la bomba
(Fig. 52/2).
14. Conecte el otro lado de los tubos flexibles de alta presión al blo-
que de distribución.
15. Conecte el tubo flexible de alta presión (Fig. 53/1) en el bloque

de distribución a la conexión (Fig. 53/2) para la palanca de ac-
cionamiento de la bomba.
16. Abra la válvula de descompresión (Fig. 53/3).
17. Accione la palanca de accionamiento de la bomba (Fig. 54/2) con

diez recorridos con la válvula de descompresión (Fig. 54/1) abier-
ta (Fig. 54/flecha).
18. Cierre la válvula de descompresión (Fig. 54/1) otra vez.
19. Presurice los elementos de la bomba con la presión de aceite

nominal. Diríjase a la tabla de presión nominal para la conexión
vástago del pistón - cruceta  Apartado Error! Reference
20. Inserte el pasador por la apertura en el manguito de soporte y
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dentro del agujero de sujeción de las tuercas de ajuste.
21. Use el pasador para apretar los tornillos con la mano.

¡ADVERTENCIA! ¡Riesgo de lesiones por una ecualización de
la presión no controlada!
Antes de iniciar el trabajo en el dispositivo de ajuste hidráulico:
- Asegúrese siempre de que la presión no puede liberarse invo-
luntariamente.
- El personal especializado apropiado debe cambiarle inmedia-
tamente cualquier componente en mal estado que se presurice
durante la operación.
El dispositivo de ajuste hidráulico contiene aceite a alta presión. Si

la válvula de descompresión se abre demasiado rápido, se podrían
provocar lesiones graves. Si se trata de modo incorrecto la alta
presión podría salir expedida de forma incontrolada y provocar le-
siones graves.
22. Libere lentamente y con cuidado la presión por medio de la vál-

vula de descompresión. (Fig. 54/1).
Fig. 55: Extracción de las bombas
23. Desconecte los tubos flexibles de alta presión de los elementos

de la bomba. (Fig. 55/2).
24. Desatornille los elementos de la bomba (Fig. 55/2) de los tornillos
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de ajuste (Fig. 55/1) (Fig. 55/flecha) y retírelos con los manguitos

de soporte (Fig. 55/3).
7.4.11 Medición y ajuste del descentramiento de la barra


 Casco protector
Herramienta especial:  Llave de pasador
Puede usar el manguito excéntrico para ajustar el descentramiento de

la barra como sea necesario. El manguito excéntrico está situado en
la fijación en la cruceta para la varilla roscada.
Medición del descentramiento de la

barra
Fig. 56: Descentramiento de la barra, medición
1. Ajuste la brida roscada (Fig. 56/2) a la cruceta (Fig. 56/1) con los
tornillos de ajuste (Fig. 56/3) a mano.
2. Haga girar el compresor alternativo una vez a mano o usando un

dispositivo y mida las fluctuaciones de avance lineal con un cali-
bre de medición (Fig. 56/4) durante una carrera del compresor
alternativo.
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3. Compare los valores determinados con el valor nominal

 Apartado Error! Reference source not found. “Datos máqui-
na compresor alternativo” en la página 138.
Si existe una desviación fuera del rango de tolerancia, será nece-

sario fijar el descentramiento de la barra.
Ajuste del descentramiento de la

barra
Fig. 57: Descentramiento de la barra, ajuste
4. Desajuste los tornillos de ajuste (Fig. 57/3) en la brida roscada

(Fig. 57/5) y guárdelos seguros.
5. Desajuste el restante (Fig. 57/6) en el manguito excéntrico
(Fig. 57/4).
6. Inserte la llave de pasador (Fig. 57/1) en el manguito excéntrico

(Fig. 57/4).
7. Gire el manguito excéntrico (Fig. 57/4) con la llave de pasador

(Fig. 57/1).
El giro de los manguitos excéntricos a 2° (1° uno por cada mangui-

to excéntrico) provoca un cambio de longitud de 0.01 mm
(0.0003937 pulgadas).
8. Apriete los tornillos sobrantes (Fig. 57/6) de los tornillos de ajuste

(Fig. 57/3) con la mano.
9. Mida el descentramiento de la barra otra vez y compare los resul-

tados con el valor nominal Error! Reference source not
found. “Datos máquina compresor alternativo” en la página 138.
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10. Siga repitiendo los pasos del 4. al 6. hasta conseguir el valor

nominal para el descentramiento de la barra.
11. Apriete los tornillos de ajuste (Fig. 57/3) con el dispositivo de

ajuste hidráulico. Manténgase fiel a la presión de la bomba esti-
pulada en el proceso  Apartado Error! Reference source not
found. “Juntas empernadas” en la página 145.
7.4.12 Rectificación de las superficies de estanqueidad


 Casco protector
Herramienta especial:  Herramientas para rectificar
Los daños en las superficies de estanqueidad en las tapas de las

válvulas o los cilindros tienen que desbastarse.
1. Limpie la superficie de estanqueidad que desea pulimentar de

suciedad, grasa o aceite.
2. Aplique pasta abrasiva a las superficies de estanqueidad daña-

das.
3. Aplique la herramienta para rectificar a la superficie de estan-

queidad y pula con un movimiento rotativo alternante.
La herramienta para rectificar no es parte de la entrega. Se puede

producir de un manguito de fundición, por ejemplo.
4. Compruebe el patrón de contacto. Para hacerlo señalice la su-

perficie de estanqueidad.
5. Siga repitiendo los pasos del 2. al 4. hasta que haya un anillo de
contacto de al menos 1.0 mm (0.03937 pulgadas) de ancho.
6. Limpie la pasta abrasiva de la superficie de estanqueidad.
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 La superficie de estanqueidad ya está de nuevo en buen es-

tado.
7.5 Acciones tras completar el mantenimiento

Tras completar el trabajo de mantenimiento y antes de encender la
máquina realice los siguientes pasos:
1. Compruebe que todas las conexiones que anteriormente estaban

sueltas están ajustadas.
2. Compruebe que todos los dispositivos y las tapas que se hayan

quitado previamente estén bien recolocados.
3. Compruebe que todas las herramientas, materiales y otro equi-

pamiento que haya utilizado están retirados de la zona de traba-
jo.
4. Limpie la zona de trabajo y retire cualquier sustancia que se haya

podido escapar, tal como líquidos, material de proceso o simila-
res.
5. Asegúrese de que todos los dispositivos de seguridad de la má-

quina están en perfecto estado.
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8 Averías
La siguiente sección describe las posibles causas de las averías y
qué hay que hacer para solucionarlas.
En caso de que los fallos se produzcan más de una vez, abrevie los
intervalos según el uso actual.
En caso de que los fallos no se puedan solucionar a partir de las si-
guientes instrucciones, contacte con el fabricante. Véase datos de
contacto en la página 2.
8.1 Seguridad
Sistema eléctrico
PELIGRO ¡Peligro de muerte a causa de la energía eléctrica!
- Apague el suministro de energía antes de iniciar el trabajo y
El contacto con las partes activas podría ser mortal. Si están co-
nectadas, los componentes eléctricos podrían estar sujetos a mo-
vimientos incontrolados que podrían provocar lesiones graves.
Asegurar para evitar que se reinicie

ADVERTENCIA ¡Peligro de muerte por un reinicio no autorizado!
- Apague todo suministro de energía antes de iniciar el trabajo y
En el caso de un reinicio no autorizado del suministro eléctrico
mientras se localiza y repara una avería, existe peligro de lesiones
graves o muerte para las personas que se hallen en la zona de
peligro.
Trabajo de localización de averías

ejecutado de forma indebida
ADVERTENCIA ¡Peligro de lesiones por una localización de averías inapropiada!
- Asegúrese de que hay suficiente espacio para el montaje antes
de iniciar el trabajo.
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- ¡Preste atención a la ordenación y la limpieza en el lugar de

montaje! Los componentes o herramientas apilados o dispersos
podrían provocar accidentes.
- Si se han retirado componentes, ponga atención para realizar
un montaje correcto, reponer todos los elementos de fijación y
apretar bien los tornillos.
- Antes de reiniciar, asegúrese de que:

- todo el trabajo de localización de averías se ha llevado a ca-
bo y se ha completado siguiendo la información y las ins-
trucciones de este manual.
- no hay personas en la zona de peligro
- todas las tapas y los dispositivos de seguridad están instala-
dos y funcionan adecuadamente.
Un trabajo de localización de averías mal ejecutado puede derivar
en lesiones graves y daños significativos en la propiedad.
Piezas móviles
ADVERTENCIA ¡Peligro de lesiones a causa de las piezas móviles!
- Antes de llevar a cabo cualquier trabajo de localización de ave-
rías sobre piezas móviles, apague la máquina y tome precau-
ciones para evitar un reinicio. Espere hasta que todas las pie-
zas hayan dejado de moverse.
- Cuando se encuentre en la zona de peligro, lleve ropa de traba-
jo protectora ajustada y con baja resistencia al desgarre. Las
piezas rotatorias y/o las piezas que se mueven secuencialmen-
te pueden provocar lesiones graves.
Comportamiento en caso de Deben seguirse los siguientes principios:

averías:
1. Iniciar un paro de emergencia inmediatamente en caso de ave-
rías que representen un peligro inmediato para personas o para
la propiedad.
2. Averigüe el motivo de la avería.
3. Si para solucionar la avería es necesario trabajar en la zona de

peligro, apague la máquina y asegúrela para evitar que se reini-
cie. Informe inmediatamente a los responsables del lugar sobre
la avería.
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4. Dependiendo de la naturaleza de la avería, debe hacer que la

solucione el personal especializado autorizado o puede hacerlo
usted mismo.
La tabla de averías a continuación muestra información sobre

quién es el responsable de solucionar la avería.
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8.2 Tabla de averías
Descripción de la avería Causa Solución Personal
Presión del aceite La bomba de aceite está Comprobar que la bomba Personal
demasiado baja en mal estado. de aceite esté en buen especializado
estado.
 Si la bomba de aceite
no funciona bien, debe
cambiarse por una
nueva.
El sistema de lubricación Comprobar que el siste- Personal

tiene una fuga. ma de lubricación funcio- especializado
na.
 Solucionar posibles
fugas.
 Cambiar los
componentes en mal
estado del sistema de
lubricación
El calentador está apa-  Encender el Personal

gado o en mal estado. calentador especializado
 En caso de avería
pida al NEAC, el
personal del Servicio
Post-Venta, que se lo
cambie.
El nivel de aceite es Comprobar el nivel de Personal

demasiado bajo. aceite especializado
 Si el nivel de aceite es
demasiado bajo, hay
que reponer el
aceite Apartado Err
or! Reference source
not found.
“Comprobación del
nivel de aceite en la
unidad de
accionamiento” en la
página 81
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Viscosidad del aceite Vaciar el aceite y reponer Personal

inadecuada con aceite de viscosidad especializado
correcta Apartado 7.4.3
“Reponer del aceite de la
unidad de accionamiento”
en la página 83.
La holgura del cojinete Comprobar la holgura del Personal de

del pie de biela no es cojinete del pie de biela servicio
correcta.  El NEAC, el personal
del Servicio Post-
Venta debe cambiar el
cojinete del pie de
biela en mal estado.

principal no es correcta cojinete principal servicio
 El NEAC, el personal
del Servicio Post-
Venta debe sustituir el
cojinete principal en
mal estado.
Sonidos de golpes Las válvulas no están Comprobar que los ajus- Personal
bien ajustadas tes de las válvulas están especializado
bien ajustados
 Ajustar los tornillos de
ajuste en la tapa de la
válvula.
 Ajustar los tornillos de
presión en la tapa de
la válvula.
Condensación o lubrican- Comprobar el aumento Personal

te acumulados en los de condensación o lubri- especializado
cilindros. cante en el cilindro.
 Drenar la
condensación o
acumulación de
lubricante.
El pistón no está ajustado Comprobar el ajuste del Personal

correctamente pistón. especializado
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 Apretar y ajustar los
tornillos del pistón
El pasador de cruceta no Comprobar el ajuste del Personal

está correctamente ajus- pasador de cruceta. de servicio
tado.  Apretar los tornillos de
ajuste del pasador de
cruceta.
La biela no está ajustada Comprobar el ajuste de la Personal de

correctamente. biela. servicio
 Pida que el NEAC, el
Post-Venta que
apriete los tornillos de
ajuste de la biela.

del pie de biela no es cojinete del pie de biela. servicio
correcta.  Pida que el NEAC, el
Post-Venta que
cambie el cojinete del
pie de biela en mal
estado.

principal no es correcta. cojinete del muñón del servicio
eje.
 Pida que el NEAC, el
Post-Venta que
cambie los cojinetes
principales en mal
estado.
La virola está en mal Comprobar la virola para Personal de

estado. determinar si está en servicio
buen estado.
 En caso de avería
pida que el NEAC, el
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Post-Venta, cambie la
virola.
Vibraciones El ajuste de la consola Comprobar el ajuste de la Personal

está suelto. consola. especializado
 Apretar el ajuste
suelto de la consola.
El ajuste del compresor Comprobar el ajuste del Personal

está suelto. compresor. especializado
 Apretar el ajuste
suelto del compresor
La frecuencia natural de Haga que midan la fre- Personal de

la máquina es demasiado cuencia natural de la servicio
alta máquina.
 Adaptar los soportes
del compresor
alternativo a la
frecuencia natural.
 Equipar el compresor
alternativo con
soportes adicionales
para compensar la
frecuencia natural.
La frecuencia natural del Mida la frecuencia natural Personal de

suelo, edificio o andamio del suelo, edificio o an- servicio
es demasiado alta. damio.
 Adaptar los soportes
del compresor
alternativo a los
valores de frecuencia.
 Equipe el compresor
alternativo con
soportes adicionales
para compensar los
valores de frecuencia.
La temperatura del gas es Las válvulas en el lado de Comprobar que las válvu- Personal de
succión o lado de presión
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demasiado alta del cilindro están en mal las estén en buen estado. servicio
estado.  Cambiar los
componentes en mal
estado de las
válvulas Apartado E
rror! Reference
source not found.
“Sustitución de las
válvulas” en la
página 97.
El asiento de válvula o Comprobar si los asien- Personal de

los soportes de la válvula tos de válvula están en servicio
en el cilindro están daña- buen estado
dos.  Rectificar los asientos
de válvula dañados
 Apartado 7.4.12
“Rectificación de las
superficies de
estanqueidad” en la
página 120.
Cambio de presión interme- Las válvulas en el lado se Comprobar si las válvulas Personal
dio succión o en el lado de en el lado de succión o el especializado
presión del cilindro están lado de presión están en
en mal estado. buen estado.
 Cambiar válvulas en
mal estado
 Apartado Error!
Reference source
not found.
válvulas” en la página
97.
Los asientos de válvula Comprobar los asientos Personal

en el cilindro están daña- de válvula especializado
dos.  Rectificar los asientos
de válvula
dañados Apartado E
rror! Reference
source not found.
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97.
Los segmentos de pistón Comprobar si los seg- Personal

están dañados. mentos de pistón están especializado
en buen estado
 Cambiar los
segmentos de pistón
en mal
estado Apartado 7.4
.7 “Sustitución de los
segmentos de pistón y
los anillos guía” en la
página 94.
Velocidad de descarga Las válvulas en el lado de Comprobar si las válvulas Personal

demasiado baja succión o en el lado de en el lado de succión o especializado
presión del cilindro están en el lado de presión del
en mal estado. cilindro están en buen
estado.
 Cambiar válvulas en
mal estado
 Apartado Error!
Reference source
not found.
97.
Asientos de válvula en el Comprobar el asiento de Personal es-

cilindro dañados. válvula. pecializado
 Rectificar los asientos

de válvula dañados
 Apartado 7.4.12
“Rectificación de las
superficies de
estanqueidad” en la
página 120.
Los segmentos del pistón Comprobar si los seg- Personal

están dañados. mentos del pistón están especializado
dañados.
 Cambiar los
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segmentos del pistón
en mal
estado Apartado 7.4
.7 “Sustitución de los
segmentos de pistón y
los anillos guía” en la
página 94.
El empaque de presión Comprobar si el empaque Personal

está en mal estado. de presión está en buen especializado
estado.
 Cambiar el empaque
de presión si está en
mal estado
 Apartado Error!
Reference source
not found.
“Sustitución del
empaque de presión”
en la página 90.
Las válvulas no están Comprobar los ajustes de Personal

correctamente ajustadas. la válvula especializado
 Reajustar los ajustes
de la válvula.
La fuerza de presión de Comprobar los tornillos Personal

las válvulas es demasia- de presión. especializado
do baja.  Reajustar los tornillos
de presión.
El descargador de la Comprobar si los descar- Personal

válvula de succión no gadores de la válvula de especializado
está ajustado correcta- succión funcionan a la
mente. perfección.
 Reajustar los
descargadores de la
válvula de succión.
 Cambiar los
descargadores de
válvula de succión en
mal estado
 Apartado Error!
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Reference source
not found.
"Sustitución del
descargador de la
válvula de succión” en
la página 105
8.3 Trabajo para solucionar averías

8.3.1 Tareas antes de solucionar las averías
1. Pare el compresor alternativo y la bomba de

aceite Apartado Error! Reference source not found. “Apagado”
en la página 63.
2. Asegure la unidad de accionamiento para evitar que se vuelva a
encender.
¡ADVERTENCIA! ¡Riesgo de lesiones mortales a causa de una
ecualización de la presión no controlada!
cualquier trabajo.
- Descargue toda energía residual.
- Cuando comprima gases explosivos o tóxicos, inertice los com-
ponentes del compresor alternativo.
El compresor alternativo contiene gas de proceso a alta presión
durante la operación. Si las tapas de las aperturas de instalación
están abiertas antes de que se haya realizado la ecualización de la
presión se pueden causar lesiones graves
8.3.2 Trabajo sobre el sistema de lubricación
Equipamiento pro-  Ropa protectora

tector:  Guantes de seguridad resistentes a las
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sustancias químicas.
Realice el trabajo en el sistema de lubricación siguiendo los pasos

de comprobación del sistema de lubricación  Apartado Error!
Reference source not found. “Revisión de fugas en el sistema de
lubricación” en la pagina Error! Bookmark not defined..
Selección del lubrificante Diríjase a la tabla de lubrificantes para encontrar el tipo de lubrifican-
te adecuado.
Reposición del lubrificante

Reponga el lubrificante siguiendo los pasos para el cambio de
aceite  Apartado 7.4.3 “Sustitución del aceite de la unidad de ac-
cionamiento” en la página 82.
8.3.3 Trabajo en las válvulas
Fijación de los tornillos de ajuste Personal:  Personal especializado

en la tapa de la válvula
1. Fije todas las tuercas de los tornillos de ajuste de válvula con una
llave de ajuste dinamométrica Apartado Error! Reference
Fijación de los tornillos de presión Personal:  Personal

de la tapa de la válvula especializado

1. Desajuste y retire todas las tuercas ciegas y guárdelas de modo

seguro.
2. Retire todos los cierres y compruebe si están dañados.
Cambie los cierres antes de realizar la reinstalación.
3. Fije todos los tornillos de presión en la tapa de la válvula con una
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llave de ajuste  Apartado Error! Reference source not found.

“Juntas empernadas” en la página 145.
4. Coloque los cierres y las tuercas ciegas.
5. Fije las tuercas ciegas con una llave de ajuste  Apartado Error!
Reference source not found. “Juntas empernadas” en la página
145.
8.3.4 Drenaje de la condensación o la acumulación de lubricante
Equipamiento pro-  Ropa protectora

tector:  Guantes de seguridad resistentes a las
sustancias químicas
1. Coloque un contenedor resistente al lubrificante y a la condensa-

ción debajo del drenaje de condensación.
2. Desajuste y retire el tornillo del drenaje de condensación en el

cilindro y guárdelo de forma segura.
 La condensación o la acumulación de lubricante manan del

cilindro.
3. Disponga la condensación o acumulación de lubricante respe-

tando el medio ambiente de acuerdo con las leyes y regulaciones
vigentes en el lugar de instalación del compresor.
4. Retire el cierre y compruebe que no esté dañado.
Cambie todos los cierres dañados antes de la reinstalación.
5. Coloque el cierre y fije el tornillo del drenaje de condensación.
8.3.5 Fijación de los ajustes del pistón

 Casco protector
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Las instrucciones de funcionamiento para el sistema de ajuste de

Superbolt® están incluidas en el apéndice de este manual.
Sin dispositivo para el torneado 1. Gire manualmente el compresor alternativo de manera que el
pistón para la respectiva fase esté posicionado en el punto muer-
to superior Apartado 5.5 “Rotación del compresor alternativo”
en la página 65.
Con dispositivo para el torneado 2. Gire el compresor usando el dispositivo para el torneado de ma-
nera que el pistón para la respectiva fase esté posicionado en el
punto muerto superior.
3. Desajuste los tornillos de ajuste en la tapa del cilindro, retire las

tuercas y guárdelas de forma segura.
4. Amarre la tapa del cilindro a la grúa con mecanismos elevadores
adecuados.
5. Desajuste la tapa del cilindro con tornillos de elevación y retírela.
6. Fije los tornillos de presión del sistema de ajuste Superbolt®

según las instrucciones de funcionamiento con una llave de ajus-
te dinamométrica Apartado Error! Reference source not
found. “Juntas empernadas” en la página 145.
8.4 Puesta en marcha tras la rectificación de la avería

Después de solucionar la avería, deberían seguirse los siguientes
pasos para reiniciar el sistema:
1. Resetee los dispositivos de paro de emergencia.
2. Informe de la avería al controlador.
3. Asegúrese de que no hay personas en la zona de peligro.
4. Inicie según las instrucciones en el apartado "Funcionamiento".
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9 Desmontaje y eliminación
Una vez la máquina haya alcanzado el final de su vida útil, debe
desmontarse y eliminarse en un modo adecuado.
El desmontaje únicamente puede realizarlo el NEAC, el personal

del Servicio Post-Venta.
ADVERTENCIA ¡Riesgo de daños mortales a causa de un desmontaje incorrecto!

- El desmontaje debe realizarlo únicamente el NEAC, el personal
del Servicio Post-Venta.
- Consulte al NEAC, el personal del servicio postventa, incluso
cuando quiera cambiar la localización posteriormente.
- No realice el desmontaje ni cambie la localización arbitraria-
mente.
Los errores producidos durante el desmontaje pueden desencad e-
nar situaciones mortales o provocar daños materiales considera-
bles.
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10 Piezas de recambio
10.1 Seguridad
Piezas de recambio incorrectas
ADVERTENCIA ¡Riesgo de lesiones por el uso de piezas de recambio no adecua-
das!
- Utilice únicamente las piezas de recambio originales del Servi-
cio Post-Venta NEAC o aquellas aprobadas por este.
- Contacte con el departamento del Servicio Post-Venta NEAC
para cualquier duda.
El uso de piezas de recambio incorrectas o en mal estado puede
provocar peligros para el personal, mal funcionamiento, o un fallo
total.
ADVERTENCIA ¡Riesgo de lesiones por el uso de piezas de recambio no adecua-

das!
- Utilice únicamente las piezas de recambio originales del Servi-
cio Post-Venta NEAC o aquellas aprobadas por este departa-
mento.
- Contacte el departamento de Post-Venta NEAC para cualquier
duda.
- Almacene piezas de recambio únicamente en lugares limpios y
secos libres de aceite y grasa.
El uso de piezas de recambio incorrectas o en mal estado no está
probado por BAM en cuanto a la capacidad de ignición y no han
sido aprobadas para el funcionamiento con oxígeno que podría
causar incendios. Esto puede provocar lesiones graves o incluso
mortales, así como daños materiales.
10.2 Piezas de recambio

Las piezas de recambio se pueden adquirir en el NEAC el departa-
mento Post-Venta, véase dirección en la página 2. La lista de piezas
de recambio está incluida en el apéndice.
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11 Datos técnicos
11.1 Hoja dimensional
Fig. 58: Dimensiones del compresor alternativo
Datos Valor Unidad
Ancho x 380 Cm
Altura y 180 Cm
Largo z 620 Cm
11.2 Requisitos para el lugar de instalación

Fundación Se necesita una fundación para montar la planta. Debe ser suminis-
trada por el usuario. El usuario debe asegurarse de que la subestruc-
tura cumple con las estipulaciones en el diagrama de fundación del
fabricante de la planta.
La fundación de la máquina debe cumplir los siguientes requisitos:
 Debe tener suficiente superficie portante con suficiente capacidad
para soportar carga.
 Debe ser una superficie sin deslizamiento.
 Debe ser plana.
Condiciones de instalación Al montar la máquina, se debe cumplir lo siguiente:

 Asegúrese de que es estable
 Las vías de evacuación y rescate deben ser de fácil acceso.
 La seguridad del personal debe estar garantizada.
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 Debe haber suficiente iluminación.

 Todas las partes de la máquina deben ser de fácil acceso y debe
existir suficiente espacio para la instalación, el mantenimiento y
atender las averías.
Requisito de espacio para el El usuario debe asegurarse de que la fundación cumple con las esti-
montaje pulaciones sobre los requisitos del espacio:
Fig. 59: Espacio requerido por la máquina para su funcionamiento, mantenimiento y reparación
Ítem Valor Unidad

Espacio entre la pared y la sección del compresor "a" > 210 cm
Espacio entre la pared y la sección del compresor "b" > 220 cm
Espacio entre la pared y las aperturas de instalación "c" > 200 cm
Espacio entre la pared y las aperturas de instalación "d" > 200 cm
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11.3 Información general

11.3.1 Datos de la máquina compresor alternativo
Tipo: ⃞ vertical ☒horizontal ⃞ Tipo V
Lubricación del cilindro: ☒no lubricación ⃞ lubricación
Manivelas compresor: ⃞1 ⃞2 ⃞3 ☒4
Diseño de la estructura: ☒atmosférico ⃞ a prueba de explosiones
Velocidad del compr e- 514 1/min Potencia del compresor: 377 kW

sor:
Mecanismo de transmi- ☒directamente aco- ⃞ engranaje ⃞ transmisión por

sión:
plado correa
Tipo de elemento ☒motor de inducción ⃞ motor sincronizado ⃞ turbina de vapor

conductor:
⃞ turbina de gas ⃞ motor ⃞ otro
Velocidad del conductor: 514 1/min Potencia del conductor: 1014 kW
Virola ☒velocidad baja ⃞ velocidad alta
Entre el compresor y el conductor o Entre el conductor y el sistema de

el sistema de engranaje engranaje
Fabricante: STROMAG AG
Modelo: High-flexible disc coupling
Tipo: PVP 66611 R-24"
API 671 aplicable: ☒Sí ⃞ No ☒Sí ⃞ No
Control de capacidad ⃞ volumen fijo ☒descargador de la válvula de suc-

ción
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⃞ bypass ⃞ HydroCOM®
Acción: ⃞ directa (aire-descarga) ☒reversa

(aire-carga/bloqueo antifallos)
para: ☒condiciones ☒puesta en mar- ☒ambos

de carga parcial cha solo
Número de pasos: ⃞1 ⃞3 ⃞5 ☒otros: cuatro
⃞ sin pasos
Distanciador: ⃞ tipo A ⃞ tipo B ⃞ tipo C ☒tipo D
Tapas: ☒metal sólido ⃞ pantalla ⃞ rejilla
Compartimento del ☒ventilado al exterior ⃞ purgado a __ [kg/cm²]

cilindro:
⃞ presurizado __ [kg/cm²] ⃞ con válvula de seguridad
Compartimiento ⃞ ventilado a __ ☒purgado a 1,7 [kg/cm²]

estructura:
⃞ presurizado __ [kg/cm²] ⃞ con válvula de seguridad
Distanciador MAWP: 2.04 [kg/cm²]
Cilindro
Servicio / Ítem Núm. Llenado de

Amoniaco
Fase 1 2
Cilindros por fase 2 2
Simple efecto o doble efecto (SE o DE) DE DE
Diámetro [mm] 735 398
Carrera [mm] 225 225
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Amoniaco
Fase 1 2
Camisa del cilindro Yes Yes
Espesor nominal de la tubería [mm] 12.5 12.5
Compensación del diseño del cilindro, [%] 16.3 16.5

media
Segmentos del pistón por cilindro 3 4
Anillos guía por cilindro 3 3
Número de válvulas por cilindro 4/4 4/4

(succión/descarga)
Tipo de válvulas Anillo Anillo
Carrera de válvula (succión/descarga) [mm] 2.0 / 1.8 2.0 / 1.6
Diámetro barra [mm] 80.0 80.0
Descentramiento de la barra
– Vertical [mm] 0.11 0.08
– Horizontal [mm] 0.035 0.035
Espacio libre del pistón (pie de bie- [mm] 11,0 / 6,5 / 5,0
la/cabeza del cigüeñal) 8,5
Presión de trabajo máx. permisible [kg/cm²] 10.2 16.3
Temperatura de trabajo máx. permisible [°C] 150 150
Presión de prueba hidrostática [kg/cm²] 15.3 24.5
Presión de prueba helio [kg/cm²] 10.2 16.3
Brida de entrada
– Tamaño / clasificación 12"-150# 8"-150#
– Cara FF-SMF FF-SMF
Brida de salida
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Amoniaco
Fase 1 2
– Tamaño / clasificación 12"-150# 8"-150#
– Cara FF-SMF FF-SMF
Agua refrigerante entrada, salida 1"NPT 1"NPT
Conexión indicador de toma 1/2"NPT 1/2"NPT
Conexión lubricación - -
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11.3.2 Peso de los componentes
Componente Valor Unidad

Compresor, total 30000 Kg
Estructura 9000 Kg
Volante 1200 Kg
Virola 230 Kg
Cilindro fase I 3800 Kg
Cilindro fase II 2800 Kg
Tapa del cilindro fase I 395 Kg
Tapa del cilindro fase II 135 Kg
Pistón con vástago del pistón fase I 415 Kg
Pistón con vástago del pistón fase II 230 Kg
11.4 Condiciones de funcionamiento

11.4.1 Datos gas de proceso
Servicio o ítem núm. Llenado de

Amoniaco
Fase 1 2
Normal o alt Normal Normal

H2 O 18.016 0,5 0,5
Amoniaco 17.031 99.5 99.5
Total [%] 100 100
Masa molar calculada [kg/kmol] 17.03 17.03
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Servicio o ítem núm. Llenado de

Amoniaco
Fase 1 2

Punto de rocío [°C]
11.4.2 Datos de funcionamiento
Servicio o ítem núm. Llenado de Llenado de

Amoniaco Amoniaco
Fase 1 2 1 2
Normal o alt Normal Normal Normal Normal

Peso molecular [kg/kmol] 17.03 17.03 17.03 17.03
Capacidad
% Capacidad 100% 100% 50%A 50%A
Barrenos de lubricación / funcionamiento - - CE/HE-S CE-S/HE

válvula CE-S/HE CE/HE-S
Flujo másico [kg/h] 5284 6864 2642 3430
Flujo volumétrico [m³/h] 6954 9034 3477 4515
Condiciones de entrada en la brida del cilindro
Presión [kg/cm²] 1.02 4.16 1.02 4.16
Temperatura [°C] -32,9 -1,1 -32,9 -1,1
Condiciones de salida en la brida del cilindro
Presión [kg/cm²] 4.32 14.17 4.32 14.17
Temperatura [°C] 79.7 98,3 79.7 98.3
Potencia
Potencia por fase [kW] 432 444 289 261
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Servicio o ítem núm. Llenado de Llenado de

Amoniaco Amoniaco
Fase 1 2 1 2

Peso molecular [kg/kmol] 17.03 17.03 17.03 17.03
Total @ eje del compresor [kW] 916 550
Servicio o ítem no. Llenado de Llenado de

Amoniaco Amoniaco
Fase 1 2 1 2

Masa molecular [kg/kmol] 17.03 17.03 17.03 17.03
Capacidad
% Capacidad 50%B 50%B 75%A 75%A
Barrenos de lubricación / funcionamiento CE- S/HE CE/HE-S CE/HE-S CE/HE

de válvula CE/HE-S CE-S/HE CE/HE CE/HE- S
Flujo másico [kg/h] 2642 3430 3982 5125
Flujo volumétrico [m³/h] 3477 4515 5241 6745
Presión [kg/cm²] 1.02 4.16 1.02 4.16
Temperatura [°C] -32,9 -1,1 -32,9 -1,1
Presión [kg/cm²] 4.32 14.17 4.32 14.17
Temperatura [°C] 79.7 98,3 79.7 98,3
Potencia
Potencia por fase [kW] 289 261 363 351
Total @ eje compresor [kW] 550 714
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Servicio o ítem no. Llenado de

Amoniaco
Fase 1 2

Masa molecular [kg/kmol] 17.03 17.03
Capacidad
% Capacidad 75%B 75%B
Barrenos de lubricación / funcionamiento CE/HE CE/HE-S

de válvula CE/HE-S CE/HE
Flujo másico [kg/h] 3982 5125
Flujo volumétrico [m³/h] 5241 6745
Presión [kg/cm²] 1.02 4.16
Temperatura [°C] -32,9 -1,1
Presión [kg/cm²] 4.32 14.17
Temperatura [°C] 79.7 98,3
Potencia
Potencia por fase [kW] 363 351
Total @ eje compresor [kW] 714
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11.4.3 Utilidades
Estructura del sistema de aceite lubricante
☒Velocidad del aceite 5,75 m³/h ☒Presión del aceite 3.06 kg/cm²
☒Viscosidad del aceite ISO VG 150 ☒Temperatura del aceite min 20 °C

max 50
☒Volumen cárter 0,64 m³
Sistema de refrigeración
⃞ Agua refrigerante ⃞ Mezcla glicol ☒Otro: aceite
Refrigerac Termosifón Tubo Caudal Presión Temp. Temp.

ión vertical [m³/h] [kg/cm²] entrada salida
forzada
[°C] [°C]
☒Cilindro fase I ☒ ⃞ ⃞ 3.3 3.1 40 Inlet+°5K
☒Cilindro fase II ☒ ⃞ ⃞ 3.4 3.1 40 Inlet+5°K
☒Empaque de presión, ☒ ⃞ ⃞ 0.5 N/A N/A Inlet+5°K

total
Sistema de gas separador y de purga
Gas separador Caudal Presión Gas de purga Caudal Presión

[m³/h] [kg/cm² [m³/h] [kg/cm²]
]
⃞ Distanciador interior ⃞ Distanciador interior
⃞ Distanciador exterior ☒Distanciador exterior / 1.2 Combus-

tión +
Junta separación intermedia
(0,3-0,5)
☒Empaque de presión 2.0 <1.43 ⃞ Empaque de presión
Sistema de aire para los instrumentos
Caudal Presión
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[m³/h] [kg/cm²]
☒Cilindro de diafragma 3.06
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11.5 Juntas empernadas
Los valores del par de apriete especificados para los tornillos son
aplicables para zonas de contacto de contacto con la tuerca y ros-
cas lubricadas.
Junta empernada Rosca Torsión Presión bomba Manguito Elemento

[Nm] [bar] soporte bomba
Perno anclaje estructura M42 1400 - - -
Distanciador estructura M24 440 - - -
Consola al distanciador M20 160 - - -
Consola a la fundación M24 185 - - -
Cruceta – vástago del pistón M36 - 1150 H3/1-3 Z3/1
Manguito excéntrico M8 25 - - -
Bloqueo del volante M14 190
Junta del colector de aceite M10 30 - - -
Junta de separación inter- M10 40 - - -

media
Virola M16 210 - - -
Fase 1
Cilindro a distanciador M24 440 - - -
Cabeza de cilindro M20 150 - - -
Tapa de la válvula M24 260 - - -
– Tuerca ciega M20 40 - - -
– Tornillo allen M20 70 - - -
Descargador válvula de suc- M12 85 - - -

ción
Perno de extensión SU- HEX/SW9 72 - - -

PERBOLT(pistón a vásta-
go del pistón)
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Empaque de presión M20 300 - - -
Brida entrada & salida 7/8"UNC 200 - - -
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Fase 2
Cilindro a distanciador M24 440 - - -
Cabeza de cilindro M16 65 - - -
Tapa de la válvula M20 155 - - -
– Tuerca ciega M20 40 - - -
– Tornillo allen M20 70 - - -
Descargador válvula de suc- M12 85 - - -

ción
Perno de extensión SU- HEX/SW9 72 - - -

PERBOLT(pistón a vásta-
go del pistón)
Empaque de presión M20 300 - - -
Brida entrada & salida 3/4"UNC 160 - - -
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11.6 Juegos y límites de desgaste para las piezas de la unidad de accionamiento

Cojinete principal
Juego nominal [mm] Límite de desgaste [mm]

Radial: 0.164 – 0.252 0.353
Axial: 0.336 – 0.571 0.740
Cojinete del pie de biela

Radial: 0.164 – 0.252 0.353
Axial: 0.336 – 0.571 0.740
Cruceta buje del perno

Radial: 0.078 – 0.144 0.190
Cruceta

Radial: 0.200 – 0.322 0.450
Junta del colector de aceite
Distancia [mm] Límite de desgaste [mm]

3x 1.00 0.00
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11.7 Dimensiones y límites de desgaste para las secciones del compresor

Diámetro camisa del cilindro
Dimensión nominal [mm] Límite de desgaste [mm]

735.00 (fase I) 736.00
398.00 (fase II) 398.50
Diámetro del vástago del pistón
Dimensión nominal [mm] Límite de desgaste [mm]

80.00 79.60
Segmento del pistón
Grosor radial [mm] Límite de desgaste [mm]

17.00 (fase I) 10.20
17.00 (fase II) 10.20
Anillo guía
Grosor radial [mm] Límite de desgaste [mm]

12.00 (fase I) 10.25
8.00 (fase II) 6.55
Empaque de presión, elemento de

sellado
Distancia [mm] Límite de desgaste [mm]

3x 3.00 0.00
11.8 Emisiones
Datos Valor Unidad
Emisión de ruido 85 dB(A)
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11.9 Placa de identificación

La placa de identificación está situada en el alojamiento del cigüeñal
y contiene la siguiente información:
Fig. 60: Placa de identificación
1 Fabricante
2 Número de serie
3 Año de fabricación
4 Tipo de compresor
5 Capacidad [Nm³/h]
6 Presión de succión [kg/cm²]
7 Presión final [kg/cm²]
8 Velocidad [1/min]
9 Rendimiento [mm]
10 Potencia nominal [kW]
11 Masa del compresor [kg]
11.10 Placa del cilindro

La placa del cilindro está situada en la respectiva sección del com-
presor y contiene la siguiente información:
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Fig. 61: Placa del cilindro
1 Número de serie del cilindro

2 Presión de funcionamiento [kg/cm²]
3 Presión y temperatura de proyecto [kg/cm² / °C]
4 Presión de prueba hidrostática [kg/cm²]
5 Holgura del pistón [mm]
6 Juego del diseño del cilindro [Vol.-%]
7 Rendimiento [mm]
8 Diámetro nominal [mm]
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12 Índice
disassembling .............................................107
A
Customer service ............................................. 10
Accident ...........................................................29 Cylinder .................................................... 46, 139
B Grinding the sealing surfaces.......................120

Bearing Cylinder cooling ............................................... 47
Crankpin bearing........................................... 40 Cylinder inner diameter
Main bearing .................................................38 Tolerances ..................................................149
Bolted joints ....................................................146 Cylinder plate..................................................150
C D
Cage ................................................................ 43 Danger areas ................................................... 52

Capacity control ..............................................138 Delivery rate ...................................................143
Checking the oil level ........................................81 Dimensional sheet ..........................................136
Compressor ......................................................46 Dimensions .....................................................136
Compressor data ............................................138 Discharge valves
Compressor section .......................................... 36 replacing .....................................................101

Connecting rod .................................................40 Draining condensation ....................................132
Contact person .................................................10 Drive unit .................................................... 35, 37
Coolant.............................................................47 Checking the oil level.................................... 81
Cooling .............................................................47 Replacing the oil ........................................... 82
Corrosion .......................................................... 58 Replacing the oil wiper packing..................... 83

Coupling .........................................................138 E
Crank housing ..................................................37
Electric power .................................................. 13
Crankpin bearing ..............................................40
Emergency ...................................................... 64
Tolerances ..................................................148 Emergency stop............................................... 64
Crankshaft ........................................................38 Environmental protection
Crosshead ........................................................41
Cleaning liquids ............................................ 31
Tolerances ..................................................148
Coolants....................................................... 31
Crosshead liner ................................................ 37 Cooling water - frost protection ..................... 31
Crosshead pin bushing Lubricants .................................................... 32
Tolerances ..................................................148 Packaging material ....................................... 59
Crosshead-piston rod connection
Process chemicals........................................ 31
assembling..................................................113
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Erection ..........................................................136 Activities before ............................................ 76

Erection conditions..........................................136 Maintenance schedule ..................................... 75
F N
Fastening points ...............................................57 Nameplate ..................................................... 149
Fault table.......................................................124
O
Fire...................................................................29
Oil inspection glass .......................................... 81
First aid.............................................................29
Oil pressure
Foundation......................................................136
checking ....................................................... 77
G Oil pump
Gas analysis ...................................................143 checking ....................................................... 77
Gas data.........................................................141 Oil wiper packing.............................................. 43
Grinding..........................................................120 replacing....................................................... 83
Guide ring.........................................................49 Tolerances ................................................. 148
replacing .......................................................94 Operating data ............................................... 143
Tolerances ..................................................149 Outboard distance piece ...........................44, 139
Overview............................................................ 9
H
External view ................................................ 33
Hazards............................................................13
Internal view ................................................. 34
I
P
Inspection at delivery ........................................56
Packaging.............................................53, 58, 68
Intermediate partition packing ...........................45
Packaging material........................................... 59
replacing .......................................................87
Piston .............................................................. 48
L Piston ring
Leakage............................................................77 replacing....................................................... 94
Loads ...............................................................53 Tolerances ................................................. 149
Location for installation ...................................136 Piston rod ........................................................ 48
Lubricating oil Measuring and setting the straight running .. 117
draining .......................................................132 Piston rod diameter
Selecting type ..............................................131 Tolerances ................................................. 149
topping up ...................................................131 Power ............................................................ 143
Preservation................................................58, 67
M
Pressure packing ............................................. 49
Main bearing.....................................................38
replacing....................................................... 90
Tolerances ..................................................148
Tolerances ................................................. 149
Maintenance
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Process gas data............................................141 Staff ................................................................. 19

Proper use........................................................12 Start-up............................................................ 63
Protective equipment ........................................22 Storage.......................................................53, 59
Substructure ...................................................136
Q
Suction valve unloader..................................... 51
Qualification......................................................19
replacing .....................................................105
R Suction valves
Relief elements .................................................27 replacing ...................................................... 97
Remaining risks ................................................ 13 Superbolt® connection..................................... 48
Remedying faults............................................130 Switching off ............................................... 63, 65
Oil system ...................................................130 Switching on .................................................... 63
Piston fastenings .........................................132 Symbols
Valves.........................................................131 in the instructions ......................................... 11
Removal from service .......................................67
T
Replacing the oil ............................................... 82
Tolerances ..............................................148, 149
Rescue measures.............................................64
Transportation.............................................53, 57
Rod runout......................................................117
U
S
Use.................................................................. 12
Safety
User................................................................. 30
General......................................................... 11
Safety devices ..................................................26 V
Seal Valve cover
Replace the Intermediate partition packing ....87 Grinding the sealing surfaces.......................120
Replace the Pressure packing .......................90 Tightening the fastening screws...................131
Sealing ring ......................................................49 Tightening the pressure screws ...................131
Sealing surfaces Valves.............................................................. 50
grinding.......................................................120 replacing ............................................... 97, 101
Service .............................................................10 Suction valve unloader ................................. 51
Short description............................................... 34 Venting ............................................................ 27
Signs ................................................................ 23
W
Cylinder plate ..............................................150
Warranty terms .................................................. 9
Nameplate ..................................................149
Weight ............................................................141
Space requirement .........................................137
Working areas.................................................. 52
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Apéndice
13 Apéndice
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Apéndice
Tabla de contenidos
A1 Declaración de conformidad
A2 Dibujo disposición general
A3 Dibujo en despiece:
A3.1 Mecanismo
A3.2 Distanciador
A3.3 Componentes de la función de trabajo
A3.4 Cilindro fase I
A3.5 Cilindro fase II
A4 Lista de piezas de recambio
A5 Junta del colector de aceite:
A5.1 Manual
A5.2 Dibujo y lista de piezas
A5.3 Unidad gas separador, manual
A5.4 Unidad gas separador, dibujo y lista de piezas
A6 Dispositivo de escape del cárter del cigüeñal:
A6.1 Manual
A7 Junta de separación intermedia:
A7.1 Manual
A8 Empaque de presión:
A8.1 Manual
A8.2 Dibujo y lista de piezas, empaque de presión fase I
A8.3 Dibujo y lista de piezas, empaque de presión fase II
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Appendix
A9 Válvula de succión:
A9.1 Manual
A9.2 Dibujo y lista de piezas, válvula de succión fase I
A9.3 Dibujo y lista de piezas, válvula de succión fase II
A10 Descargador válvula de succión:
A11 Válvula de descarga:
A11.1 Manual
A11.2 Dibujo y lista de piezas, válvula de descarga fase I
A11.3 Dibujo y lista de piezas, válvula de descarga fase II
A12 Dibujo montaje pistón a vástago:
A12.1 Montaje pistón a vástago fase I
A12.2 Montaje pistón a vástago fase II
A12.3 Sistema de preajuste Superbolt®, manual
A12.4 Sistema de preajuste Superbolt®, dibujo
A13 Volante:
A13.1 Dibujo
A13.2 Sistema de bloqueo del volante, manual
A14 Virola:
A14.1 Manual
A14.2 Dibujo
A15 Herramientas especiales:
A15.1 Palanca de accionamiento de la bomba
A15.2 Dispositivo de ajuste de pernos Z1/1 y Z1/3
A16 Sistema de aceite lubricante:
2010-08-31 173
Apéndice
A16.1 Tabla de lubricantes, unidad de accionamiento
A16.2 Bomba de aceite mecánica, manual
A16.3 Bomba de aceite mecánica, dibujo y lista de piezas
174 2010-08-31
Tabla de lubricantes, unidad de accionamiento
A16.1 Tabla de lubricantes, unidad de accionamiento

ISO VG 150 Proveedor
ACER 150 Agip Schmiertechnik GmbH
BLASIA 150 Paradiesstraße 14
97080 Würzburg
www.agip.de
DEGOL CL 150 T Aral Aktiengesellschaft

Degol BG 150 Neuhöfer Brückenstraße 127–152
21107 Hamburgo
www.aral-lubricants.de
BP Energol RC 150 Deutsche BP Aktiengesellschaft

BP Energol GR-XP 150 Neuhöfer Brückenstraße 127–152
21107 Hamburgo
www.deutschebp.de
Hyspin AWS 150 Castrol Industrie GmbH

Alpha SP 150 Erkelenzer Straße 20
Tribol 1100/150 41179 Mönchengladbach
Optigear BM 150 www.castrol-industrie.com
Vactra Oil Heavy NUTO 150 ESSO DEUTSCHLAND GmbH

SPARTAN EP 150 Kapstadtring 2
Mobilgear 629 22297 Hamburgo
www.ExxonMobil.de
RENOLIN DTA 150 Fuchs Europe Schmierstoffe GmbH

RENOLIN CLP 150 Friesenheimer Straße 15
RENOLIN Unisyn CLP 150 68169 Mannheim
www.fuchs-europe.de
CRUCOLAN 150 Klüber Lubrication München KG

Klüberoil GEM 1-150N Geisenhausenerstr. 7
Klüberoil 4UH1-150N 81379 Múnich
www.klueber.com
turb HTU 150 OMV Refining & Marketing GmbH
2010-08-31 175
Tabla de lubricantes, unidad de accionamiento
ISO VG 150 Proveedor

gear HST 150 Lassallestraße 3
1020 Viena, Austria
www.omv.com
Morlina 115 Shell Deutschland Oil GmbH

Omala Oil 150 22284 Hamburgo
CIRKAN RO 150 TOTAL Deutschland GmbH

CARTER EP 150 Kirchfeldstraße 61
40217 Düsseldorf
www.total.de
Wiolan CN 150 SRS Schmierstoff Vertrieb GmbH

Ersolan 150 Neuenkirchener Straße 8
48499 Salzbergen
www.srs-oil.de
176 2010-08-31
2010-08-31 177
ADJUSTABLE PARAMETERS
PRE-RUN TIME RUN UP TIME
NNN NNN
RUN DOWN TIME TEST TIME
NNN NNN
DISPLAY
CONFIGURATION
MODE
Overview
Alarm time Acknowledge time Message
* 3/29/2008 7:05:28 AM 3/29/2008 7:05:28 AM ABCDE FGHIJK LMNOPQ RSTUV WXYZ
ABCDE FGHIJK LMNOPQ RSTUV WXYZ
Ack Silence Alarm

Alarm Alarms Status
Ack Sort
Clear All
All Alarms
Overview
ALARM SET-POINT SCREEN
LOW ALARM ST.PTS. PRESS. LOW-LOW ALARM ST.PTS. PRESS. LOW ALARM ST.PTS. LEVEL.
PIT-01 #.### KG/CM2 PIT-01 #.### KG/CM2 LIT-01 #### MM
PIT-11 #.### KG/CM2 PIT-11 #.### KG/CM2 HIGH ALARM ST.PTS.

ROD DROP.
PIT-29 #.### KG/CM2 PIT-25 #.### KG/CM2 ZT-02 #.### MM
PIT-27 #.### KG/CM2 ZT-03 #.### MM
PIT-32 #.### KG/CM2 ZT-05 #.### MM
HIGH ALARM ST.PTS. PRESS. HIGH HIGH ALARM ST.PTS. PRESS.

ZT-06 #.### MM
PIT-01 #.### KG/CM2 PIT-01 #.### KG/CM2
PIT-04 #.### KG/CM2 PIT-04 #.### KG/CM2

ALARM SET POINT
PIT-09 #.### KG/CM2 PIT-09 #.### KG/CM2 PAGE 2
PDIT-13 #.### KG/CM2D PDIT-13 #.### KG/CM2D Overview

HIGH ALARM HIGH-HIGH ALARM HIGH ALARM HIGH ALARM
ST.PTS. TEMP. ST.PTS. TEMP. ST.PTS. TEMP. ST.PTS. TEMP.
TIT-02 ###.# °C TE-43 ###.# °C TE-74 ###.# °C
TIT-03 ###.# °C TIT-03 ###.# °C TE-44 ###.# °C TE-33 ###.# °C
TIT-55 ###.# °C TIT-55 ###.# °C TE-84 ###.# °C TE-83 ###.# °C
TIT-06 ###.# °C TE-85 ###.# °C TE-42 ###.# °C
TIT-07 ###.# °C TIT-07 ###.# °C
TIT-56 ###.# °C TIT-56 ###.# °C
TIT-11 ###.# °C
TE-45 ###.# °C TE-45 ###.# °C
TE-46 ###.# °C TE-46 ###.# °C

ALARM SET POINT
PAGE 3
TIT-11 ###.# °C TIT-11 ###.# °C
TIT-61 ###.# °C
Overview
HIGH ALARM HIGH ALARM HIGH ALARM HIGH ALARM
ST.PTS. TEMP. ST.PTS. TEMP. ST.PTS. TEMP. ST.PTS. TEMP.
TE-66 ###.# °C TE-21 ###.# °C TE-75 ###.# °C TE-34 ###.# °C
TE-67 ###.# °C TE-22 ###.# °C TE-76 ###.# °C TE-35 ###.# °C
TE-68 ###.# °C TE-24 ###.# °C TE-77 ###.# °C TE-36 ###.# °C
TE-69 ###.# °C TE-25 ###.# °C TE-78 ###.# °C TE-37 ###.# °C
TE-70 ###.# °C TE-27 ###.# °C TE-79 ###.# °C TE-38 ###.# °C
TE-71 ###.# °C TE-28 ###.# °C TE-80 ###.# °C TE-39 ###.# °C
TE-72 ###.# °C TE-30 ###.# °C TE-81 ###.# °C TE-40 ###.# °C
TE-73 ###.# °C TE-31 ###.# °C TE-82 ###.# °C TE-41 ###.# °C
ALARM SET POINT

PAGE 4 Overview
LOW ALARM LOW LOW ALARM

ST.PTS. TEMP. ST.PTS. TEMP.
TIT-11 ###.# °C TIT-11 ###.# °C
HIGH ALARM HIGH HIGH ALARM

ST.PTS. VIBR ST.PTS. VIBR.
VT-01 ##.# MM/S VT-01 ##.# MM/S
VT-02 #.## G VT-02 #.## G
VT-03 #.## G VT-03 #.## G
VT-04 #.## G VT-04 #.## G
VT-05 #.## G VT-05 #.## G

ALARM SET POINT
PAGE 1
Overview
CAPACITY CONTROL
REMOTE CAPACITY CONTROL
COMPRESSOR
SY-01 LOAD STATUS
PCV-30 O% LOADED
SY-02
5O% LOADED A MODE
SY-03
75% LOADED A MODE
SY-04
100% LOADED
CE HE CE HE CE HE CE HE
1ST STG 1ST STG 2ND STG 2ND STG

CYLINDER CYLINDER CYLINDER CYLINDER
A B A B
Overview
COOLING OIL SYSTEM
COOLING OIL
RETURN
1ST STG 1ST STG 2ND STG 2ND STG

CYL A CYL B CYL A CYL B
LOW LEVEL
LOW PRESS LIT-04
HIGH TEMP PIT-29 #### MM
###.# KG/CM2 MAIN COOLING
TIT-61 OIL PUMP
###.# °C LT
TT
RUNNING COOLING OIL

SUPPLY
AUX COOLING
OIL PUMP
RUNNING
Overview
COMP VALVE TEMPS
HIGH TEMP HIGH TEMP HIGH TEMP HIGH TEMP HIGH TEMP HIGH TEMP HIGH TEMP HIGH TEMP
TE-22 TE-21 TE-27 TE-28 TE-67 TE-66 TE-70 TE-71
###.# °C ###.# °C ###.# °C ###.# °C ###.# °C ###.# °C ###.# °C ###.# °C
HIGH TEMP HIGH TEMP HIGH TEMP HIGH TEMP
TE-24 TE-30 TE-68 TE-72
###.# °C 1ST STG ###.# °C ###.# °C 1ST STG ###.# °C
CYL B CYL A
TE-25 TE-31 TE-69 TE-73
###.# °C ###.# °C ###.# °C ###.# °C
TE-33 TE-42 TE-74 TE-83
COMPRESSOR
###.# °C ###.# °C ###.# °C ###.# °C
TE-34 TE-38 TE-75 TE-79

###.# °C ###.# °C ###.# °C ###.# °C
HIGH TEMP 2ND STG
HIGH TEMP HIGH TEMP 2ND STG
HIGH TEMP
CYL B CYL A
TE-35 TE-39 TE-76 TE-80
###.# °C ###.# °C ###.# °C ###.# °C
###.# °C ###.# °C ###.# °C ###.# °C ###.# °C ###.# °C ###.# °C ###.# °C
HIGH TEMP HIGH TEMP HIGH TEMP HIGH TEMP HIGH TEMP HIGH TEMP HIGH TEMP HIGH TEMP
VIBR. / ROD DROP Overview

LUBE OIL SYSTEM PDIT-13
##.## KG/CM2
OIL FILT
LOW TEMP PDIT HIGH DP
LOW LOW TEMP TIT-11 HIGH HIGH
TT
HIGH TEMP ###.# °C DP
OIL FILT
LOW PRESS PIT-11

LOW-LOW ##.## Kg/Cm2
PRESS PCV-14
PT LUBE PCV-19
OIL
COOLER
MAIN LUBE TCV-14

OIL PUMP
RUNNING AUX LUBE

LOW LEVEL OIL PUMP
LIT-01
#### MM
RUNNING
Overview
COMPRESSOR BC-359
PROCESS
CAPACITY CONTROL
LOG IN LUBE OIL SYSTEM
VIBRATION / TEMP / ROD DROP
COOLING OIL SYSTEM
LOGOUT PURGE SYSTEM
ALARM HISTORY
ALARM SET-POINTS
STATUS SCREEN
ADJUSTABLE PARAMETERS
ESPANOL
COMPRESSOR PROCESS
FIT-01
######Kg/hr
INLET 1ST STAGE
SUCTION TT
TIT-02
PIT-01 VESSEL
###.# °C
#.### KG/CM2 HIGH TEMP
LO PRESS
LO-LO PRESS
PT
HI-PRESS
HI-HI PRESS
1ST STAGE 1ST STAGE
CYLINDER A CYLINDER B
TIT-03 TT TT TIT-55
###.# °C ###.# °C
HIGH TEMP HIGH TEMP
HI-HI TEMP HI-HI TEMP
OUTLET
PIT-04 1ST STAGE

##.## KG/CM2 DISCH
VESSEL
HI-PRESS
HI-HI PRESS PT
Process Pg2 Overview
COMPRESSOR PROCESS PG2
INLET 2ND STAGE

SUCTION TT
TIT-06
PIT-06 VESSEL
###.# °C
##.## KG/CM2 HIGH TEMP
LO PRESS
LO-LO PRESS
PT
HI-PRESS
HI-HI PRESS
2ND STAGE 2ND STAGE
CYLINDER A CYLINDER B
TIT-07 TT TT TIT-56
###.# °C ###.# °C
HIGH TEMP HIGH TEMP
HI-HI TEMP HI-HI TEMP
OUTLET
PIT-09 2ND STAGE FIT-06

##.## KG/CM2 DISCHARGE ######Kg/hr
VESSEL
HI-PRESS
HI-HI PRESS PT
Process Pg1 Overview
PURGE SYSTEM
PIT-27 LOW
##.## KG/CM2 PRESS
PT
PCV-29
1ST STG 1ST STG
CYL A CYL B
FILTER
COALESCER
MAIN
DRIVE
MOTOR
COMPRESSOR
COMPRESSOR
RUNNING
2ND STG 2ND STG

CYL A CYL B
Overview
VIBRATION / TEMPERATURE / ROD DROP
HIGH TEMP HIGH TEMP
HI-HI VIB TE-44 HI-HI VIB TE-85
HIGH VIB ###.# °C HIGH VIB ###.# °C
VT-02 VT-04
##.## MM/S 1ST STAGE
##.## MM/S 1ST STAGE
CYL B CYL A
HIGH ALARM HIGH ALARM

RPM ZT-02 ZT-05
XT-01 ###.#mm ###.#mm
##### VT-01
MAIN ##.## MM/S
DRIVE HI-HI VIB
MOTOR HIGH VIB
RUNNING
ZT-03 ZT-06
TE-45 TE-46
###.# °C ###.# °C ###.#mm ###.#mm
HIGH ALARM HIGH ALARM
HIGH TEMP HIGH TEMP 2ND STAGE 2ND STAGE
CYL B CYL A
VT-05
##.## MM/S
TE-43 VT-03 TE-84 HIGH VIB
###.# °C ##.## MM/S ###.# °C HI-HI VIB
HIGH TEMP HIGH VIB HIGH TEMP
HI-HI VIB
CYL TEMPS Overview
MAX STARTS PER STATUS SCREEN
DAY
OKAY PUSH TO PUSH TO
STARTS REM # ACTIVATE TEST CANCEL TEST
MODE MODE
MAX STARTS PER
HOUR PANEL NOT IN TEST MODE
OKAY AUX LUBE RUN STATUS
STARTS REM # TEST TIME REMAINING ###.# SEC STOPPED
COMP. READY TO START AUX LUBE HOA STATUS
COMP. LOAD STATUS
READY TO START AUTO HAND OFF
0% LOADED
COMP. START INITIATED
50% LOADED
MAIN COP RUN STATUS
NOT INITIATED STOPPED
COMP. PRE-RUN TMR. TIMING 75% LOADED MAIN COP HOA STATUS
TIMING ##### AUTO HAND OFF
100% LOADED
COMP. RUN STATUS AUX COP LUBE RUN STATUS
STOPPED STOPPED
LOCAL START CONTROL
COMP. RUN UP TMR. TIMING AUX COP LUBE HOA STATUS
TIMING ##### AUTO HAND OFF
RUNDOWN TMR. TIMING COMP. HOUR METER
TIMING ##### CRANKCASE OIL HEATER ON HOURS ########
COMP. COMMON ALARM MINUTES ###
COOLING OIL HEATER ON
ALARM
COMP. SHUTDOWN ALARM
SHUTDOWN
Overview
PARAMETROS AJUSTABLES
(SEGUNDOS)
Tiempo Tiempo
de pre-lub de arranque
NNN NNN
Tiempo de
post-lub. Tiempo de Prueba
NNN NNN
MOSTRAR MODO
DE
CONFIGURACION
Vista General
Alarm time Acknowledge time Message
* 3/29/2008 7:06:05 AM 3/29/2008 7:06:05 AM ABCDE FGHIJK LMNOPQ RSTUV WXYZ
ABCDE FGHIJK LMNOPQ RSTUV WXYZ
Confirmar Silenciar
Alarma Alarmas Estado de
Confirmar Borrar Alarma
Todo Todo
Vista General
PANTALLA de ALARMAS
BAJA ALARMA PRES. BAJA-BAJA PARO PRES. BAJA ALARMA NIVEL.
PIT-11 #.### KG/CM2 PIT-11 #.### KG/CM2 ALTA ALARMA

CAIDA DE VASTAGO
PIT-29 #.### KG/CM2 PIT-25 #.### KG/CM2 ZT-02 #.### MM
PIT-27 #.### KG/CM2 ZT-03 #.### MM
PIT-32 #.### KG/CM2 ZT-05 #.### MM
ALTA ALARMA PRES. ALTA-ALTA PARO PRES.

ZT-06 #.### MM
PIT-01 #.### KG/CM2 PIT-01 #.### KG/CM2
PIT-04 #.### KG/CM2 PIT-04 #.### KG/CM2
AJUSTE ALARMA
PIT-09 #.### KG/CM2 PIT-09 #.### KG/CM2 PAGINA 2
PDIT-13 #.### KG/CM2D PDIT-13 #.### KG/CM2D

Vista General
PANTALLA de ALARMAS
ALTA ALARMA ALTA-ALTA PARO ALTA ALARMA ALTA ALARMA
TEMP. TEMP. TEMP. TEMP.
TIT-02 ###.# °C
TE-43 ###.# °C TE-74 ###.# °C
TIT-03 ###.# °C TIT-03 ###.# °C

TE-44 ###.# °C TE-33 ###.# °C
TIT-55 ###.# °C TIT-55 ###.# °C

TE-84 ###.# °C TE-83 ###.# °C
TIT-06 ###.# °C
TE-85 ###.# °C TE-42 ###.# °C
TIT-07 ###.# °C TIT-07 ###.# °C
TIT-56 ###.# °C TIT-56 ###.# °C
TIT-11 ###.# °C
TE-45 ###.# °C TE-45 ###.# °C
TE-46 ###.# °C TE-46 ###.# °C

AJUSTE ALARMA
TIT-11 ###.# °C TIT-11 ###.# °C PAGINA 3
TIT-61 ###.# °C Vista General

PANTALLA de ALARMAS
ALTA ALARMA ALTA ALARMA ALTA ALARMA ALTA ALARMA
TEMP. TEMP. TEMP. TEMP.
TE-66 ###.# °C TE-21 ###.# °C TE-75 ###.# °C TE-34 ###.# °C
TE-67 ###.# °C TE-22 ###.# °C TE-76 ###.# °C TE-35 ###.# °C
TE-68 ###.# °C TE-24 ###.# °C TE-77 ###.# °C TE-36 ###.# °C
TE-69 ###.# °C TE-25 ###.# °C TE-78 ###.# °C TE-37 ###.# °C
TE-70 ###.# °C TE-27 ###.# °C TE-79 ###.# °C TE-38 ###.# °C
TE-71 ###.# °C TE-28 ###.# °C TE-80 ###.# °C TE-39 ###.# °C
TE-72 ###.# °C TE-30 ###.# °C TE-81 ###.# °C TE-40 ###.# °C
TE-73 ###.# °C TE-31 ###.# °C TE-82 ###.# °C TE-41 ###.# °C
AJUSTE ALARMA
PAGINA 4 Vista General
PANTALLA de ALARMAS
BAJA ALARMA ALTA ALARMA

TEMP. TEMP.
TIT-11 ###.# °C TIT-11 ###.# °C
ALTA ALARMA ALTA-ALTA PARO

VIBR. VIBR.
VT-01 ##.# MM/S VT-01 ##.# MM/S
VT-02 #.## G VT-02 #.## G
VT-03 #.## G VT-03 #.## G
VT-04 #.## G VT-04 #.## G
VT-05 #.## G VT-05 #.## G

AJUSTE ALARMA
PAGINA 1
Vista General
CONTROL de CAPACIDAD
CONTROL DE CAPACIDAD LOCAL
ESTADO DE CARGA
DE COMPRESOR
SY-01
O% CARGADO
PCV-30 SY-02 5O% CARGADO MODO A
SY-03 75% CARGADO MODO B
SY-04
100% CARGADO
CE HE CE HE CE HE CE HE
Cilindro A Cilindro B
1era Etapa 1era Etapa
2da Etapa 2da Etapa
Vista General
SISTEMA DE ACEITE DE ENFRIAMIENTO
RETORNO DEL
ACEITE DE ENFR.
Cilindro A Cilindro B Cilindro A Cilindro B

1era Etapa 1era Etapa 2da Etapa 2da Etapa
NIVEL BAJA
PRESION BAJA LIT-04
TEMP-ALTA PT BOMBA PPAL. #### MM
PIT-32
DE ACEITE DE ENFR.
TIT-61 ###.# KG/CM2
###.# °C LT
TT
CORRIENDO
SUMINISTRO DEL
ACEITE ENFR.
BOMBA AUX.
DE ACEITE DE ENFR.
CORRIENDO
Vista General
TEMP VALVULAS COMP
TEMP-ALTA TEMP-ALTA TEMP-ALTA TEMP-ALTA TEMP-ALTA TEMP-ALTA TEMP-ALTA TEMP-ALTA
###.# °C ###.# °C ###.# °C ###.# °C ###.# °C ###.# °C ###.# °C ###.# °C
TEMP-ALTA TEMP-ALTA TEMP-ALTA TEMP-ALTA
TE-24 TE-30 TE-68 TE-72
CILINDRO CILINDRO
###.# °C B ###.# °C ###.# °C A ###.# °C
TE-25 TE-31 TE-69 TE-73
###.# °C ###.# °C ###.# °C ###.# °C
TE-33 TE-42 TE-74 TE-83
COMPRESOR
###.# °C ###.# °C ###.# °C ###.# °C
TE-34 TE-38 TE-75 TE-79

###.# °C ###.# °C ###.# °C ###.# °C
TEMP-ALTA CILINDRO TEMP-ALTA TEMP-ALTA CILINDRO TEMP-ALTA
B A
TE-35 2da Etapa TE-39 TE-76 2da Etapa TE-80
###.# °C ###.# °C ###.# °C ###.# °C
###.# °C ###.# °C ###.# °C ###.# °C ###.# °C ###.# °C ###.# °C ###.# °C
TEMP-ALTA TEMP-ALTA TEMP-ALTA TEMP-ALTA TEMP-ALTA TEMP-ALTA TEMP-ALTA TEMP-ALTA
VIBR. / VASTAGO Vista General

SISTEMA de ACEITE de LUBRICACION PDIT-13
FILTROS ##.## KG/CM2D
de ACEITE
PDIT DP ALTA
TEMP-BAJA
TEMP-BAJA-BAJA TIT-11 BAJA-BAJA
TT
TEMP-ALTA ###.# °C DP
PRESION BAJA PIT-11

PRESION ##.## Kg/Cm2
BAJA-BAJA PCV-14
PT PCV-19
ENFRIADOR
de ACEITE
BOMBA PRINCIPAL TCV-14

de ACEITE
BOMBA AUXILIAR
CORRIENDO de ACEITE
BAJA NIVEL
LIT-01
#### MM
PARADO
Vista General
COMPRESOR BC-359
PROCESO
CONTROL de CAPACIDAD
LOG IN SISTEMA de ACEITE de LUBRICACION
VIBRACION/TEMPERATURES
SISTEMA DE ACEITE DE ENFRIAMIENTO
LOGOUT
SISTEMA de PURGA
HISTORIAL de ALARMAS
PUNTOS de ALARMAS
PANTALLA de ESTADO
PARAMETROS AJUSTABLES
ENGLISH
PROCESO DE COMPRESOR
FIT-01
######Kg/hr
ENTRADA
1era ETAPA TT
BOTELLA de TIT-02
PIT-01 PULSACION ###.# °C
#.### KG/CM2 de SUCCION TEMP ALTA
PRES. BAJA
PRES. BAJA-
BAJA PT
PRESS ALTA
PRES. ALTA-
ALTA
TIT-03 TT TT TIT-55
###.# °C ###.# °C
TEMP ALTA TEMP ALTA
TEMP ALTA- TEMP ALTA-
ALTA ALTA
SALIDA
PIT-04 1era ETAPA

##.## KG/CM2 BOTELLA de
PRESS ALTA PULSACION
de DESCARGA
PRES. ALTA-
ALTA PT Vista
Proceso Pg2 General
PROCESO DE COMPRESOR
ENTRADA
2da ETAPA TT
BOTELLA de TIT-06
PIT-06 PULSACION ###.# °C
##.## KG/CM2 de SUCCION TEMP ALTA
PRES. BAJA
PRES. BAJA-
BAJA PT
PRESS ALTA
PRES. ALTA-
ALTA
2da Etapa 2da Etapa
TIT-07 TT TT TIT-56
###.# °C ###.# °C
TEMP ALTA TEMP ALTA
TEMP ALTA- TEMP ALTA-
ALTA ALTA
SALIDA
PIT-09 2da ETAPA FIT-06

##.## KG/CM2 BOTELLA de ######Kg/hr
PRESS ALTA PULSACION
de DESCARGA
PRES. ALTA-
ALTA PT
Vista
Proceso Pg1 General
SISTEMA de PURGA
PIT-27 PRESION
##.## KG/CM2 BAJA
PT
PCV-29
CILINDRO CILINDRO
A B
FILTRO
MOTOR
PRINCIPAL
COMPRESOR
CORRIENDO
CILINDRO CILINDRO
A B
2da Etapa 2da Etapa
Vista General
VIBRACION / TEMPERATURA / CAIDA DE VASTAGO
TEMP-ALTA TEMP-ALTA
VIB ALTA-ALTA
TE-44 VIB ALTA-ALTA TE-85
VIB ALTA ###.# °C VIB ALTA ###.# °C
VT-02 VT-04
##.## MM/S CILINDRO ##.## MM/S CILINDRO
B A
CAIDA DE 1era Etapa CAIDA DE 1era Etapa
VASTAGO ALTA VASTAGO ALTA
RPM ZT-02 ZT-05
XT-01 ###.#mm ###.#mm
##### VT-01
##.## MM/S
MOTOR VIB ALTA-ALTA
PRINCIPAL VIB ALTA
CORRIENDO
ZT-03 ZT-06
TE-45 TE-46
###.# °C ###.# °C ###.#mm ###.#mm
CAIDA DE CAIDA DE
TEMP-ALTA TEMP-ALTA CILINDRO VASTAGO ALTA CILINDRO VASTAGO ALTA
B A
2da Etapa 2da Etapa VT-05
##.## MM/S
TE-43 VT-03 TE-84 VIB ALTO
###.# °C ##.## MM/S ###.# °C VIB ALTA-ALTA
TEMP-ALTA VIB ALTA TEMP-ALTA
VIB ALTA-ALTA
CIL TEMPS Vista General
ARRANQUES MAXIMOS PANTALLA de ESTADO
POR DIA
NO ARRANQUES PERMITIDOS PRESIONE PARA PRESIONE PARA
# ACTIVAR MODO CANCELAR MODO
ARRANQUES RESTANTES DE PRUEBA
DE PRUEBA
ARRANQUES MAXIMOS
POR HORA PANEL NO EN MODO PRUEBA ESTADO DE LUBR.AUX
NO ARRANQUES PERMITIDOS CORRIENDO
ARRANQUES RESTANTES# TIEMPO DE PRUEBA
PERMANECIENDO ###.# SEC SELECTOR DE LUBR. AUX
COMP. LISTO PARA ARRANCAR AUTO MAN. APAG.
LISTO ESTADO DE CARGA DE COMPR. BOMBA PPAL. ACEITE
SEQUENCIA DE ARRANQUE 0% CARGADO DE ENFR.
INICIADA CORRIENDO
50% CARGADO
TIEMPO DE PRE-LUB.
SELECTOR PPAL. DE
75% CARGADO ACEITE ENFR.
NO CONTANDO ##### AUTO MAN. APAG.
ESTADO DE ARRANQUE 100% CARGADO BOMBA AUX. ACEITE
CORRIENDO DE ENFR.
CONTROL DE ARRANQUE REMOTO CORRIENDO
TIEMPO DE ARRANQUE
CALENTADOR ACEITE DE CARCAZA SELECTOR AUX. DE
NO CONTANDO ##### ACEITE DE ENFR.
TIEMPO DE POST-LUB. CALENTADOR ACEITE DE ENFR. AUTO MAN. APAG.
NO CONTANDO ##### TIEMPO DE SERVICIO DEL COMP.
COMP. ALARMA COMUN HORAS ########
NORMAL
MINUTOS ###
COMP. PARO COMUN
PARO Vista General
Installation Instructions
SLC 500™ Analog Input Modules

(Catalog Numbers 1746-NI16I and 1746-NI16V)
Inside
Important User Information .................................................................... 2
For More Information ................................................................................3
Hazardous Location Considerations ....................................................... 4
Environnements dangereux .................................................................... 4
Electrostatic Damage.............................................................................. 5
1746-NI16 Power Requirements............................................................. 5
Module Location in Chassis.................................................................... 6
Heat and Noise Considerations .............................................................. 6
Module Installation and Removal........................................................... 7
Terminal Wiring....................................................................................... 9
Input Devices ........................................................................................ 13
Transducer Source Impedance.............................................................. 13
Specifications ....................................................................................... 15
Publication 1746-IN001B-US-P
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2 SLC 500™ Analog Input Modules
Important User Information

Because of the variety of uses for the products described in this publication, those
responsible for the application and use of this control equipment must satisfy
themselves that all necessary steps have been taken to assure that each application
and use meets all performance and safety requirements, including any applicable
laws, regulations, codes and standards.
The illustrations, charts, sample programs and layout examples shown in this guide
are intended solely for purposes of example. Since there are many variables and
requirements associated with any particular installation, Allen-Bradley does not
assume responsibility or liability (to include intellectual property liability) for actual
use based upon the examples shown in this publication.
Allen-Bradley publication SGI-1.1, Safety Guidelines for the Application, Installation
and Maintenance of Solid-State Control (available from your local Allen-Bradley
office), describes some important differences between solid-state equipment and
electromechanical devices that should be taken into consideration when applying
products such as those described in this publication.
Reproduction of the contents of this copyrighted publication, in whole or part,
without written permission of Rockwell Automation, is prohibited.
ATTENTION
Identifies information about practices or circumstances that can
lead to personal injury or death, property damage, or economic
! loss.
Attention statements help you to:

• identify a hazard
• avoid the hazard
• recognize the consequences
IMPORTANT Identifies information that is critical for successful application

and understanding of the product.
@JO#VTQQE ".
SLC 500™ Analog Input Modules 3
For More Information

For detailed information on planning and installing your system, see the following
publications:
Publication Publication
Number
Industrial Automation Wiring and Grounding Guidelines 1770-4.1
SLC 500™ Analog Input Modules User Manual 1746-UM001A-US-P
SLC 500™ Modular Hardware Style Operation and Installation Manual 1747-6.2
SLC 500™ Fixed Hardware Style Operation and Installation Manual 1747-6.21
If you would like a manual, you can:

• download a free electronic version from the internet:
www.theautomationbookstore.com
• purchase a printed manual by:
– contacting your local distributor or Rockwell Automation representative
– visiting www.theautomationbookstore.com and placing your order
– calling 1.800.963.9548 (USA/Canada)
or 001.330.725.1574 (Outside USA/Canada)
@JO#VTQQE ".
Hazardous Location Considerations

This equipment is suitable for use in Class I, Division 2, Groups A, B, C, D or
non-hazardous locations only. The following ATTENTION statement applies to
use in hazardous locations.
WARNING EXPLOSION HAZARD

• Substitution of components may impair suitability for Class I,
Division 2.
! • Do not replace components or disconnect equipment unless
power has been switched off.
• Do not connect or disconnect components unless power has
been switched off.
• This product must be installed in an enclosure.
Environnements dangereux
Cet équipement est conçu pour être utilisé dans des environnements de Classe 1,
Division 2, Groupes A, B, C, D ou non dangereux. La mise en garde suivante
s’applique à une utilisation dans des environnements dangereux.
MISE EN GARDE DANGER D’EXPLOSION

• La substitution de composants peut rendre cet équipement
impropre à une utilisation en environnement de Classe 1,
! Division 2.
• Ne pas remplacer de composants ou déconnecter
l'équipement sans s'être assuré que l'alimentation est coupée.
• Ne pas connecter ou déconnecter des composants sans s'être
assuré que l'alimentation est coupée.
• Ce produit doit être installé dans une armoire.
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Electrostatic Damage
Electrostatic discharge can damage semiconductor devices inside this module if you
touch backplane connector pins. Guard against electrostatic damage by observing
the following precautions.
ATTENTION Electrostatic discharge can degrade performance or cause

permanent damage. Handle the module as stated below.
• Wear an approved wrist strap grounding device when
! handling the module.
• Touch a grounded object to rid yourself of electrostatic charge
before handling the module.
• Handle the module from the front, away from the backplane
connector. Do not touch backplane connector pins.
• Keep the module in its static-shield bag when not in use, or
during shipment.
1746-NI16 Power Requirements

The 1746-NI16 module receives its power through the SLC 500 chassis backplane
from the fixed or modular +5V dc/+24V dc chassis power supply. The +5V dc
backplane supply powers the SLC circuitry and the +24V dc backplane supply
powers the module analog circuitry. The maximum current drawn by the module is
shown in the table below.
5V dc Amps 24V dc Amps

125 mA 75 mA
When you are using a modular system configuration, add the values shown in the
table above to the requirements of all other modules in the SLC chassis to prevent
overloading the chassis power supply.
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Module Location in Chassis

Modular Chassis Considerations
Place your 1746-NI16 module in any slot of an SLC 500 modular, or modular
expansion chassis, except for the extreme left slot (slot 0) in the first chassis. This slot
is reserved for the processor or adapter modules.
Operating Temperature Range +0°C to +60°C (+32°F to +140°F)
Fixed Expansion Chassis Considerations
IMPORTANT The 2-slot, SLC 500 fixed I/O expansion chassis (1746-A2)
supports only specific combinations of modules. If you are using
the 1746-NI16 module in a 2-slot expansion chassis with another
SLC I/O or communication module, refer to the 1746-NI16 user
manual to determine whether the combination can be supported.
Heat and Noise Considerations

Most applications require installation in an industrial enclosure to reduce the effects
of electrical interference. Analog inputs are highly susceptible to electrical noise.
Electrical noise coupled to the analog inputs reduces the performance (accuracy) of
the module.
Group your modules to minimize adverse effects from radiated electrical noise and
heat. Consider the following conditions when selecting a slot for the analog input
module. Position the module:
• in a slot away from sources of electrical noise such as hard-contact switches,

relays, and AC motor drives
• away from modules which generate significant radiated heat, such as the 32-point
I/O module (series C or earlier)
In addition, route shielded twisted-7pair analog input wiring away from any
high-voltage I/O wiring.
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Module Installation and Removal

When installing the module in a chassis, it is not necessary to remove the terminal
block from the module. However, if the terminal block is removed, use the write-on
label (shown below) located on the side of the terminal block to identify the module
location and type.
SLOT RACK
• MODULE
ATTENTION Remove power before removing or inserting this module. When

you remove or insert a module with power applied, an electrical
arc may occur. An electrical arc can cause personal injury or
property damage by:
! • sending an erroneous signal to your system’s field devices,
causing unintended machine motion
• causing an explosion in a hazardous environment
Electrical arcing causes excessive wear to contacts on both the
module and its mating connector. Worn contacts may create
electrical resistance.
Terminal Block Removal

1. Loosen the two terminal block release screws.
Terminal Block
Release Screws
2. Grasp the terminal block at the top and bottom and pull outward and down.
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Module Installation Procedure

1. Align the circuit board of the analog input module with the card guides located at
the top and bottom of the chassis.
2. Slide the module into the chassis until both top and bottom retaining clips are
secured. Apply firm even pressure on the module to attach it to its backplane
connector. Never force the module into the slot.
3. Cover all unused slots with the Card Slot Filler, Catalog Number 1746-N2.
Top and Bottom Module

Release(s)
Card
Guide
Module Removal Procedure

1. Press the releases at the top and bottom of the module and slide the module out
of the chassis slot.
2. Cover all unused slots with the Card Slot Filler, Catalog Number 1746-N2.
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Terminal Wiring
The 1746-NI16 module contains an 18-position, removable terminal block. The
terminal pin-out is shown below.
ATTENTION Disconnect power to the SLC before attempting to install,

remove, or wire the removable terminal wiring block.
To avoid cracking the removable terminal block, alternate the
! removal of the slotted terminal block release screws.
Terminal Block
(Terminal Block Spare Part Catalog Number 1746-RT25G)
Channel 0
Channel 1
Channel 2
Channel 3
Channel 4
Channel 5
Channel 6
Channel 7
Analog Com
Analog Com
Channel 8
Channel 9
Channel 10
Channel 11
Channel 12
Channel 13
Channel 14
Channel 15
Terminal Block Release Screw

Maximum Torque = 0.7 to 0.9 Nm (6 to 8 in-lbs.)
Pre-wired Cables and Terminal Blocks

The following 1492 cables and terminal blocks are available to assist in wiring the
1746-NI16 module:
Allen-Bradley Prewired 1492-ACAB005A46, 0.5m (1.6 ft.

Cables 1492-ACAB010A46, 1.0 m (3.3 ft.)
1492-ACAB025A46, 2.5 m (8.2 ft.)
1492-ACAB050A46, 5.0 m (16.4 ft.)
Allen-Bradley User Terminal 1492-AIFM8-3
Blocks 1492-AIFM16-F-3
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Wiring Single-Ended Inputs

The diagram below shows typical wiring for the 1746-NI16V module.
(2)
Channel 0
Voltage +
- IN0 IN1
Transmitter +
(2)
Channel 2
+ + IN2 IN3
Voltage
Transmitter -
(2)
+ IN4 IN5
Channel 4
+
Voltage
-
Transmitter (2) + IN7
IN6
Channel 6
+
Voltage
- Analog Analog
Transmitter -
Com Com
(1)
Vdc (1)
+
power supply(5) IN8 IN9 (3)
-
IN10 IN11 (3)

Optional second +
Vdc power
-
supply(6) IN12 IN13 (3)
IN14 IN15 (3)

(4)
(1) There are two common terminals for all of the 16 voltage inputs. These two analog common terminals are
connected internally.
(2) All shield wires should be connected to chassis mounting screws.
(3) Unused channels should be connected to the analog common terminals (0 Volts).
(4) If separate shielded cables are used for each analog input channel, interposing terminal blocks are needed
to terminate up to 16 common wires. Then 1 to 4 common wires should be wired from the interposing
terminal block to the 2 common terminals on the 1746-NI16V module.
(5) The module does not provide loop power for analog inputs. Use a power supply that matches the transmitter
specifications.
(6) More than one power supply can be used if all supplies are class 2.
NOTE Although the above diagram has 12 unused inputs, only 4

channels are shown connected to the Analog Com as an
example.
@JO#VTQQE ".

The diagram below shows typical wiring for the 1746-NI16I module.
Channel 0 (2)
2-wire current +
+
Transmitter -
IN0 IN1
Channel 2 (2)
+ +
2-wire current IN2 IN3
-
Transmitter
Channel 4 (2)
2-wire current + + IN4 IN5
Transmitter -
Channel 6 +
(2) + IN6 IN7
3-wire current
Transmitter -
Analog Analog
-
Com Com
(1) (1)
Vdc +
power supply(5) IN8 IN9
(3)
-
IN10 IN11 (3)

Optional second +
Vdc power
supply(6) -
IN12 IN13 (3)
IN14 IN15
(3)
(4)
(1) There are two common terminals for all of the 16 current inputs. These two analog common terminals are
connected internally.
(2 All shield wires should be connected to chassis mounting screws.
(3) Unused channels should be connected to the analog common terminals (0 Volts).
(4) If separate shielded cables are used for each analog input channel, interposing terminal blocks are needed
to terminate up to 16 common wires. Then 1 to 4 common wires should be wired from the interposing
terminal block to the 2 common terminals on the 1746-NI16I module.
(5) The module does not provide loop power for analog inputs. Use a power supply that matches the transmitter
specifications.
(6) More than one power supply can be used if all supplies are class 2.
NOTE Although the above diagram has 12 unused inputs, only 4

channels are shown connected to the Analog Com as an
example.
@JO#VTQQE ".
Wiring Guidelines
ATTENTION
To prevent shock hazard, care should be taken when wiring the
module to analog signal sources. Before wiring any analog module,
disconnect power from the SLC 500 system and from any other
! source to the analog module.
Follow the guidelines below when planning your system wiring.
• To limit noise, keep signal wires as far away as possible from power and load lines.
• To ensure proper operation and high immunity to electrical noise, always use
Belden™ 8761 (shielded, twisted pair) or equivalent wire.
• Connect the shield drain wire to the earth ground of the chassis.
• Tighten terminal screws using a standard or cross-head screwdriver. Each screw

should be turned tight enough to immobilize the wire’s end. Excessive tightening
can strip the terminal screw. The torque applied to each screw should not exceed
0.7 to 0.9 Nm (6 to 8 in-lb) for each terminal.
• Follow system grounding and wiring guidelines found in your SLC 500 Modular
Hardware Style Installation and Operation Manual, publication 1747-6.2.
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Input Devices
Transducer Source Impedance
If the source impedance of the input device and associated cabling is too high, it will
affect the accuracy of the channel data word. Source impedance of 2000 ohms will
produce up to 0.01% of module error over and above the specified accuracy of the
module.
You can compensate for device impedance error by implementing the following
equation in your ladder program:
(R s R in)
VS V measured
R in
Vs = input device voltage
where: Rs = input device impedance

Rin = 1746-NI16 input impedance
(See Specifications on page 17)
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Wiring Input Devices to the 1746-NI16

After the analog input module is properly installed in the chassis, follow the wiring
procedure below using Belden 8761 cable.
ATTENTION
Care should be taken to avoid connecting a voltage source to a
current input module. Improper module operation or damage to
! the voltage source can occur.
Cable
(Cut foil shield and

Signal Wire drain wire.)
Foil Shield Signal Wire

Drain Wire
(Twist the drain wire and the foil shield together and connect to earth ground or to the chassis
mounting screws.)
To wire your 1746-NI16 module follow these steps.
1. At each end of the cable, strip some casing to expose the individual wires.
2. Trim the signal wires to 50 mm (2 inch) lengths. Strip about 5 mm
(3/16 inch) of insulation away to expose the end of the wire.
3. At one end of the cable, twist the drain wire and foil shield together.
4. At the other end of the cable, cut the drain wire and foil shield back to the cable.
5. Connect the signal wires to the 1746-NI16 terminal block or interposing
terminal block.
6. Connect the shield drain wire to chassis ground.
7. Connect the other end of the cable to the voltage or current transmitter terminals.
8. Repeat steps 1 through 7 for each channel on the module.
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Specifications
Electrical Specifications
Description Specification
Backplane Current Consumption 125 mA at 5V dc
75 mA at 24V dc
Backplane Power Consumption 2.425W maximum (0.625W at 5V dc, 1.8W at 24V dc)
Number of Channels 16 (backplane isolated)
I/O Chassis Location Any I/O module slot except slot 0
A/D Conversion Method Sigma - Delta
Input Filtering Low-pass digital filter with programmable filter
frequencies
Normal Mode Rejection >80 dB at 50/60 Hz
(between [+] input and [–] input) >75 dB at dc
>100 dB at 50/60 Hz
Common Mode Rejection Greater than or equal to 75 dB at DC
(between inputs and chassis
Greater than or equal to 100 dB at 50/60 Hz
ground)
Input Filter Frequencies 6 Hz, 10 Hz, 20 Hz, 40 Hz, 60 Hz, 80 Hz, 100 Hz, 250 Hz
Isolation 500V ac isolation for 1 second
Common-Mode Voltage Range ±10.25V relative to analog common terminal
(20.5V maximum between any two signal input terminals)
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Physical Specifications
LED Indicators 5 green status indicators
one for each group of 4 channels and one for module status
Module ID Code Class 1 Class 3
NI16V 3505 10406
NI16I 3504 10403
Recommended Cable Belden #8761 or equivalent
Maximum Wire Size Two 14 AWG wires per terminal
Maximum Cable NI16V Voltage Source (with less than 10Ω impedance): 1250Ω
Impedance maximum loop impedance, for <1LSB error
NI16I Current Source (transmitter properly wired to its power supply):
249Ω maximum loop impedance, to meet common-mode
voltage requirements
Terminal Block Removable, Allen-Bradley spare part
Catalog Number 1746-RT25G
Allen-Bradley Prewired 1492-ACAB005A46, 0.5m (1.6 ft.)
Cables 1492-ACAB010A46, 1.0 m (3.3 ft.)
1492-ACAB025A46, 2.5 m (8.2 ft.)
1492-ACAB050A46, 5.0 m (16.4 ft.)
Allen-Bradley User Terminal 1492-AIFM8-3
Blocks 1492-AIFM16-F-3
Environmental Specifications
Operating Temperature +0°C to +60°C (+32°F to +140°F)
Storage Temperature -40°C to +85°C (-40°F to +185°F)
Relative Humidity 5% to 95% (without condensation)
Agency Certification UL listed
C-UL approved
CE compliant for all applicable directives
Hazardous Environment Class I Division 2 Hazardous Environment Groups A, B, C, D
Classification
@JO#VTQQE ".
Input Specifications
Type of Input (Selectable) NI16V ±10V dc, 1 to 5V, 0 to 5V, or 0 to 10V
NI16I ±20 mA, 4 to 20 mA, 0 to 1 mA, 0 to 20 mA
Type of Data (Selectable) Engineering Units (1 mV/step or 1 µA/step)
Scaled-for-PID (0 to +16,383 range)
Proportional Counts (-32,768 to +32,767 range)
Proportional Counts (User Defined Range, Class 3 only)
1746-NI4 Data Format
Input Impedance NI16V 20 MΩ
NI16I 249 Ω
Maximum Voltage Input NI16V ±30V between any two signal terminals
without damage
Maximum Voltage Input NI16I ±8V between any two signal terminals
without damage
Current Input (maximum) ±30 mA (Between analog com and any input terminal)
Time to Detect Open Circuit Less Than 5 seconds
Module Update Time (1)
Input Resolution NI16V 312 µV(2)

NI16I 640 nA
Display Resolution 1 mV or 1 µA
Module Error Over Full NI16V Voltage input types (±10V dc, 1 to 5V dc, 0 to 5V dc, 0 to
Temperature Range 10V dc): ±0.1%
(0°C to 60°C, 32°F to 140°F)
NI16I Current input types (0 to 20 mA, 4 to 20 mA, 0 to 1mA,
±20 mA): ±0.3%
Input Offset Drift with NI16V 90 µV/°C
Temperature
NI16I 360 nA/°C
Gain Drift with Temperature NI16V 15 ppm/°C
NI16I 20 ppm/°C
Calibrated Accuracy at 25°C NI16V Better than 0.05% of range
NI16I Better than 0.15% of range
(1) Depends on filter selected. Refer to the 1746-NI16 User Manual, publication 1746-UM001A-US-P.
(2) Depends on data mode: Engineering Units or Proportional Counts.
@JO#VTQQE ".
Notes:
@JO#VTQQE ".
@JO#VTQQE ".
SLC 500 is a trademark of Rockwell Automation.
Belden is a trademark of Belden, Inc.
Publication 1746-IN001B-US-P - December 1999 PN 40071-069-01(C)

Supersedes Publication 1746-IN001A-US-P - September 1999 © 2006 Rockwell Automation, Inc. Printed in Singapore.
@JO#VTQQE ".
Digital I/O Modules
Input Module Catalog Numbers: 1746-IA4, 1746-IA8, 1746-IA16, 1746-IB8,

1746-IB16, 1746-IC16, 1746-IG16, 1746-IH16, 1746-IM4, 1746-IM8,
1746-IM16, 1746-IN16, 1746-ITB16, 1746-ITV16, 1746-IV8, 1746-IV16
Output Module Catalog Numbers: 1746-OA8, 1746-OA16, 1746-OAP12,

1746-OB8, 1746-OB6EI, 1746-OB16, 1746-OB16E, 1746-OBP8, 1746-OBP16,
1746-OG16, 1746-OV8, 1746-OV16, 1746-OVP16, 1746-OW4, 1746-OW8,
1746-OW16, 1746-OX8
Combination Input/Output Module Catalog Numbers: 1746-IO4, 1746-IO8,

1746-IO12, 1746-IO12DC
Topic Page
Important User Information 3
Overview 4
Hazardous Location Considerations 4
Environnements Dangereux 5
Install and Remove the Module 5
Octal Label Kit Installation (for PLC processors only) 6
Apply the Octal Filter Label 7
Apply the Octal Door Label 7
Removable Terminal Blocks 7
Fuse Protection and Blown Fuse Diagnostics 8
Fuse Protection (1746-OBP16 and 1746-OVP16 modules) 9
Fuse Protection (1746-OAP12 modules) 9
Blown Fuse Diagnostics 9
Processor Operation in Case of Blown Fuse - Processor Continues 11
Publication 1746-IN027C-EN-P - August 2008

2 Digital I/O Modules
Processor Operation in Case of Blown Fuse - Processor Faults 12

Recovery From Blown Fuse/Processor Fault/Processor Shutdown 14
Replacement Fuse Recommendations 14
Replace Fuses 15
Electronically Protected Modules (1746-OB6EI and 1746-OB16E) 16
Auto Reset Operation 17
Short Circuit/Overload Current Diagnostics 17
Recovery from Channel Shutdown 17
Wiring Diagrams 18
Labeling for SLC/PLC Systems 18
Input Modules - ac 19
Input Modules - dc 21
Output Modules - ac 23
Output Modules - dc 24
Relay Contact Output Modules 27
Input/Output Combination Modules 28
Specifications 30
General I/O 30
Heat Dissipation 30
Input Modules - ac 32
Input Modules - dc 34
Output Modules - ac 37
Output Modules - dc 38
Relay Contact Output Modules 43
Relay Contact Ratings 44
Input/Output Combination Modules 44

Digital I/O Modules 3

Solid state equipment has operational characteristics differing from those of electromechanical equipment.
Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication
SGI-1.1 available from your local Rockwell Automation sales office or online at
http://literature.rockwellautomation.com) describes some important differences between solid state
equipment and hard-wired electromechanical devices. Because of this difference, and also because of the
wide variety of uses for solid state equipment, all persons responsible for applying this equipment must
satisfy themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages
resulting from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many
variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot
assume responsibility or liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits,
equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell
Automation, Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
WARNING
Identifies information about practices or circumstances that can cause an explosion in
a hazardous environment, which may lead to personal injury or death, property
damage, or economic loss.
Identifies information that is critical for successful application and understanding of

IMPORTANT
the product.
ATTENTION
Identifies information about practices or circumstances that can lead to personal injury
or death, property damage, or economic loss. Attentions help you to identify a hazard,
avoid a hazard, and recognize the consequences.
SHOCK HAZARD
Labels may be located on or inside the equipment, for example, a drive or motor, to
alert people that dangerous voltage may be present.
BURN HAZARD
Labels may be located on or inside the equipment, for example, a drive or motor, to
alert people that surfaces may reach dangerous temperatures.

Overview
In addition to providing the module’s electrical specifications, this document tells
you how to:
• install the module into a chassis.
• wire the module’s terminal block.
• install the Octal Filter Label.

nonhazardous locations only. The following warning statement applies to use in
hazardous locations.
EXPLOSION HAZARD
WARNING
Substitution of components may impair suitability for Class I, Division 2.
Do not replace components or disconnect equipment unless power has been

switched off or the area is known to be nonhazardous.
Do not connect or disconnect components unless power has been switched

off or the area is known to be nonhazardous.
All wiring must comply with N.E.C. article 501-4(b).

Environnements Dangereux
Cet équipement est conçu pour être utilisé dans des environnements de Classe I,
DANGER D’EXPLOSION
WARNING
La substitution de composants peut rendre cet équipement impropre à une
utilisation en environnement de Classe I, Division 2.
Ne pas remplacer de composants ou déconnecter l'équipement sans s'être

assuré que l'alimentation est coupée.
Ne pas connecter ou déconnecter des composants sans s'être assuré que

l'alimentation est coupée.
Install and Remove the Module
ATTENTION
Never install, remove, or wire modules with power applied to chassis.
IMPORTANT The first slot of the chassis is reserved for the processor or the 1747-ASB
module.

Follow these steps to install the module.

1. Disconnect power.
Module Installation
2. Align the circuit board of
module with the chassis
card guide. (A)
3. Slide the module into the

chassis until the bottom B
tabs lock into place. (B) D
4. Route the wires down and

Slot 1 A
away from the module,
securing them with the wire
tie. (C)
5. Cover all unused slots with

Card Slot Filler, catalog
number 1746-N2, to keep
the chassis free from debris.
6. To remove the module, C

press and hold the module
release located on each
self-locking tab, and slide Max 2 mm2 (14 AWG).
Max 2 wires per terminal.
the module out of the
Max torque: 0.9 Nm (8 lb-in).
chassis slot. (D)
Octal Label Kit Installation (for PLC processors only)

The octal label kit consists of an octal filter label and a door label. Use these octal
labels to replace the decimal labels that are attached to the I/O modules.
TIP The octal label kit can be obtained from your Allen-Bradley distributor. The
octal kit is ordered based on the catalog number of the I/O module.
Please refer to the SLC 500 Modular Hardware Style User Manual,
publication 1747-UM011, for a listing of octal label kit catalog numbers.

ATTENTION
Do not touch or remove the terminal block when the SLC 500 system is
powered. Contact with ac line potential may cause injury to personnel.
Apply the Octal Filter Label

1. Remove the octal filter label from its paper carrier.
2. Align the octal filter label numbers horizontally to the module color bar and
over the decimal filter numbers.
Refer to page 8 for filter label placement.
3. Apply the octal label to the filter.
4. Press firmly to be sure that the label adheres properly.
Apply the Octal Door Label

1. Remove the octal door label from its paper carrier.
2. Align the octal label directly over the decimal door label on the inside of the
door.
Refer to page 8 for door label placement.
3. Press firmly to be sure that the label adheres properly.
Removable Terminal Blocks

Colored terminal blocks are removable by loosening the upper and lower retaining
screws. Black terminal blocks are not removable.

Installing Octal Labels

Module Color Bar Octal Filter Label
Beveled Edge Upper Retaining Screw Max Torque

OCTAL
= 0.6 Nm (5.3 lb-in)
Removable
Terminal
Block
Terminal Wiring
Max 2mm2 (14 AWG).
Max 2 wires per terminal.
Max torque: 0.9 Nm (8 lb-in).
1746-xxxx 1746-xxxx (OCTAL)
Octal Door Label
Lower Retaining Screw Max
Torque = 0.6 Nm (5.3 lb-in)
Fuse Protection and Blown Fuse Diagnostics

This section describes fusing characteristics for the following modules:
• 1746-OBP16
• 1746-OVP16
• 1746-OAP12

Fuse Protection (1746-OBP16 and 1746-OVP16 modules)

The fuse on the 1746-OBP16 and 1746-OVP16 modules (shown on page 10)
provides short-circuit protection for 13 mm2 (16 AWG) or larger wiring to external
loads. In the event of a short circuit on an output channel, it is likely that the
transistor associated with that channel will be damaged. In this event the module
should be replaced or the load moved to a spare output channel.
The fuse does not provide overload protection. In the event of an overload on an
output channel, it is likely that the fuse will not blow and the transistor associated
with that channel will be damaged. To provide overload protection for your
application, user-supplied fuses should be installed externally and properly sized to
match your individual load characteristics.
Fuse Protection (1746-OAP12 modules)

A fuse is provided on each common of the 1746-OAP12 module (shown on page
11) for a total of two fuses. The fuses are designed to protect the module from
short-circuit conditions. The fuse does not provide overload protection. In the event
of an overload on an output channel, it is likely that the fuse will not blow and the
output device associated with that channel will be damaged. To provide overload
protection for your application, user-supplied fuses should be installed externally.
The recommended fuse for overload protection is SAN-O HT. Select the fuse rating
according to your load. Do not use HT fuses rated higher than 2.0 Amps.
Blown Fuse Diagnostics

If the fuse blows on the 1746-OBP16, 1746-OVP16, or 1746-OAP12 module, the
following occurs:
• The blown fuse LED indicator will illuminate, provided power (5V dc via
backplane and load power via external supply) is applied to the module.
• A processor error will occur if JP1 connects pins 2 and 3. (See figures on
page 10 and page 11.)

Location of Jumpers and Fuses for 1746-OBP16 and 1746-OVP16 Modules
Location for 1746-OBP16 Fuse (F1)
JP1
3
2
1
Jumper for Processor Left Side View

Notification (JP1)
Location for 1746-OVP16 Fuse (F1)

WHEN FUSE OPENS
OUTPUT 2 1 PROCESSOR
JP1 CONTINUES
F Blown Fuse LED
U
S Indicator 3 2 PROCESSOR
E
FAULTS
REPLACEMENT FUSE:
LITTELFUSE 322010 or 332010
A-B CAT. NO. 1746-F8
Front View
Jumper Settings and
Fuse Replacement
Information

Location of Jumpers and Fuses for 1746-OAP12 Module
F1
3 2 1
JP1
Left Side View

Jumper for Processor
Notification (JP1)
F2
WHEN FUSE OPENS
OUTPUT 2 1 PROCESSOR
F Blown Fuse LED JP1 CONTINUES
U
S Indicator 3 2 PROCESSOR
E
FAULTS
REPLACEMENT FUSE:
SAN-O HQ 6.3A
A-B CAT. NO. 1746-F9
Jumper Settings and
Fuse Replacement
Information
Front View
Processor Operation in Case of Blown Fuse - Processor Continues

The factory set position for JP1 is shown on page 12. For this JP1 configuration, the
processor operation will continue if the module fuse blows.

JP1 Factory Set Position (no processor notification)

JP1
3
JP1 is in Factory Set position. There
2 is no processor notification for
blown fuse.
1746-OBP16 and 1746-OVP16
3 2 1
JP1
1746-OAP12
Processor Operation in Case of Blown Fuse - Processor Faults

The Processor Fault position for JP1 is shown on the following page. For this JP1
configuration, the processor generates a nonrecoverable error for all SLC 500
processors. For a nonrecoverable error, note the following:
• Processor operation halts and the processor fault light flashes.
• All outputs are reset to OFF.
• The processor major fault bit S:1/13 is set.
• Monitor processor status file word S:6 for error code xx58 for SLC 500 and
5/01 processors, and error code xx60 for SLC 5/02 and later processors.

JP1 in Processor Fault Notification Position

JP1
3
JP1 is in processor fault position.

1746-OBP16 and 1746-OVP16 Processor is notified when fuse is
blown.
1746-OAP12
3 2 1
JP1
IMPORTANT When using SLC 5/02 processor and later processors, a User-fault routine
cannot be used to clear the major fault bit.
ATTENTION For 1746-OBP16 and 1746-OVP16 modules, all outputs on the module are OFF
if the fuse blows. For the 1746-OAP12 module, all outputs on the same
common as the blown fuse are OFF. If processor operation is allowed to
continue after a blown fuse, extreme care should be taken to be sure the
safety of personnel and guard against equipment damage.
For additional information on processor fault codes and User-fault routines refer to
the following publications:
• Your programming device’s reference manual
• HHT User Manual, publication 1747-NP002:
– Chapter 28, Troubleshooting Faults
– Chapter 29, Understanding the Fault Routine

This table defines operation of all SLC 500 processors in the case of a blown fuse in
1746-OBP16, 1746-OVP16, and 1746-OAP12 modules.
.
Processor Operation After a Blown Fuse (1746-OBP16, 1746-OVP16, and
1746-OAP12 modules)
JP1 Set to JP1 Set to
Processor Continues Processor Faults
No error. Processor continues with 1746-OBP16 and 1746-OVP16 Nonrecoverable error. Processor
outputs de-energized. 1746-OAP12 outputs, on the same operations stop and all outputs reset to
common as the blown fuse, are de-energized. OFF.
Recovery From Blown Fuse/Processor Fault/Processor Shutdown

Processor operation will stop under the following conditions:
• The output module fuse blows due to a short circuit.
• JP1 is set to the Processor Faults position (pins 2 and 3 connected).
If the above conditions occur, the following procedures should be used for
recovery.
1. Follow fuse replacement procedures shown on page 15.
2. Clear the processor major fault bit S:1/13.
3. Clear processor status file S:6 major error code (optional).
4. Return the processor to Run mode.

For additional information on processor fault codes and clearing processor fault
bits, refer to the following user manuals:
• Your programming device’s reference manual
• HHT User Manual, publication 1747-NP002
– Chapter 28, Troubleshooting Fault
– Chapter 29, Understanding the Fault Routine
Replacement Fuse Recommendations

Use the following replacement fuses:
• 1746-OBP16 and 1746-OVP16 modules - Littelfuse #322010,10A or
#332010,10A. This fuse is required to maintain UL/CSA rating. Replacement
Fuse Kit is catalog number
1746-F8 (five fuses per kit).

• 1746-OAP12 module - Use SAN-O HQ 6.3A for replacement. This fuse is

required to maintain UL/CSA rating. Replacement Fuse Kit is catalog number
1746-F9 (five fuses per kit).
Replace Fuses
ATTENTION
Never install, remove, or wire modules with power applied to chassis.
1. Remove SLC 500 system power and correct the conditions causing the short
circuit.
2. Remove the output module from the chassis.
3. Remove the fuse.

• 1746-OBP16 and 1746-OVP16 modules: Use a wide-tipped, slotted-head
screwdriver to remove the blown fuse. Slide the screwdriver tip under
the fuse and use a twisting motion to pry the fuse from the fuse clip. Use
care so that the printed circuit board and surrounding electronics are not
damaged.
• 1746-OAP12 module: A fuse holder is provided with each fuse. Simply
grasp the fuse holder with needle-nose pliers, or your fingers, and pull it
out.
4. Replace the fuse.

• 1746-OBP16 and 1746-OVP16 modules: Center the replacement fuse over
the fuse clip and press down. If you use a tool to press the fuse in place,
apply pressure to the metal end caps only, not the center of the fuse.
• 1746-OAP12 module: Insert a new fuse into the fuse holder, align the
fuse holder on fuse clips, and press down.
5. Replace the output module in the chassis.
6. Restore SLC 500 system power.
7. Clear processor fault bits as indicated in the steps provided on page 14.

Electronically Protected Modules (1746-OB6EI and 1746-OB16E)

The electronic protection of the 1746-OB6EI and 1746-OB16E modules have been
designed to provide protection for the modules from short circuit and overload
current conditions. The protection is based on a thermal cut-out principle. In the
event of a short circuit or overload current condition on an output channel, that
channel will limit current within milliseconds after its thermal cut-out temperature
has been reached. All other channels continue to operate as directed by the CPU
(processor) module.
IMPORTANT The modules do not provide protection against reverse polarity wiring or
wiring to ac power sources. Electronic protection is not intended to replace
fuses, circuit breakers, or other code-required wiring protection devices.
E-FUSE LED Indicator

OUTPUT
OUTPUT
F
U
E E-FUSE LED Indicator
S
F
E
U
S
E
There is no jumper setting on this module.
Front View

Auto Reset Operation
IMPORTANT The 1746-OB6EI and 1746-OB16E modules perform auto-reset under

overload conditions. When an output channel overload occurs, that channel
will limit current within milliseconds after its thermal cut-out temperature
has been reached. While in current limit, the output channel can cool below
the thermal cut-out temperature allowing the module to auto-reset and
resume control of the output channel as directed by the processor until the
thermal cut-out temperature is again reached.
Removing power from an overloaded output channel would also allow the
output channel to cool below the thermal cut-out temperature, allowing
auto-reset to occur when power is restored. The output channel would
operate as directed by the processor until the thermal cut-out temperature is
again reached.
To avoid auto-reset of an output channel under overload conditions, an

external mechanical fuse can be used to open the circuit when overloaded.
Short Circuit/Overload Current Diagnostics

If a short circuit or overload current condition occurs on an output channel:
• the E-FUSE LED indicator will illuminate provided that power is applied to
the module. Power required: 5V dc via backplane and load power via an
external supply.
• all other channels continue to operate as directed by the CPU (processor)
module.
Recovery from Channel Shutdown

1. Remove the SLC 500 system power and correct the conditions causing the
short circuit or overload current condition.
2. Restore the SLC 500 system power.

The module automatically resets and resumes control of the output channel
and associated load.

Wiring Diagrams
The wiring diagrams in these installation instructions are examples only. It is not
necessary to connect an I/O device to each and every I/O module terminal.
Labeling for SLC/PLC Systems

In this document, 16-point I/O module wiring diagrams include both decimal and
octal numbers for I/O addressing and wire identification (see figure below). To
wire your 16-point I/O module when used in a SLC system, use the decimal
numbers in the upper left portion of each box. When used in a PLC system, use the
octal numbers in the lower right portion of the box.
As shipped from the factory, the I/O module has a decimal address label on
the inside of its door. A separate octal conversion kit can be ordered, to allow
you to convert your module to the octal system.
TIP You can order the octal label kit from your Allen-Bradley Distributor. The
octal kit is ordered based on the catalog number of the I/O module.
Please refer to the SLC 500 Modular Hardware Style User Manual,
publication 1747-UM011, for a listing of octal label kit catalog numbers.
IMPORTANT Be sure the octal labels are used with your PLC system. Directions on how to
install the labels are included with the kit and on page 6 of this document.
Decimal and Octal Labeling for 16-point I/O Modules

1746-IA16
100/120V ac
L1
IN 0
0 IN 1
For SLC (decimal) 1
IN 2
2 IN 3
IN 4 3
4 IN 5
IN 14 IN 6 5
100/120V ac 6 IN 7
16 IN 8 7
10 IN 9
IN 10 11
12 IN 11
IN 12 13
For PLC (octal) 14 IN 13
IN 14 15
16 IN 15
17
L2 AC COM
AC COM
Internally Connected
Commons SLC
PLC

Input Modules - ac
Wiring Diagrams (1746-IA4, 1746-IA8, 1746-IA16)
1746-IA4 1746-IA8
100/120V ac 100/120V ac
NOT L1 IN 0
USED
NOT
USED IN 1
NOT
USED IN 2
NOT
USED IN 3
L1 100/120V ac
IN 0 IN 4
IN 1 IN 5
100/120V ac IN 2 IN 6
IN 3 IN 7
L2 AC COM L2 AC COM
Internally Connected AC COM
Commons
1746-IA16
100/120V ac
L1
IN 0
0 IN 1
IN 2 1
2 IN 3
IN 4 3
4 IN 5
IN 6 5
100/120V ac 6 IN 7
IN 8 7
10 IN 9
IN 10 11
12 IN 11
IN 12 13
14 IN 13
IN 14 15
16 IN 15
17
L2 AC COM
AC COM
Internally Connected
Commons SLC
PLC

Wiring Diagrams (1746-IM4, 1746-IM8, 1746-IM16)

1746-IM4 1746-IM8
200/240V ac 200/240V ac
NOT L1
USED IN 0
NOT
USED IN 1
NOT
USED IN 2
NOT
USED IN 3
L1 200/240V ac
IN 0 IN 4
IN 1 IN 5
200/240V ac IN 2
IN 6
IN 3 IN 7
L2 AC COM L2 AC COM
Internally Connected AC COM

Commons
1746-IM16
200/240V ac
L1
IN 0
0 IN 1
1
IN 2
2 IN 3
IN 4 3
4 IN 5
IN 6 5
200/240V ac 6 IN 7
IN 8 7
10 IN 9
IN 10 11
12 IN 11
13
IN 12
14 IN 13
IN 14 15
16 IN 15
17
L2 AC COM
AC COM
Internally Connected SLC
Commons PLC

Input Modules - dc
Wiring Diagram (1746-IN16)
1746-IN16
24V ac/dc Sinking
L1 or +DC
IN 0
0 IN 1
1
IN 2
2 IN 3
IN 4 3
4 IN 5
5
IN 6
V ac/dc 6 IN 7
IN 8 7
10 IN 9
IN 10 11
12 IN 1 1
IN 12 13
14 IN 13
IN 14 15
16 IN 15
AC/DC 17
L2 or -DC COM AC/DC
COM
Internally Connected SLC
Commons PLC
Wiring Diagram (1746-IB8, 1746-IB16, 1746-ITB16, 1746-IC16, 1746-IH16)
1746-IB8 1746-IB16,1746 -ITB16 1746-IC16 1746-IH16

24V dc Sinking 24V dc Sinking 48V dc Sinking 125V dc Sinking
+DC
+DC IN 0 IN 0
0 IN 1
IN 1 IN 2 1
24V dc 2 IN 3
IN 2 (IB16, ITB16) IN 4 3
4 IN 5
IN 3 48V dc IN 6 5
24V dc (IC16) 6 IN 7
7
IN 4 IN 8 6
10 IN 9
125V dc IN 10 11
IN 5
(IH16) 12 IN 1 1
13
IN 6 IN 12
14 IN 13
IN 7 15
IN 14
16 IN 15
-DC DC COM DC 17
-DC COM DC COM
DC COM
Internally Connected Internally Connected Commons SLC
Commons PLC

Wiring Diagram (1746-IV8, 1746-IV16, 1746-ITV16)

1746-IV8 1746-IV16, 1746-ITV16
24V dc Sourcing 24V dc Sourcing
-DC
IN 0
-DC IN 0
0 IN 1
1
IN 1 IN 2
2 IN 3
IN 4 3
IN 2 4 IN 5
5
IN 6
IN 3 6 IN 7
24V dc 24V dc
IN 8 7
IN 4 IN 9
10
IN 10 11
IN 5 12 IN 1 1
IN 12 13
IN 6 IN 13
14
IN 14 15
IN 7
16 IN 15
17
+DC VDC +DC VDC
VDC
VDC
Internally Internally SLC
Connected V dc Connected V dc PLC
Wiring Diagram (1746-IG16)
1746-IG16
TTL Input (Low = True)
+DC +5 DC IN 0
IN 1 0
1 IN 2
IN 3 2
3 IN 4
IN 5 4
5 IN 6
IN 7 6
7 IN 8
+5V dc
IN 9 10
11 IN 10
IN 1 1 12
13 IN 12
IN 13 14
15 IN 14
IN 15 16
17
DC COM
-DC
SLC
PLC

Output Modules - ac
Wiring Diagrams (1746-OA8, 1746-OA16)
1746-OA8 1746-OA16
100...240V ac Triac Output 100...240V ac Triac Output
L1
VAC 1
OUT0
OUT 1 0
VA C 1 L1
1 OUT 2
OUT 3 2
OUT 0
100-240V ac 3 OUT 4
CR
OUT 5 4
OUT 1 100-240V ac CR 5 OUT 6
OUT 7 6 CR
CR CR
OUT 2 7
OUT 3 CR L2 L2
VAC 2 L1
VAC 2 L1 OUT 9
11 OUT 8
OUT 1 1 10
OUT 4
13 OUT 10
100-240V ac
OUT 5 OUT 13 12 100-240V ac
CR 15 OUT 12
CR
OUT 6 CR OUT 15 14
CR 17 OUT 14
16 CR
OUT 7 CR L2 SLC
PLC
L2
Wiring Diagram (1746-OAP12)

1746-OAP12
100...240V ac High Current Triac Output
Internally
L1 VAC 1
VAC 1
Connected
OUT 1
1
OUT 0
Commons
CR OUT 3 0
3 OUT 2
100-240V ac OUT 5 2
CR 5 OUT 4
NOT 4 CR
USED
NOT
USED
L2
L2
OUT 7
7 OUT 6
OUT 9 6
CR 11 OUT 8
100-240V ac
OUT 11 10
CR 13 OUT 10
12 CR
VAC 2
VAC 2 L1
SLC Internally Connected
PLC
Commons

Output Modules - dc
Wiring Diagrams (1746-OB6EI)
1746-OB6EI
10...30V dc Transistor Output-sourcing
Channel-to-channel Isolated
+DC VDC 1
VDC 0 +DC
10-30V dc CR OUT 1
OUT 0 10-30V dc
DC
-DC COM 1 DC -DC
COM 0
+DC VDC 3
VDC 2 +DC
10-30V dc CR OUT 3
OUT 2 10-30V dc
-DC DC
COM 3 DC -DC
COM 2
+DC VDC 5
VDC 4 +DC
10-30V dc CR OUT 5
OUT 4 10-30V dc
DC
-DC COM 5 DC -DC
COM 4

Wiring Diagrams (1746-OB8, 1746-OBP8, 1746-OB16, 1746-OB16E, 1746-OBP16)
1746-OB8 1746-OBP8
10...50V dc Transistor Output-sourcing 20.4...26.4V dc Transistor Output-sourcing
+DC VDC1
OUT 0
VDC +DC CR OUT 1
OUT 2
OUT 0 CR OUT 3
20.4-26.4V dc DC
COM1
OUT 1 NC
NC
OUT 2 NC
OUT 3
10-50V dc -DC
OUT 4 CR
NC
OUT 5 CR NC
NC
OUT 6 +DC VDC2
CR OUT 4
OUT 7 CR OUT 5
CR
20.4-26.4V dc OUT 6
DC -DC OUT 7
COM CR
DC
COM2
-DC
1746-OB16, 1746-OB16E, 1746-OBP16

10...50V dc, 10...30V dc, 20.4...26.4V dc SLC
Transistor Output-sourcing PLC
+DC VDC
OUT 0
0
OUT 1
1 OUT 2
2
OUT 3
3 OUT 4
OUT 5 4
CR OUT 6
5
6
OUT 7
10-50V dc (OB16) CR 7 OUT 8
CR
10-30V dc (OB16E) OUT 9 10
11 OUT 10
20.4-26.4V dc (OBP16) CR
OUT 11 12
13 OUT 12
CR
OUT 13 14
CR 15 OUT 14
16 CR
OUT 15
CR 17
DC COM
-DC

Wiring Diagrams (1746-OV8, 1746-OV16, 1746-OVP16)
1746-OV8 1746-OV16, 1746-OVP16

10...50V dc Transistor 10...50V dc or 20.4...26.4V dc Transistor
Output Sinking Output Sinking
+DC
VDC +DC VDC
OUT 0
0
OUT 0 OUT 1
1 OUT 2
OUT 3 2
OUT 1
3 OUT 4
OUT 2 10-50V dc (OV16) CR OUT 5 4
5 OUT 6
20.4-26.5V dc (OVP16) OUT 7 6
OUT 3 CR 7 OUT 8 CR
10-50V dc 10
OUT 4 CR OUT 9
11 OUT 10
CR
OUT 1 1 12
OUT 5 CR
13 OUT 12
CR
OUT 13 14
OUT 6
CR CR 15 OUT 14
16 CR
OUT 7 OUT 15
CR CR
17
DC COM
DC COM -DC -DC
SLC
PLC
Wiring Diagrams (1746-OG16)
1746-OG16
TTL Output (Low = True)
+DC
VDC
OUT 0 L
OUT 1 0
L
1 OUT 2 L
2
L OUT 3
3 OUT 4 L
4
L OUT 5
5 OUT 6 L
OUT 7 6
+5V dc L
7 OUT 8 L
10
L OUT 9
11 OUT 10
L
12
L OUT 11
13 OUT 12
L
OUT 13 14
L 15 OUT 14
16 L
OUT 15
L 17
DC COM
-DC
SLC
PLC

Relay Contact Output Modules

Wiring Diagrams (1746-OW4, 1746-OW8, 1746-OW16)
1746-OW4 1746-OW8
Relay Output Relay Output
VAC-VDC L1 or +DC VAC-VDC L1 or +DC

1
OUT 0 OUT 0
V ac/dc V ac/dc
OUT 1 OUT 1
OUT 2 CR OUT 2 CR
OUT 3 CR L2 or -DC OUT 3 CR

L2 or -DC
NOT VAC-VDC L1 or +DC
USED 2
NOT
USED OUT 4
NOT V ac/dc
USED OUT 5
NOT OUT 6 CR
USED
OUT
NOT7
USED OUT 7 CR L2 or -DC
1746-OW16
Relay Output
L1 or +DC
VAC-VDC
1 OUT0
OUT 1 0
1 OUT 2
OUT 3 2
V ac/dc 3 OUT 4 CR
OUT 5 4
CR 5 OUT 6
6 CR
OUT 7
CR 7
L2 or -DC L1 or +DC
VAC-VDC
OUT 9 2
11 OUT 8
10
OUT 11
OUT 10
13
OUT 13 12 V ac/dc
CR
15 OUT 12 CR
OUT 15 14
CR 17 OUT 14
16 CR
SLC
PLC
L2 or -DC

Wiring Diagram (1746-OX8)
1746-OX8
Channel-to-channel Isolated Relay Output
VAC-VDC
VS0 L1 0
OUT 0 CR VS0 L2
VS1 L1 VAC-VDC
1
OUT 1 VS1 L2
VS2 VDC VAC-VDC
2
OUT 2 VS2 DC COM
VAC±VDC
VS3 VDC 3
OUT 3 CR VS3 DC COM
NOT USED
NOT
USED
VAC-VDC
VS4 L1 4
OUT 4 CR VS4 L2
VAC-VDC
VS5 L1 5
OUT 5 VS5 L2
VS6 VDC VAC-VDC
6
OUT 6 VS6 DC COM
VAC-VDC
VS7 VDC 7
OUT 7 CR VS7 DC COM
Input/Output Combination Modules

Wiring Diagram (1746-IO4, 1746-IO8)
1746-IO4 1746-IO8
100/120V ac Input - Relay Output 100/120V ac Input - Relay Output
VAC-VDC L1 or +DC VAC-VDC L1 or +DC
OUT 0 V ac/dc OUT 0

V ac/dc
OUT 1 CR L2 or -DC OUT 1
NOT CR
OUT 2
USED
NOT OUT 3 CR L2 or -DC
USED
L1 IN 0 L1 IN 0
IN 1 IN 1
NOT
100/120V ac USED 100/120V ac IN 2
NOT IN 3
USED
OUT 7 OUT 7
L2 AC COM L2 AC COM

Wiring Diagram (1746-IO12)
1746-IO12
100/120V ac Input - Relay Output
L1 or +DC
VAC-VDC
OUT 0
OUT 1
OUT 2
V ac/dc OUT 3
OUT 4 CR
CR OUT 5
NOT
USED
L2 or -DC
L1
NOT
USED
IN 0
IN 1
IN 2
IN 3
100/120V ac IN 4
IN 5
NOT
NOT USED
USED AC COM
L2
Wiring Diagram (1746-IO12DC)

1746-IO12DC
24V dc Input - Relay Output
L1 or +DC
VAC-VDC
OUT 0
OUT 1
OUT 2
V ac/dc
OUT 3
OUT 4 CR
CR OUT 5
NOT
USED
L2 or -DC
+DC
NOT
USED
IN 0
IN 1
IN 2
IN 3
10-30V dc
IN 4
IN 5
NOT
NOT USED
USED DC COM
-DC

Specifications
General I/O
Attribute Value
Temperature, operating 0...60 °C (32...140 °F)(3)
Temperature, storage -40...85 °C (-40...185 °F)
Operating humidity 5...95% (noncondensing)
Noise immunity NEMA standard ICS 2-230
Vibration, operating Displacement 0.015 in. peak at 5...57 Hz
Acceleration 2.5 g at 57...2000 Hz
Shock, operating 30 g (all modules except relay contact)
10 g (relay contact modules: 1746-OW, 1746-OX, and combination I/O
modules)
1500V
Isolation(1)
Agency certification UL listed
CSA certified or C-UL approved as indicated by product marking
CE compliant for all applicable directives when product or packaging is
marked
C-Tick marked for all applicable acts
Class I, Division 2 Hazardous Environment
Hazardous environment class(2)
UL-A196, CSA, C-UL
(1) Electro-optical isolation between I/O terminals and control logic.
(2)
Some modules are classified Class 1, Division 2 by CSA only or C-UL only as shown in the specification table for the
respective module.
(3)
Temperature is for air surrounding the SLC 500 system. Temperature range exceptions are indicated with certain modules.
Heat Dissipation
The following tables contain values for the heat dissipated by each I/O module.
Use them to calculate the total amount of heat dissipated by your SLC 500 control
system. For details on how to calculate total heat dissipation, refer to the SLC 500
Modular Hardware Style User Manual, publication 1747-UM011. Please note the
following definitions:
• Watts per point - the heat dissipation that can occur in each field wiring
point when energized at nominal voltage.
• Minimum Watts - the amount of heat dissipation that can occur when there is
no field power present.

• Total Watts - the Watts per point multiplied by the number of points, plus the
minimum Watts (with all points energized).
Input Module Heat Dissipation

Catalog Numbers Watts per Point Min Watts Total Watts
1747-IA4 0.27 0.175 1.30
1746-IA8 0.27 0.250 2.40
1746-IA16 0.27 0.425 4.80
1746-IB8 0.20 0.250 1.90
1746-IB16 0.20 0.425 3.60
1746-IC16 0.22 0.425 3.95
1746-IG16 0.02 0.700 1.00
1746-IH16 0.32 0.217 5.17
1746-IM4 0.35 0.175 1.60
1746-IM8 0.35 0.250 3.10
1746-IM16 0.35 0.425 6.00
1746-IN16 0.35 0.425 6.00
1746-ITB16 0.20 0.425 3.60
1746-ITV16 0.20 0.425 3.60
1746-IV8 0.20 0.250 1.90
1746-IV16 0.20 0.425 3.60
Output Module Heat Dissipation

Catalog Numbers Watts per Point Min Watts Total Watts
1746-OA8 1.000 0.925 9.00
1746-OA16 0.462 1.850 9.30
1746-OAP12 1.000 1.850 10.85
1746-OB6EI 0.440 0.230 2.90
1746-OB8 0.775 0.675 6.90
1746-OB16 0.388 1.400 7.60
1746-OB16E 0.150 0.675 3.07
1746-OBP8 0.300 0.675 3.08
1746-OBP16 0.310 1.250 6.26
1746-OG16 0.033 0.900 1.50
1746-OV8 0.775 0.675 6.90
1746-OV16 0.388 1.400 7.60
1746-OVP16 0.310 1.250 6.26
1746-OW4 0.133 1.310 1.90
1746-OW8 0.138 2.590 3.70
1746-OW16 0.033 5.170 5.70
1746-OX8 0.825 2.590 8.60

Combination Input/Output Module Heat Dissipation

Catalog Numbers Watts per Point Minimum Watts Total Watts
1746-IO4 0.27 per input point 0.75 1.60
0.133 per output point
1746-IO12DC 0.20 per input point 1.84 3.90
Input Modules - ac
Specifications for Input Modules 1746-IA4, 1746-IA8, and 1746-IA16

Attribute Value
1746-IA4 1746-IA8 1746-IA16(1)
Voltage category 100/120V ac signal input
Number of inputs 4 8 16
Points per common 4 8 16
Voltage, operating 85...132V ac at 47...63 Hz
Backplane current consumption 5V dc 0.035 A 0.050 A 0.085 A
24V dc 0.0 A
Signal delay, max On = 35 ms
Off = 45 ms
Off-state voltage, max 30V ac
Off-state current, max 2 mA
Input current at 120V ac, nom 12 mA
Inrush current, max (2) 0.8 A
Inrush current time duration, max 0.5 ms
(1) Removable terminal block.
(2)
An ac input device must be compatible with SLC 500 input circuit inrush current. A current limiting resistor can be used to
limit inrush current; however, the operating characteristics of the ac input-circuit will be affected.

Specifications for Input Modules 1746-IM4, 1746-IM8, and 1746-IM16

Attribute Value
1746-IM4 1746-IM8 1746-IM16(1)
Backplane current consumption 5V dc 0.035 A 0.050 A 0.085 A
24V dc 0.0 A
Signal delay (max.) On = 35 ms
Off = 45 ms
Off-state voltage, max 50V ac
Off-state current, max 2 mA
Input current at 240V ac, nom 12 mA
Inrush current, max(2) 1.6 A
Inrush current time duration, max 0.5 ms
(1)
Removable terminal block.
(2) An ac input device must be compatible with SLC 500 input circuit inrush current. A current limiting resistor can be used to
limit inrush current; however, the operating characteristics of the ac input circuit will be affected.

Input Modules - dc
Specifications for Input Modules 1746-IB8, 1746-IB16, 1746-ITB16, and 1746-IC16
Attribute Value
1746-IB8 1746-IB16(1) 1746-ITB16(1) 1746-IC16(1)(2)
Voltage category 24V dc signal input (sinking) 48V dc signal input (sinking)
Number of inputs 8 16 16 16
Points per common 8 16 16 16
Voltage, operating 10...30V dc (sinking) 30...60V dc at 55 °C (131 °F) sinking
30...55V dc at 60 °C (140 °F) sinking
Backplane 5V dc 0.050 A
current 24V dc 0.0 A
consumption
Signal delay, max On = 8 ms On = 8 ms On = 0.3 ms On = 4 ms
Off = 8 ms Off = 8 ms Off = 0.5 ms(3) Off = 4 ms
Off-state voltage, max 5.0V dc 10.0V dc
Off-state current, max 1 mA 1 mA 1.5 mA 1.5 mA
Input current, nom 8 mA at 24V dc 4.1 mA at 48V dc
(2)
Use ID Code 0509 when configuring your system with programming software or the HHT.
(3) Typical signal delay for these modules: ON = 0.1 ms, OFF = 0.25 ms at 24V dc.
Specifications for Input Modules 1746-IV8, 1746-IV16, and 1746-ITV16

Attribute Value
1746-IV8 1746-IV16(1) 1746-ITV16(1)
Voltage category 24V dc signal input (sourcing)
Voltage, operating 10...30V dc (sourcing)
Backplane current 5V dc 0.050 A 0.085 A 0.085 A
consumption 24V dc 0.0 A
Signal delay, max On = 8 ms On = 8 ms On = 0.3 ms
Off = 8 ms Off = 8 ms Off = 0.5 ms(2)
Off-state voltage, max 5.0V dc
Off-state current, max 1 mA 1 mA 1.5 mA
Input current at 24V dc, nom 8 mA
(1)
(2) Typical signal delay for these modules: ON = 0.1 ms, OFF = 0.25 ms at 24V dc.

Specifications for Input Module 1746-IG16

Attribute Value(1)
Voltage category 5V dc TTL signal input (sourcing)
Number of inputs 16
Points per common 16
Voltage, operating +5 V to DC COM 4.5...5.5V dc (sourcing) 50 mV peak to peak ripple (max)
Backplane current consumption 5V dc 0.140 A
24V dc 0.0 A
Signal delay, max On = 0.25 ms
Off = 0.50 ms
Off-state voltage 2...5.5 V dc (2)
Off-state current, max 4.1 mA
Input current at 5V dc, nom 3.7 mA
(1)
(2)
TTL inputs are inverted (-0.2...0.8V dc = low voltage = True = ON). Use a NOT instruction in your ladder program to convert to
traditional True = High logic.
ATTENTION To avoid potential damage to TTL modules, handle them by the ends of the
module, not metallic surfaces. Electrostatic discharges can damage the
module. take care to prevent exposure of terminals or components to
electrostatic charges.
Careful wire routing within the enclosure helps cut down electrical noise between
I/O lines. Refer to the SLC 500 Modular Hardware Style User Manual, publication
1747-UM011, for recommended wiring procedures for TTL modules.
Limit cable length to 15 m (50 ft) per point for inputs in standard environments.
Refer to Allen-Bradley Programmable Controller Wiring and Grounding Guidelines,
publication 1770-IN041, for complete information.
Specifications for Input Module 1746-IN16

Attribute Value(1)
Voltage category 24V ac/dc Signal Input
Number of inputs 16
Voltage, operating dc 10...30V dc (sinking)
ac 10...30V ac
24V dc 0.0 A

Specifications for Input Module 1746-IN16

Signal delay, max dc On = 15 ms
Off = 15 ms
ac On = 25 ms
Off = 25 ms
Off-state voltage, max dc 3.0V dc
ac 3.0V ac
Off-state current, max dc 1 mA
ac 1 mA
Input current, nom dc 8 mA at 24V dc
ac 8 mA at 24V ac
Inrush current, max 0.02 A (ac only)
Specifications for Input Module 1746-IH16

Attribute Value(1)(2)(3)
Voltage category 125V dc signal input (sinking)
Number of inputs 16
Voltage, operating Range: Points ON Simultaneously, max:
90...146V dc 6 at 146V dc and 30 °C (86 °F)
12 at 146V dc and 50 °C (122 °F)
14 at 132V dc and 55 °C (131 °F)
16 at 125V dc and 60 °C (140 °F)
Backplane current 5V dc 0.085 A
Signal delay, max On = 9 ms
Off = 9 ms
Off-state voltage, max 20.0V dc
Off-state current, max 0.8 mA
Input current, nom 2.15 mA at 125V dc
2.25 mA at 132V dc
(1)
(2) Use ID Code 0507 when configuring your system with programming software or the HHT.
(3)
If the input module is connected in parallel with an inductive load, use surge suppression across the load to protect the
input module from damage caused by reverse voltage. Refer to the SLC 500 Modular Hardware Style User Manual,
publication 1747-UM011, for more information on surge suppression.

Output Modules - ac
Specifications for Output Modules 1746-OA8, 1746-OA16, and 1746-OAP12
Attribute Value
1746-OA8 1746-OA16(1) 1746-OAP12(1)(2)(3)
Number of outputs 8 16 12
Signal delay, max resistive load.(4) On = 1 ms
Off = 11.0 ms
Off-state leakage, max(5) 2 mA
Load current, min 10 mA
Continuous current per point(6) 1.0 A at 30 °C (86 °F) 0.50 A at 30 °C (86 °F) 2.0 A at 30 °C (86 °F)
0.50 A at 60 °C (140 °F) 0.25 A at 60 °C (140 °F) 1.25 A at 55 °C (131 °F)
1.0 A at 60 °C (140 °F)
Continuous current 8.0 A at 30 °C (86 °F) 8.0 A at 30 °C (86 °F) 9.0 A at 30 °C (86 °F)
per module, max 4.0 A at 60 °C (140 °F) 4.0 A at 60 °C (140 °F) 6.8 A at 55 °C (131 °F)
6.0 A at 60 °C (140 °F)
On-state voltage drop, max 1.50V at 1.0 A 1.50V at 0.50 A 1.2V at 2.0 A
Surge current per point(7), max 10.0 A for 25 ms 10.0 A for 25 ms 17.0 A for 25 ms(8)
(2)
A fused common and blown fuse LED indicator are provided on this module. See Fuse Protection and Blown Fuse
Diagnostics.
(3) Use ID Code 2803 when configuring your system with programming software or the HHT.
(4)
Triac outputs turn on at any point in the ac line cycle, and turn off at ac line zero cross.
(5) To limit the effects of leakage current through solid-state outputs, a loading resistor can be connected in parallel with your
load. For 120V ac operation, use a 15 KΩ, 2 W resistor. For 240V ac operation, use a 15 KΩ, 5 W resistor.
(6)
Recommended surge suppression: For triac outputs when switching 120V ac inductive loads, use Harris Metal-Oxide
Varistor, model number V220MA2A. Refer to the SLC 500 Modular Hardware Style User Manual, publication 1747-UM011,
for more information on surge suppression.
(7) Repeatability is once every 1 s at 30 °C (86 °F). Repeatability is once every 2 s at 60 °C (140 °F).
(8)
Surge current = 35 A per common for 10 ms.

Output Modules - dc
Specifications for Output Modules 1746-OB8, 1746-OB16, and 1746-OB16E
Attribute Value
1746-OB8 1746-OB16(1) 1746-OB16E(1)(2)
Voltage category 24V dc Signal Output
Voltage, operating (V dc) 10...50 (source) 10...30 (source)
Signal delay, max. resistive load. On = 0.1 ms On = 0.1 ms On = 1.0 ms(3)
Off = 1.0 ms Off = 1.0 ms Off = 1.0 ms
Continuous current per point(5) 1.0 A at 30 °C (86 °F) 0.50 A at 30 °C (86 °F) 1.0 A at 30 °C (86 °F)(6)
Continuous current per module 8.0 A at 30 °C (86 °F) 8.0 A at 30 °C (86 °F) 8.0 A at
4.0 A at 60 °C (140 °F) 4.0 A at 60 °C (140 °F) 0...60 °C (32...140 °F)
Surge current per point(7) 3.0 A for 10 ms 3.0 A for 10 ms 2.0 A for 10 ms(8)
(1)
(2) Use the following ID Code when configuring your system with programming software or the HHT: 1746-OB16E = 2920.
(3)
Fast turn-off modules (1746-OB6EI, 1746-OBP8 series B and later, 1746-OB16E series B and later, 1746-OBP16, and
1746-OVP16) provide fast OFF delay for inductive loads. Comparative OFF delay times for 1746-OB8/1746-OV8 and fast
turn-off modules, when switching Bulletin 100-B110 (24W sealed) contactor, are: 1746-OB8/1746-OV8 OFF delay = 152 ms;
fast turn-off modules OFF delay = 47 ms.
(4) To limit the effects of leakage current through solid state outputs, a loading resistor can be connected in parallel with your
load. For transistor outputs, 24V dc operation, use a 5 KΩ, 1/2 W resistor.
(5)
Recommended surge suppression: For transistor outputs when switching 24V dc inductive loads, use a 1N4004 diode
reverse-wired across the load. Refer to the SLC 500 Modular Hardware Style User Manual, publication 1747-UM011, for
more information on surge suppression.
(6) Fast off delay for inductive loads is accomplished with surge suppressors on the 1746-OB6EI, 1746-OBP8 series B and later,
1746-OB16E series B and later, 1746-OBP16, and 1746-OVP16 modules. A suppressor at the load is not needed unless
another contact is connected in series. If this is the case, a 1N4004 diode should be reverse wired across the load. This
defeats the fast turn-off feature.
(7)
Repeatability is once every 1 s at 30 °C (86 °F). Repeatability is once every 2 s at 60 °C (140 °F).
(8) Surge current = 32 A per module for 10 ms.

ATTENTION A transient pulse occurs in transistor outputs when the external dc supply
voltage is applied to the output common terminals (for example, via the
master control relay). This can occur regardless of the processor having
power or not. For most applications, the energy of this pulse is not sufficient
to energize the load.
Refer to the SLC 500 Modular Hardware Style User Manual, publication
1747-UM011, for more information on transient pulses and guidelines to
reduce inadvertent processor operation.
Specifications for Output Modules 1746-OB6EI, 1746-OBP8, and 1746-OBP16

Attribute Value
1746-OB6EI(1)(2) 1746-OBP8(1)(2)(3) 1746-OBP16(1)(2)(4)(5)
Points per common Individually Isolated 4 16
Voltage, operating (V dc) 10...30 (source) 20.4...26.4 (source)
Signal delay, max On = 1.0 ms(6) On = 1.0 ms(6) On = 0.1 ms(6)
Resistive load Off = 2.0 ms Off = 2.0 ms Off = 1.0 ms
Off-state leakage, Max(7) 1 mA
Load current, Min 1 mA
2.0 A at 0 to 60 °C 2.0 A at 0 to 60 °C 1.5 A at 30 °C (86 °F)
Continuous current per point(8)(9)
(140 °F) (140 °F) 1.0 A at 60 °C (140 °F)
Continuous current per module 12.0 A at 0 to 60 °C 8.0 A at 0 to 60 °C 6.4 A at
(140 °F) (140 °F) 0...60 °C (32...140 °F)
Surge current per point(10) 4.0 A for 10 ms 4.0 A for 10 ms 4.0 A for 10 ms
Surge current per module(10) 24.0 A for 10 ms 32.0 A for 10 ms 32.0 A for 10 ms
Electronic protection yes no no
(2)
Use the following ID Code when configuring your system with programming software or the HHT: 1746-OB6EI = 2619,
1746-OBP8 = 2721 and 1746-OBP12 = 2921.
(3)
An external fuse can be used to protect this module from short circuits. Recommended fuse is SANO MQ4-3.15A, 5x20
mm.
(4) A fused common and blown fuse LED indicator are provided on this module. See Fuse Protection and Blown Fuse
Diagnostics.

(5)
Certified for Class 1, Division 2 hazardous location by CSA.
(6) Fast turn-off modules (1746-OB6EI, 1746-OBP8 series B and later, 1746-OB16E series B and later, 1746-OBP16, and
turn-off modules; when switching Bulletin 100-B110 (24W sealed) contactor, are: 1746-OB8/1746-OV8 OFF delay = 152 ms;
(7)
To limit the effects of leakage current through solid state outputs, a loading resistor can be connected in parallel with your
load. For transistor outputs, 24V dc operation, use a 5.6 KΩ, 1/2 W resistor.
(8) Recommended surge suppression: For transistor outputs when switching 24V dc inductive loads, use a 1N4004 diode
reverse-wired across the load (also see footnote 9). Refer to the SLC 500 Modular Hardware Style User Manual,
publication 1747-UM011, for more information on surge suppression.
(9)
Fast off delay for inductive loads is accomplished with surge suppressors on the 1746-OB6EI, 1746-OBP8 series B and later,
(10)

Specifications for Output Modules 1746-OV8, 1746-OV16, and 1746-OVP16

Attribute Value
1746-OV8 1746-OV16(1) 1746-OVP16(1)(2)(3)(4)
Voltage, operating (V dc) 10...50 (sink) 20.4...26.4 (sink)
Backplane 5V dc 0.135 A 0.270 A 0.250 A
current 24V dc 0.0 A
consumption
Signal delay, max. resistive load. On = 0.1 ms On = 0.1 ms(5)
Off = 1.0 ms Off = 1.0 ms
Continuous current per point (7) 1.0 A at 30 °C (86 °F) 0.50 A at 30 °C (86 °F) 1.5 A at 30 °C (86 °F)(8)
Continuous current per module 8.0 A at 30 °C (86 °F) 6.4 A at
4.0 A at 60 °C (140 °F) 0...60 °C (32...140 °F)
Surge current per point (9) 3.0 A for 10 ms 4.0 A for 10 ms(10)
(2)
A fused common and blown fuse LED indicator are provided on this module. See Fuse Protection and Blown Fuse Diagnostics.
(3) Use the following ID Code when configuring your system with programming software or the HHT: 1746-OVP16 = 2922.
(4)
(5)
Fast turn-off modules (1746-OB6EI, 1746-OBP8 series B and later, 1746-OB16E series B and later, 1746-OBP16, and
turn-off modules; when switching Bulletin 100-B110 (24Ws sealed) contactor, are: 1746-OB8/1746-OV8 OFF delay = 152 ms;
(6)
To limit the effects of leakage current through solid state outputs, a loading resistor can be connected in parallel with your
load. For transistor outputs, 24V dc operation, use a 5.6 KΩ, 1/2 W resistor.
(7) Recommended surge suppression: For transistor outputs when switching 24V dc inductive loads, use a 1N4004 diode
reverse-wired across the load (also see footnote 9). Refer to the SLC 500 Modular Hardware Style User Manual, publication
1747UM011, for more information on surge suppression.
(8)
Fast off delay for inductive loads is accomplished with surge suppressors on the 1746-OB6EI, 1746-OBP8 series B and later,
(9)
(10) Surge current = 32 A per module for 10 ms.

Specifications for Output Module 1746-OG16

Attribute Value(1)
Number of outputs 16
Voltage category 5V dc TTL Signal Input (sinking)
Voltage, operating 4.5...5.5V dc(2)
(VDC to DC COM) 50 mV peak to peak ripple (max.)
24V dc 0.0 A
Signal delay, max resistive load On = 0.25 mA
Off = 0.50 mA
Off-state voltage 4.5...5.5V dc(2)
Off-state leakage, max 0.1 mA
Load current, min 0.15 mA
Continuous current per point 24 mA
(1)
(2)
TTL outputs are inverted (0...0.4V dc = low voltage = True = ON). Use a NOT instruction in your ladder program to convert to
traditional True = High logic.
ATTENTION To avoid potential damage to TTL modules, handle them by the ends of the
module, not metallic surfaces. Electrostatic discharges can damage the
module. Take care to prevent exposure of terminals or components to
electrostatic charges.
Careful wire routing within the enclosure helps cut down electrical noise between
I/O lines. Refer to the SLC 500 Modular Hardware Style User Manual, publication
1747-UM011, for recommended wiring procedures for TTL modules.
Limit cable length to 3 m (10 ft) per point for outputs in standard environments.

Refer to Allen-Bradley Programmable Controller Wiring and Grounding Guidelines,

publication 1770-IN041, for complete information.
Relay Contact Output Modules

Specifications for Output Modules 1746-OW4, 1746-OW8, 1746-OW16, and
1746-OX8
Attribute Value
1746-OW4(1) 1746-OW8(1) 1746-OW16(1)(2) 1746-OX8(1)(2)
Number of outputs 4 8 16 8
Points per common 4 4 8 Individually
Isolated
Voltage category ac/dc Relay
Operating voltage 5V dc 5...125
24V ac 5...265
Backplane current 5V dc 0.045 A 0.085 A 0.170 A 0.085 A
consumption 24V dc 0.045 A 0.090 A 0.180 A 0.090 A
Signal delay, max On = 10.0 ms
Resistive load Off = 10.0 ms
Off-state leakage, max 0 mA
Load current, min 10 mA at 5V dc
Continuous current per point(3) See relay contact ratings. (Table and Table on page 44)
Continuous current per module 8.0 A ac 16.0 A ac 16.0 A ac (4)
8.0 A /Common 8.0 A /Common 8.0 A /Common
(1)
(2)
(3)
Recommended surge suppression: For relay contact outputs, refer to the SLC 500 Modular Hardware User Manual,
publication 1747-UM011. Connecting surge suppressors across your external inductive load will extend the life of SLC 500
relay contacts.
(4)
The continuous current per module must be limited so the module power does not exceed 1440VA.

Relay Contact Ratings

Relay Contact Rating Table for Output Modules 1746-OW4, 1746-OW8, and
1746-OW16
Voltages Amperes(2) Amperes(2) Volt-Amperes
Make Break Continuous Make Break
Volts (ac), max 120 15 1.5 2.5 1800 180
240 7.5 0.75
Volts (dc), max 125 0.22(3) 1.0 28
24 1.2(3) 2.0 28
Relay Contact Rating Table for Output Module 1746-OX8

Voltages Amperes(1) Amperes Volt-Amperes
Make Break Continuous(2) Make Break
Volts (ac), max 120 30 3.0 5.0 3600 360
240 15 1.5
Volts (dc), max 125 0.22 (3) 1.0 28
24 1.2(3) 2.0 28
(1)
Recommended surge suppression: For relay contact outputs, refer to the SLC 500 Modular Hardware User Manual,
publication 1747-UM011. Connecting surge suppressors across your external inductive load will extend the life of SLC 500
relay contacts.
(2)
The continuous current per module must be limited so the module power does not exceed 1440 VA.
(3) For dc voltage applications, the make/break ampere rating for relay contacts can be determined by dividing 28VA by the
applied dc voltage. For example, 28VA/48V dc = 0.58 A. For dc voltage applications less than 14V, the make/break ratings for
relay contacts cannot exceed 2 A.
Input/Output Combination Modules
Specifications for Combination Modules 1746-IO4, 1746-IO8, 1746-IO12, and

1746-IO12DC
Attribute Value
1746-IO4(1)(2) 1746-IO8(1)(2) 1746-IO12(1)(3)(4) 1746-IO12DC(3)(5)(6)(7)
Points per module 2 inputs 4 inputs 6 inputs 6 inputs
2 outputs 4 outputs 6 outputs 6 outputs
Points per common 2 4 6 6
Voltage category (inputs) 120V ac 24V dc
Voltage, operating (inputs) 85...132V ac 10...30V dc
Voltage category (outputs) 100/120V ac Relay contact output

Specifications for Combination Modules 1746-IO4, 1746-IO8, 1746-IO12, and

1746-IO12DC
Voltage, operating (outputs) 5...265V ac
5...125V dc
Backplane current 5V dc 0.030 A 0.060 A 0.090 A 0.080 A
consumption 24V dc 0.025 A 0.045 A 0.070 A 0.060 A
(1)
(2) See specifications for catalog numbers 1746-IA4 and 1746-OW4. Continuous Current per 1746-IO4 Module is 4.0 A.
Continuous Current per 1746-IO8 Module is 8.0 A.
(3)
(4) See specifications for catalog numbers 1746-IA16 and 1746-OW16. Continuous Current per 1746-IO12 Module is 8.0 A.
(5)
See specification for catalog numbers 1746-IB16 and 1746-OW16. Continuous Current per 1746-IO12DC Module is 8.0 A.
(6) Certified for Class 1, Division 2 hazardous location by C-UL.
(7)
Use the following ID Code when configuring your system with programming software or the HHT: 1746-IO12DC = 1512.
Combination I/O modules (Catalog Numbers 1746-IO4, 1746-IO8, 1746-IO12 and

TIP
1746-IO12DC):
For the first several seconds of any power-up or when power is applied to a rack that is
not under processor control, the output LED indicators of the combination IO modules in
the rack will be illuminated.
Racks are not under processor control if one of the following conditions exist:
• Modular Hardware Style (only): Processor is absent from the rack or the rack
interconnect cable is not properly connected.
• Modular Hardware Style and Fixed Hardware Style: The processor does not have the
firmware PROM installed or the processor is not functioning properly.

Notes:

Notes:

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If you experience a problem with a hardware module within the first 24 hours of installation,
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phone number above to obtain one) to your distributor in order to complete the return
process.
Outside United States Please contact your local Rockwell Automation representative for return procedure.
You can view or download publications at http://literature.rockwellautomation.com. To order

paper copies of technical documentation, contact your local Rockwell Automation distributor
or sales representative.
Allen-Bradley, TechConnect, Rockwell Automation, and SLC 500 are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Publication 1746-IN027C-EN-P - August 2008 PN 40071-160-01(3)

Supersedes Publication 1746-IN027B-EN-P - January 2007 Copyright © 2008 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.
SLC 500™ Analog Input Module

(Catalog Number 1746-NI8)
Inside…
Important User Information ........................................................................... 2
For More Information ...................................................................................... 3
Hazardous Location Considerations ............................................................. 4
Environnements dangereux .......................................................................... 4
Electrostatic Damage.................................................................................... 5
1746-NI8 Power Requirements..................................................................... 5
Module Location in Chassis .......................................................................... 6
Heat and Noise Considerations .................................................................... 7
Module Installation and Removal.................................................................. 7
Terminal Wiring ........................................................................................... 10
Input Devices .............................................................................................. 15
Specifications.............................................................................................. 17
Publication 1746-IN006A-US-P
@JO"VTQQE ".
2 SLC 500™ Analog Input Module

Because of the variety of uses for the products described in this publication, those
responsible for the application and use of this control equipment must satisfy
themselves that all necessary steps have been taken to assure that each application
and use meets all performance and safety requirements, including any applicable
laws, regulations, codes and standards.
The illustrations, charts, sample programs and layout examples shown in this guide
are intended solely for purposes of example. Since there are many variables and
requirements associated with any particular installation, Allen-Bradley does not
assume responsibility or liability (to include intellectual property liability) for actual
use based upon the examples shown in this publication.
Allen-Bradley publication SGI-1.1, Safety Guidelines for the Application, Installation
and Maintenance of Solid-State Control (available from your local Allen-Bradley
office), describes some important differences between solid-state equipment and
electromechanical devices that should be taken into consideration when applying
products such as those described in this publication.
Reproduction of the contents of this copyrighted publication, in whole or part,
without written permission of Rockwell Automation, is prohibited.
ATTENTION
Identifies information about practices or circumstances that
can lead to personal injury or death, property damage, or
! economic loss.
Attention statements help you to:

• identify a hazard
• avoid the hazard
• recognize the consequences
IMPORTANT Identifies information that is critical for successful application

and understanding of the product.
@JO"VTQQE ".
SLC 500™ Analog Input Module 3
For More Information

For detailed information on planning and installing your system, see the following
publications:
Publication Publication
Number
Industrial Automation Wiring and Grounding Guidelines 1770-4.1
SLC 500™ Analog Input Modules User Manual 1746-6.8
SLC 500™ Modular Hardware Style Operation and Installation Manual 1747-6.2
SLC 500™ Fixed Hardware Style Operation and Installation Manual 1747-6.21
If you would like a manual, you can:

• download a free electronic version from the internet:
www.theautomationbookstore.com
• purchase a printed manual by:
– contacting your local distributor or Rockwell Automation representative
– visiting www.theautomationbookstore.com and placing your order
– calling 1.800.963.9548 (USA/Canada)
or 001.330.725.1574 (Outside USA/Canada)
@JO"VTQQE ".

non-hazardous locations only. The following WARNING statement applies to use
in hazardous locations.
WARNING EXPLOSION HAZARD

• Substitution of components may impair suitability for Class I,
Division 2.
! • Do not replace components or disconnect equipment unless
power has been switched off.
• Do not connect or disconnect components unless power has
been switched off.
• All wiring must comply with N.E.C. article 501-4(b).
Environnements dangereux
Cet équipement est conçu pour être utilisé dans des environnements de Classe 1,
MISE EN GARDE DANGER D’EXPLOSION

• La substitution de composants peut rendre cet équipement
impropre à une utilisation en environnement de Classe 1,
! Division 2.
• Ne pas remplacer de composants ou déconnecter
l'équipement sans s'être assuré que l'alimentation est
coupée.
• Ne pas connecter ou déconnecter des composants sans
s'être assuré que l'alimentation est coupée.
@JO"VTQQE ".
Electrostatic Damage
Electrostatic discharge can damage semiconductor devices inside this module if you
touch backplane connector pins. Guard against electrostatic damage by observing
the following precautions.
ATTENTION Electrostatic discharge can degrade performance or cause

permanent damage. Handle the module as stated below.
• Wear an approved wrist strap grounding device when
! handling the module.
• Touch a grounded object to rid yourself of electrostatic charge
before handling the module.
• Handle the module from the front, away from the backplane
connector. Do not touch backplane connector pins.
• Keep the module in its static-shield bag when not in use, or
during shipment.
1746-NI8 Power Requirements

The 1746-NI8 module receives its power through the SLC 500™ chassis backplane
from the fixed or modular +5V dc/+24V dc chassis power supply. The +5V dc
backplane supply powers the SLC circuitry and the +24V dc backplane supply
powers the module analog circuitry. The maximum current drawn by the module is
shown in the table below.
5V dc Amps 24V dc Amps

200 mA 100 mA
When you are using a modular system configuration, add the values shown in the
table above to the requirements of all other modules in the SLC chassis to prevent
overloading the chassis power supply.
@JO"VTQQE ".
Module Location in Chassis

Modular Chassis Considerations
Place your 1746-NI8 module in any slot of an SLC 500 modular, or modular
expansion chassis, except for the extreme left slot (slot 0) in the first chassis. This slot
is reserved for the processor or adapter modules.
IMPORTANT For applications using the upper limit of the operating

temperature range, the 1746-NI8 module (or multiple modules)
should be placed in the right-most slot(s) of the chassis.
Operating Temperature Range

Temperature Chassis Location
+0°C to +55°C (+32°F to +131°F) Any slot except slot 0.
0°C to +60°C (32°F to 140°F) In right most slot of chassis
Fixed Expansion Chassis Considerations
IMPORTANT The 2-slot, SLC 500 fixed I/O expansion chassis (1746-A2)
supports only specific combinations of modules. If you are using
the 1746-NI8 module in a 2-slot expansion chassis with another
SLC I/O or communication module, refer to the 1746-NI8 user
manual to determine whether the combination can be
supported.
@JO"VTQQE ".
Heat and Noise Considerations

Most applications require installation in an industrial enclosure to reduce the effects
of electrical interference. Analog inputs are highly susceptible to electrical noise.
Electrical noise coupled to the analog inputs reduces the performance (accuracy) of
the module.
Group your modules to minimize adverse effects from radiated electrical noise and
heat. Consider the following conditions when selecting a slot for the analog input
module. Position the module:
• in a slot away from sources of electrical noise such as hard-contact switches,
relays, and AC motor drives
• away from modules which generate significant radiated heat, such as the 32-point
I/O module (series C or earlier)
In addition, route shielded twisted-pair analog input wiring away from any
high-voltage I/O wiring.
Module Installation and Removal

When installing the module in a chassis, it is not necessary to remove the terminal
block from the module. However, if the terminal block is removed, use the write-on
label (shown below) located on the side of the terminal block to identify the module
location and type.
SLOT RACK
• MODULE
ATTENTION Remove power before removing or inserting this module. When

you remove or insert a module with power applied, an electrical
arc may occur. An electrical arc can cause personal injury or
property damage by:
! • sending an erroneous signal to your system’s field devices,
causing unintended machine motion
• causing an explosion in a hazardous environment
Electrical arcing causes excessive wear to contacts on both the
module and its mating connector. Worn contacts may create
electrical resistance.
@JO"VTQQE ".
Terminal Block Removal

To remove the terminal block:
1. Loosen the two terminal block release screws.

.
Terminal Block Release

Screws
Maximum Torque =
0.7 to 0.9 Nm (6 to 8 in-lbs)
2. Grasp the terminal block at the top and bottom and pull outward and down.
Switch Settings to Select Voltage or Current Input

Before installing the module in the chassis, use the DIP switches on the module
circuit board to select between voltage and current inputs for channels 0 through 7.
The switch settings are
• OFF = VOLTAGE INPUT
• ON = CURRENT INPUT.
CURRENT O 12 O 12 O 12 O 12
N N N N
VOLTAGE CH0 CH7
@JO"VTQQE ".
Module Installation Procedure

1. Align the circuit board of the analog input module with the card guides located at
the top and bottom of the chassis.
2. Slide the module into the chassis until both top and bottom retaining clips are
secured. Apply firm even pressure on the module to attach it to its backplane
connector. Never force the module into the slot.
3. Cover all unused slots with the Card Slot Filler, catalog number 1746-N2.
Top and Bottom Module

Release(s)
Card
Guide
Module Removal Procedure

1. Press the releases at the top and bottom of the module and slide the module out
of the chassis slot.
2. Cover all unused slots with the Card Slot Filler, catalog number 1746-N2.
@JO"VTQQE ".
Terminal Wiring
The 1746-NI8 module contains an 18-position, removable terminal block. The
terminal pin-out is shown below.
ATTENTION Disconnect power to the SLC before attempting to install,

remove, or wire the removable terminal wiring block.
To avoid cracking the removable terminal block, alternate the
! removal of the slotted terminal block release screws.
Terminal Block
(Terminal Block Spare Part Catalog Number 1746-RT25G)
Shield
Channel 0 (+)
Channel 0 (-)
Channel 1 (+)
Channel 1 (-)
Channel 2 (+)
Channel 2 (-)
Channel 3 (+)
Channel 3 (-)
Channel 4 (+)
Channel 4 (-)
Channel 5 (+)
Channel 5 (-)
Channel 6 (+)
Channel 6 (-)
Channel 7 (+)
Channel 7 (-)
Shield
Terminal Block Release Screw

Maximum Torque=0.7 to 0.9 Nm
(6 to 8 in-lbs.)
@JO"VTQQE ".

The following diagram shows typical wiring for the 1746-NI8 module.
IMPORTANT Follow these guidelines when wiring the module.
• Use shielded communication cable (Belden™ 8761) and keep length as short as
possible.
• Connect only one end of the cable shield to earth ground.
• Connect the shield drain wires for channels 0 to 3 to the top shield terminal.
• Shield terminals are internally connected to chassis ground which is connected to
earth ground via the SLC backplane.
• Single-ended source commons may be jumpered together at the terminal block.
• Channels are not isolated from each other.
• If a different signal source has an analog common, it cannot and must not be
connected to the module.
• Common mode voltage range is ±10.5 volts. The voltage between any two
terminals must be less than 15 volts.
• The module does not provide power for the analog inputs.
• Use a power supply that matches the transmitter (sensor) specifications.
@JO"VTQQE ".
Typical 1746-NI8 Wiring
Power
Supply
Shield
Connections
+ + +
single-end Channel 0
signal source
- -
shield
+
single-end +
Channel 1
signal source
-
shield
+ +
single-end Channel 2
signal source
-
shield
+
single-end +
Channel 3
signal source
-
shield
+ +
+ differential Channel 4
signal source -
- -
shield
+
+ differential +
Channel 5
signal source -
- -
shield
+
+ +
differential Channel 6
signal source -
- -
shield
+
+ +
differential Channel 7
signal source -
- -
shield
Shield
@JO"VTQQE ".
When wiring single-ended analog input devices to the analog input module, the
number of total wires necessary can be limited by jumpering all “IN” terminals
together. Note that differential inputs are more immune to noise than single-ended
inputs.
IMPORTANT The module does not provide loop power for analog inputs. Use
a power supply that matches the transmitter specifications.
Wiring Schematic for Single-Ended Analog Input Connections

Transmitter 1746-NI8
Power + + Signal
Supply - IN 0+
IN 0-
Transmitter
+ Signal
IN 1+
IN 1-
Transmitter
+ Signal
IN 2+
IN 2-
Transmitter
Supply Signal
+ Ground
IN 3+
IN 3-
@JO"VTQQE ".
Wiring Schematics for 2, 3, and 4-Wire Analog Input Devices

2-Wire Transmitter
Transmitter
+ - Module
Power + IN +
Supply - IN -
3-Wire Transmitter Transmitter

Supply
GND Module
Power + IN +
Supply- IN -
4-Wire Transmitter Transmitter

Supply Signal Module
Power + + + IN +
Supply - IN -
- -
IMPORTANT The module does not provide loop power for analog inputs. Use
a power supply that matches the transmitter specifications.
@JO"VTQQE ".
Wiring Guidelines
ATTENTION
To prevent shock hazard, care should be taken when wiring the
module to analog signal sources. Before wiring any analog
module, disconnect power from the SLC 500 system and from
! any other source to the analog module.
Follow the guidelines below when planning your system wiring.

• To limit noise, keep signal wires as far away as possible from power and load lines.
• To ensure proper operation and high immunity to electrical noise, always use
Belden™ 8761 (shielded, twisted-pair) or equivalent wire.
• Connect the shield drain wire to the shield terminal on the 1746-NI8 module.
Up to four shield wires may be connected to each shield screw terminal that
provides a connection to chassis ground.
• Tighten terminal screws using a screwdriver. Each screw should be turned tight
enough to immobilize the wire’s end. Excessive tightening can strip the terminal
screw. The torque applied to each screw should not exceed 0.9 Nm (8 in-lb) for
each terminal.
• Follow system grounding and wiring guidelines found in your SLC 500 Modular
Hardware Style Installation and Operation Manual, publication 1747-6.2.
Input Devices
Transducer Source Impedance
If the source impedance of the input device and associated cabling is too high, it
affects the accuracy of the channel data word. Source impedance of 500 ohms
produces up to 0.05% of module error over and above the specified accuracy of the
module.
You can compensate for device impedance error by implementing the following
equation in your ladder program:
(R s R in)
VS V measured
R in
Vs = input device voltage
Rs = input device impedance
where:
Rin = 1746-NI8 input impedance (See Specifications on page 17.)
@JO"VTQQE ".
Wiring Input Devices to the 1746-NI8

After the analog input module is properly installed in the chassis, follow the wiring
procedure below using Belden 8761 cable.
ATTENTION
Care should be taken to avoid connecting a voltage source to a
current input module. Improper module operation or damage to
! the voltage source can occur.
Cable
(Cut foil shield
and drain wire.)
Signal Wire
Signal Wire
Signal Wire
Drain Wire Foil Shield Signal Wire
(Twist the drain wire and foil shield together

and connect to earth ground or to the shield
terminal on the 1746-NI8 module.)
To wire your 1746-NI8 module follow these steps.
1. At each end of the cable, strip some casing to expose the individual wires.
2. Trim the signal wires to 50 mm (2 inch) lengths. Strip about 5 mm (3/16 inch) of
insulation away to expose the end of the wire.
3. At one end of the cable, twist the drain wire and foil shield together. This end of
the cable is connected to one of the shield terminals on the 1746-NI8 module.
Connect shields for channels 0 through 3 to the upper shield terminal and shields
for channels 4 through 7 to the lower shield terminal.
4. At the other end of the cable, cut the drain wire and foil shield back to the cable.
5. Connect the signal wires and shield drain wire to the 1746-NI8 terminal block or
interposing terminal block.
6. Connect the other end of the cable to the voltage or current transmitter terminals.
7. Repeat steps 1 through 6 for each channel on the module.
@JO"VTQQE ".
Specifications
Electrical Specifications
Backplane Current Consumption 200 mA at 5V dc
100 mA at 24V dc
Backplane Power Consumption 3.4W maximum (1.0W at 5V dc, 2.4W at 24V dc)
Number of Channels 8 (backplane isolated)
I/O Chassis Location Any I/O module slot except slot 0
A/D Conversion Method Successive appoximation, switched capacitor
Input Filtering Low-pass digital filter with programmable filter
frequencies
Normal Mode Rejection Provided by low-pass filter
(between [+] input and Analog Com
Common Mode Rejection Greater than or equal to 75 dB at DC
(between inputs and chassis
Greater than or equal to 100 dB at 50/60 Hz
ground)
Input Filter Frequencies 1 Hz
2 Hz
5 Hz
10 Hz
20 Hz
50 Hz
75 Hz
Calibration The module performs continuous autocalibration
Isolation 500V dc continuous between the analog inputs and the
backplane
530V ac and 750V dc pulse withstand for one second
Common-Mode Voltage Range ±10.5V (15V maximum between any two terminals)
@JO"VTQQE ".
Physical Specifications
LED Indicators 9 green status indicators
one for each of 8 channels and one for module status
Module ID Code Class 1 Interface: 3526
Class 3 Interface: 12726
Recommended Cable Belden #8761 or equivalent
Maximum Wire Size Two 14 AWG wires per terminal
Maximum Cable Voltage Source (with less than 10Ω impedance):
Impedance 40Ω maximum loop impedance, for <1LSB error
Current Source (transmitter properly wired to its power supply):
250Ω maximum loop impedance, to meet common-mode voltage
requirements
Terminal Block Removable, Allen-Bradley spare part Catalog Number 1746-RT25G
Environmental Specifications
Operating Temperature 0°C to +55°C (32°F to 133°F) in any slot except 0
0°C to 60°C (32°F to 140°F) in right most slot of chassis
Storage Temperature -40°C to +85°C (-40°F to +185°F)
Relative Humidity 5% to 95% (without condensation)
Agency Certification UL listed
CSA approved
CE compliant for all applicable directives
Hazardous Environment Class 1 Division 2 Hazardous Environment
Classification
@JO"VTQQE ".
Input Specifications
Type of Input (Selectable) ±10V dc
1 to 5V dc
0 to 5V dc
0 to 10V dc
0 to 20 mA
4 to 20 mA
±20 mA
0 to 1 mA
Type of Data (Selectable) Engineering Units
Scaled-for-PID
Proportional Counts (-32,768 to +32,767 range)
Proportional Counts (User Defined Range, Class 3 only)
1746-NI4 Data Format
Input Impedance 1 MΩ
Voltage Input (maximum) ±30V between any two signal terminals
Current Input (maximum) 30 mA
Time to Detect Open Circuit 1 module scan
Input Step Response (1)
Input Resolution 1 mV or 1 µA
Display Resolution 1 mV or 1 µA
Overall Module Accuracy Voltage input types
(0°C to +60°C, +32°F to +140°F) (±10V dc, 1 to 5V dc, 0 to 5V dc, 0 to 10V dc): ±0.1%
Current Input Types
(0 to 20 mA, 4 to 20 mA, ±20 mA):±0.05%
Current Input Type (0 to 1 mA): ±0.5%
Overall Module Drift Voltage input type: ±6 ppm/°C
Current Input Type: ±12 ppm/°C
( 1 Depends
) on filter selected. Refer to the 1746-NI8 User Manual, publication 1746-6.8.
@JO"VTQQE ".
SLC 500 is a trademark of Rockwell Automation.
Belden is a trademark of Belden, Inc.
Publication 1746-IN006A-US-P - February 2000 PN 40071-081-01 (A)

© 2006 Rockwell Automation, Inc. All rights reserved. Printed in Singapore.
@JO"VTQQE ".
SLC 500 Power Supplies
Catalog Numbers 1746-P1, 1746-P2, 1746-P3, 1746-P4, 1746-P5, 1746-P6,

1746-P7
Topic Page
Notice d’installation 3
Installationsanleitung 17
Istruzioni per l'installazione 31
Instrucciones de instalación 45
取付説明書 59
Publication 1746-IN004E-MU-P - September 2007

2 SLC 500 Power Supplies

Solid state equipment has operational characteristics differing from those of electromechanical equipment.
Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication
SGI-1.1 available from your local Rockwell Automation sales office or online at
http://literature.rockwellautomation.com) describes some important differences between solid state
equipment and hard-wired electromechanical devices. Because of this difference, and also because of the
wide variety of uses for solid state equipment, all persons responsible for applying this equipment must
satisfy themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages
resulting from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many
variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot
assume responsibility or liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits,
equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell
Automation, Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
WARNING
Identifies information about practices or circumstances that can cause an explosion in
a hazardous environment, which may lead to personal injury or death, property
damage, or economic loss.
Identifies information that is critical for successful application and understanding of

IMPORTANT
the product.
ATTENTION
Identifies information about practices or circumstances that can lead to personal injury
or death, property damage, or economic loss. Attentions help you to identify a hazard,
avoid a hazard, and recognize the consequences.
SHOCK HAZARD
Labels may be on or inside the equipment, for example, a drive or motor, to alert
people that dangerous voltage may be present.
BURN HAZARD
Labels may be on or inside the equipment, for example, a drive or motor, to alert
people that surfaces may reach dangerous temperatures.
Publication 1746-IN004E-MU-P - September 2007

Instrucciones de instalación
Fuentes de alimentación SLC 500
(Números de catálogo 1746-P1, 1746-P2, 1746-P3, 1746-P4, 1746-P5,

1746-P6 y 1746-P7)
Descripción general
Instale la fuente de alimentación eléctrica usando estas instrucciones de instalación.
Las únicas herramientas que necesita son un destornillador plano (1/8 pulg.) y un
destornillador Phillips (1/4 pulg., #2).
Una descarga electrostática puede dañar los circuitos integrados

ATENCIÓN y los semiconductores si una persona toca los pines del
conector del backplane. Siga estas pautas cuando manipule la
!
fuente de alimentación:
• Toque un objeto que esté conectado a tierra para descargar
el potencial electroestático de su cuerpo.
• No toque el conector de backplane ni los pines del
conector.
• No toque ningún componente de los circuitos dentro de la fuente
de alimentación eléctrica.
• Utilice una estación de trabajo con protección antiestática, si está
disponible.
• Mantenga las fuentes de alimentación eléctrica en su envase
antiestático cuando no esté en uso.
Si el equipo no se instala y se usa según lo descrito en este

IMPORTANTE
manual, puede verse afectada la protección proporcionada por
el equipo.
Publicación 1746-IN004E-MU-P - Septiembre de 2007

46 Fuentes de alimentación SLC 500
Consideraciones respecto a lugares peligrosos

Los productos con la marca CL1, DIV 2, GP A, B, C, D son apropiados para uso en
lugares Clase I, División 2, Grupos A, B, C, D o en lugares no peligrosos solamente.
Cada producto se suministra con marcas en la placa de especificaciones que
indican el código de temperatura para lugares peligrosos. Cuando se combinan
productos en un sistema, el código de temperatura más adverso (número “T” más
bajo) puede usarse como ayuda para determinar el código de temperatura general
del sistema. La combinación de equipos en el sistema está sujeta a investigación
por parte de la autoridad local con jurisdicción al momento de la instalación.
PELIGRO DE EXPLOSIÓN
ADVERTENCIA
• No desconecte el equipo a menos que esté desconectada la
alimentación eléctrica, excepto en el caso de que el área se
! considere no peligrosa.
• No desconecte las conexiones a este equipo a menos que
esté desconectada la alimentación eléctrica, excepto en el
caso de que el área se considere no peligrosa. Asegure las
conexiones externas a este equipo con tornillos, seguros
deslizantes, conectores roscados u otros medios
proporcionados con este producto.
• La sustitución de componentes puede menoscabar la
idoneidad para Clase I, División 2.
• Todo el cableado debe cumplir con las especificaciones de
N.E.C. artículo 501-4(b).
Instale el cable de interconexion de chasis (opcional)

Para conectar hasta tres chasis SLC 500 juntos, instale el cable de interconexión de
chasis antes de instalar la fuente de alimentación.
.
Chasis SLC 500/A
Para obtener más información, vea el

documento SLC 500 Modular
Hardware Style User Manual
(publicación 1747-UM011).

Fuentes de alimentación SLC 500 47
Instalación de la fuente de alimentación

1. Alinee la tarjeta de circuitos de la fuente de alimentación con las guías para
tarjeta situadas al lado izquierdo del chasis.
2. Deslice la fuente de alimentación hasta que quede al ras con el chasis.

Luego fije la fuente de alimentación al chasis.
Use estos tornillos para fijar la fuente de

alimentación al chasis. Par de apriete
máximo 1.2 Nm (11 pulg.-lb.).
Cableado de la fuente de alimentación eléctrica

Para obtener más información sobre el cableado, vea el
SUGERENCIA
documento Allen-Bradley Programmable Controller
Grounding and Wiring Guidelines, número de publicación
1770-4.1.
Consulte la publicación 1746-IN016 para obtener información
sobre la instalación del chasis y los requisitos de conexión a
tierra.

1. Coloque el puente de voltaje de entrada de manera que coincida con el

voltaje de entrada. (Esto no se aplica a las fuentes de alimentación 1746-P3,
-P5, -P6 y -P7, las cuales no tienen puente).
Establezca el puente de entrada antes de conectar la

ATENCIÓN alimentación eléctrica. Cuando está conectada la
alimentación eléctrica, hay voltaje peligroso presente en
!
los pines expuestos; el contacto con los pines puede
causar lesiones al personal.
Si conecta o desconecta el cableado a los bloques de

ADVERTENCIA terminales, o si instala o desinstala la fuente de
alimentación con la alimentación eléctrica conectada,
!
podría ocurrir un arco eléctrico. Esto podría causar una
explosión en lugares peligrosos. Antes de proceder,
asegúrese de que esté desconectada la alimentación
eléctrica o de que el área esté considerada como no
peligrosa.
Número de catálogo Número de catálogo

1746-P1 y 1746-P2 1746-P4
Selección del puente

Fusible
85-132 VCA
Selección del puente

170-250 VCA
100/120 Volts
200/240 Volts

2. Conecte el tornillo de tierra de la fuente de alimentación a la conexión a

tierra o bus de tierra más cercano. Utilice cable de cobre de 1.68 mm (calibre
14 AWG) 75° (Categoría 1 según el documento Industrial Automation
Wiring and Grounding Guidelines, publicación 1770-4.1) y mantenga los
conductores tan cortos como sea posible.
La fuente de alimentación 1746-P4 se muestra a continuación.
3. Consulte la página 65 para obtener información sobre consideraciones

especiales de cableado para la fuente de alimentación 1746-P3.
Tierra del chasis
Apriete los tornillos de los

terminales a 0.8 Nm (7 pulg.-lb.)
Bus de tierra más cercano
4. Conecte la alimentación de entrada. Vea la ilustración en la página 64.
Desconecte la alimentación de entrada antes de conectar

ATENCIÓN los cables; El no cumplir con esta indicación puede
causar lesiones personales graves y/o daño al equipo.
! Utilice cable de cobre de 1.68 mm (calibre 14 AWG). Apriete los

tornillos terminales a un par de apriete de 0.8 N-m (7 lb-pulg.)


1746-P1 y -P2 1746-P3
120/240V ac + 24V dc
Alimentación Alimentación
de entrada VAC NEUT de entrada DC NEUT
CHASSIS GROUND CHASSIS GROUND

1746-P4 1746-P5
+125V dc
Alimentación
85–132V ac de entrada DC NEUT
Selección
de puente P4 JUMPER
CHASSIS GROUND
170–250 V ac
Número de catálogo
L1 85–132/170–250 1746-P6
Alimentación
de entrada P4
L2 NEUTRAL +48V dc
Alimentación
de entrada DC NEUT
CHASSIS GROUND
CHASSIS GROUND
Número de catálogo
1746-P7
+ 12/24V dc
Alimentación
de entrada DC NEUT
CHASSIS GROUND
La fuente de alimentación SLC 500 puede sufrir daño debido a

ATENCIÓN sobretensión al conmutar cargas inductivas tales como motores,
arrancadores de motor, solenoides y relés. Para proteger la
!
fuente de alimentación SLC 500 en estas aplicaciones, use un
transformador de aislamiento para aislar la fuente de
alimentación de la sobretensión dañina.

Consideraciones de cableado de la fuente de alimentación 1746-P3

Esta información describe consideraciones especiales de cableado para la fuente de
alimentación eléctrica 1746-P3 no identificadas como revisión (REV) B.
El voltaje aplicado al terminal 1746-P3 DC NEUT estará presente en la

ATENCIÓN tierra lógica SLC y en el puerto DH-485 del procesador. Para evitar
diferenciasdepotencialnodeseadasenlatierralógicadelcontrolador
!
y/o daño al chasis SLC, el terminal DC NEUTRAL de la fuente de
alimentación de CC externa debe estar aislado de la tierra del chasis
SLC o conectado a la tierra física como se muestra en la siguiente
ilustración.
Procesador Chasis SLC 500

1746-P3
Fuente de alimentación de CC externa Puerta

DH-485
Port
Tierra lógica SLC
+24V dc
+24V dc
DC Neut
DC Neut
Tierra del
chasis
•
Se recomienda instalar un Conexión a
cable de puente entre el tierra
Conexión a tierra terminal DC NEUT y la tierra
del chasis de la fuente de
alimentación externa.
Los chasis SLC 500 Serie A (1746-A4, 1746-A7, 1746-A10 y 1746-A13)

IMPORTANTE
fabricados antes de noviembre de 1992 tienen una resistencia entre la
tierra lógica y la tierra del chasis, tal como se ilustra en el dibujo de la
siguiente página. Esta resistencia podría sufrir daño si no se sigue la
recomendación de cableado descrita en la nota de "Atención"
proporcionada anteriormente. Vea la figura en la siguiente página para
encontrar la ubicación de la resistencia. Los chasis SLC 500 Serie A
(1746-A4, 1746-A7, 1746-A10 y 1746-A13) con fecha de fabricación de
Noviembre de 1992 o posterior no tienen esta resistencia. Los chasis
SLC 500 Serie B tienen una resistencia de 1 MΩ que limita la corriente
entre la tierra lógica y la tierra del chasis.

Procesador Chasis SLC 500

1746-P3
Puerta
Not Used DH-485
Port
Not Used
Tierra lógica SLC
+24V dc
Resistencia
DC Neut •
Chassis
Tierra del chasis
Ground •
Conexión a
tierra
5. (Opcional) Para las fuentes de alimentación 1746-P1, 1746-P2, 1746-P4,

1746-P5 y 1746-P6, use los terminales PWR OUT +24V dc y PWR OUT COM
para activar las cargas y detectores de 245 VCC. Los terminales en los
equipos 1746-P1, 1746-P2, 1746-P5 y 1746-P6 proporcionan una fuente de
alimentación de 24 VCC, 200 mA sin fusible, aislada. Los terminales en el
equipo 1746-P4 proporcionan una fuente de alimentación de 24 VCC, 1 A,
sin fusible, aislada. (Las fuentes de alimentación 1746-P3 y 1746-P7 no
tienen provisión para una fuente de alimentación externa).

1746-P1, 1746-P2, 1746-P5 y 1746-P6 1746-P4
Alimentación PWR OUT +24V dc PWR OUT +24V dc

Alimentación
de usuario de usuario
PWR OUT COM PWR OUT COMMON

Operación del SLC 500 con condición de sobrecorriente de

alimentación de usuario de 24 VCC
N.º de Cat. Operación del SLC Procedimiento de

recuperación
1746-P1 Serie A (fabricado en Japón) Desactivación de la fuente de Volver a cargar programa de
alimentación eléctrica, fallo de CPU usuario
1746-P1 Serie A (fabricado en Malasia- Desactivación de 24 VCC de usuario, la Corregir condición de
producción actual) CPU continúa funcionando sobrecorriente
1746-P2 Serie A, B Desactivación de la fuente de Volver a cargar programa de
1746-P2 Serie C Desactivación de 24 VCC de usuario, la Corregir condición de
CPU continúa funcionando sobrecorriente
1746-P4 Serie A Desactivación de la fuente de Volver a cargar programa de
1746-P5 Serie A Desactivación de 24 VCC de usuario, la Corregir condición de
1746-P6 Serie A Desactivación de 24 VCC de usuario, la Corregir condición de
En el caso de los equipos 1746-P1 (fabricado en Malasia),

ATENCIÓN 1746-P2 Serie C, 1746-P5 Serie A y 1746-P6 Serie A, para evitar
una operación no esperada debido a desactivación de la
!
alimentación de 24 VCC de usuario, monitoree la salida de
24 VCC de usuario con un canal de entrada de 24 VCC.
6. Quite la etiqueta protectora.

Operación con bajo voltaje de la fuente de alimentación

Los controladores SLC 500 continúan funcionando (retención) por un corto período
de tiempo si el voltaje de entrada a la fuente de alimentación cae por debajo del
rango de voltaje de operación recomendado. El controlador continúa escaneando el
programa de usuario y controlando las E/S durante este tiempo. El tiempo de
retención de la CPU para cada fuente de alimentación se muestra en las páginas 68
y 70.
Los controladores SLC 500 se desactivan (se detiene el escán y se inhabilitan las
salidas) si se desconecta el voltaje de entrada a la fuente de alimentación, o éste
cae por debajo del rango de operación recomendado por un período mayor al
tiempo de retención de la CPU. El controlador continúa la operación
automáticamente cuando el voltaje de entrada regresa a su estado normal.
Si el voltaje de entrada a la fuente de alimentación 1746-P7 cae dentro del rango de
4 a 9 V por un período mayor que el tiempo de retención de la CPU, el controlador
se desactivará y no se volverá a activar hasta que el voltaje de entrada aumente a 11
VCC.
Especificaciones generales (1746-P1, 1746-P2, 1746-P3 y 1746-P4)

Atributo Valor
1746-P1 1746-P2 1746-P3 1746-P4
Voltaje de línea 85-132/170-265 VCA 19.2-28.8 VCC 85-132/170-250 VCA
47-63 Hz 47-63 Hz
Requisito de 135 VA 180 VA 90 VA 150 VA
alimentación de
línea típico
Corriente de entrada 20 A 45 A
al momento del
arranque, máx.
Capacidad de 2 A a 5 VCC 5 A a 5 VCC 3.6 A a 5 VCC 10.0 A a 5 VCC
corriente interna 0.46 A a 24 VCC 0.96 A a 24 VCC 0.87 A a 24 VCC 2.88 A a 24 VCC(1)
Protección de 1746-F1 o 1746-F2 o 1746-F3 o El fusible está
fusible(2) equivalente(3) (4) equivalente(3) (5) equivalente(3) (6) solado.
Capacidad de 200 mA No aplicable 1 A(1)
corriente de
alimentación de
usuario de 24 VCC
Rango de voltaje de 18-30 VCC 20.4-27.6 VCC
alimentación de
usuario de 24 VCC
Protección contra 15 A No aplicable 15 A
sobrecorriente
proporcionada por el
usuario(7), máx.

Atributo Valor
1746-P1 1746-P2 1746-P3 1746-P4
Temperatura 0°C a +60°C (+32°F a +140°F) 0°C a +60°C
ambiente de La capacidad de corriente se reduce 5% por encima (+32°F a +140°F)
funcionamiento de +55°C (131 °F). sin reducción de la
capacidad nominal
Aislamiento(8) 1800 VCA RMS durante 1 s 600 VCA eficaces 2600 VCC durante
(RMS) durante 1 1s
s (versión B o
posterior)
Tiempo de retención 20 ms (carga plena) 3000 ms (sin carga) 5 ms (carga plena) 20 ms (carga plena)
de la CPU(9) 1000 ms (sin carga) 3000 ms (sin carga)
Certificaciones Equipo de control industrial en Lista UL para lugares peligrosos Equipo de control
(cuando el producto Clase 1, División 2, Grupos A, B, C, D industrial en Lista UL
tiene la marca) Equipo de control industrial en Lista UL para lugares peligrosos Equipo de control de
Clase 1, División 2, Grupos A, B, C, D proceso con
certificación CSA
para lugares
peligrosos Clase 1,
Div 2,
Grupos A, B, C, D
CE(10)
Directiva 89/336/EEC EMC de la Unión Europea, cumple con las especificaciones:
EN 50082-2, inmunidad industrial
EN50081-2, emisiones industriales
Directiva 73/23/EEC LVD de la Unión Europea, cumple con las especificaciones:
EN61131-2, controladores programables
Ley de Radiocomunicaciones Australianas C-Tick,
cumple con las especificaciones:
AS/NZS 2064, emisiones industriales
(1) Toda la alimentación de salida combinada (backplane 5 volts, backplane 24 volts y fuente de usuario 24 volts) no puede
sumar más de 70 watts.
(2) El fusible de la fuente de alimentación tiene el propósito de proteger contra el peligro de incendio debido a condiciones de
cortocircuito. Es posible que este fusible no proteja a la fuente de alimentación contra un cableado incorrecto o fenómenos
transitorios excesivos en la línea de alimentación eléctrica.
(3) Los tamaños de los fusibles están especificados para dispositivos finales solamente. Es posible que se requiera reducir el
tamaño del fusible dependiendo del tamaño del cableado del circuito.
(4) Fusibles equivalentes: Fusible 250V-3A, nagasawa ULCS-61ML-3 o BUSSMAN AGC 3
(5) Fusible equivalente: Fusible 250V-3A, SANO SOC SD4 o BUSSMAN AGC 3
(6) Fusible equivalente: Fusible de 125 V, 5 A, LITTLEFUSE 223.
(7) Use protección contra sobrecorriente tipo retardo en todos los conductores no provistos de conexión a tierra.
(8) Aislamiento provisto entre los terminales de entrada y el backplane.
(9) El tiempo de retención de la CPU es para 0 V a menos que se especifique lo contrario. El tiempo de retención depende de la
carga de la fuente de alimentación.
(10) Vea el vínculo de certificación de productos en http://ab.com para obtener información detallada sobre Declaraciones de
conformidad, Certificados y otros detalles de certificación.

Especificaciones generales (1746-P5, 1746-P6 y 1746-P7)

Atributo Valor
1746-P5 1746-P6 1746-P7
Voltaje de línea 90-146 VCC 30-60 VCC 10-30 VCC(1)
Requisito de alimentación 85 VA 100 VA Entrada de 12 VCC: 50 VA Entrada de 24 VCC: 75 VA
de línea típico
Corriente de entrada al 20 A 20 A (necesario para el encendido)
momento del arranque,
máx.
Capacidad de corriente 5 A a 5 VCC Entrada de 12 VCC: Entrada de 24 VCC:
interna 0.96 A a 24 VCC 2.0 A a 5 VCC 3.6 A a 5 VCC
0.46 A a 24 VCC 0.87 A a 24 VCC
Vea la tabla de capacidad de corriente del equipo P7 en la
página 71.
Protección de fusible(2) El fusible está solado.
Capacidad de corriente de 200 mA No aplicable
alimentación de usuario de
24 VCC
Rango de voltaje de 18-30 VCC
alimentación usuario
de 24 VCC
Temperatura ambiente de 0°C a +60°C (+32°F a +140°F)
funcionamiento La capacidad de corriente se reduce 5% por encima de +55°C (131 °F).
Aislamiento(3) 1800 VCA RMS durante 1 s 600 VCA RMS durante 1 s
Tiempo de retención de la 20 ms 5 ms Entrada de 12 VCC: Entrada de 24 VCC:
CPU(4) (carga plena) (carga plena) 1.37 ms a 0 VCC 40 ms a 0 VCC
3000 ms (sin 1500 ms (sin (carga plena) (carga plena)
carga) carga) 895 ms a 0 VCC 1860 ms a 0 VCC
(sin carga) (sin carga)
10 ms a 9 VCC 790 ms a 11 VCC
(carga plena) (carga plena)
continuo a 9 VCC (sin carga) continuo a 11 VCC (sin
carga)
Certificaciones Equipo de control industrial en Lista UL para lugares peligrosos Clase 1, División 2,
(cuando el producto tiene Grupos A, B, C, D
la marca) Equipo de control industrial en Lista UL para lugares peligrosos Clase 1, División 2,
Grupos A, B, C, D
CE(5)
Directiva 89/336/EEC EMC de la Unión Europea, cumple con las especificaciones:
EN 50082-2, inmunidad industrial
EN50081-2, emisiones industriales
Directiva 73/23/EEC LVD de la Unión Europea, cumple con las especificaciones:
EN61131-2, controladores programables
Ley de Radiocomunicaciones Australianas C-Tick,
cumple con las especificaciones:
AS/NZS 2064, emisiones industriales
(1) Vea la página 68 para obtener información acerca del funcionamiento con voltaje insuficiente de la fuente
de alimentación eléctrica.
(2) El fusible de la fuente de alimentación tiene el propósito de proteger contra el peligro de incendio debido a condiciones de
cortocircuito. Es posible que este fusible no proteja a la fuente de alimentación contra un cableado incorrecto o fenómenos
transitorios excesivos en la línea de alimentación eléctrica.
(3) Aislamiento provisto entre los terminales de entrada y el backplane.
(4) El tiempo de retención de la CPU es para 0 V a menos que se especifique lo contrario. El tiempo de retención depende de la
carga de la fuente de alimentación.
(5) Vea el vínculo de certificación de productos en http://ab.com para obtener información detallada sobre Declaraciones de
conformidad, Certificados y otros detalles de certificación.

Capacidad de corriente de la fuente de alimentación 1746-P7
Corriente de Corriente de
salida de 24 VCC salida de 5 VCC
0.87 A 3.6 A
0.625 A 2.64 A
0.46 A 2.0 A
Voltaje de entrada
10V dc 12.2V dc 19.2V dc 30V dc
15V dc
Dimensiones físicas
Controlador: Longitud, Profundidad, Altura, aprox.

aprox. mm aprox. mm mm (pulg.)
(pulg.) (pulg.)
1746-P1 65 (2.56) 140 (5.70) 140 (5.51)
1746-P2 85 (3.35)
1746-P3
1746-P4 110 (4.33) 145 (5.70)
1746-P5 85 (3.35) 140 (5.70)
1746-P6
1746-P7

Servicio de soporte de Rockwell Automation
Rockwell Automation proporciona información técnica en la Internet para ayudarle a utilizar sus
productos. En http://support.rockwellautomation.com, encontrará manuales técnicos, una base de
conocimientos con respuestas a preguntas frecuentes, notas técnicas y de aplicación, ejemplos de
códigos y vínculos a Service Packs de software, y la facilidad MySupport que puede personalizar
para aprovechar al máximo las herramientas.
Con el fin de brindarle un nivel adicional de soporte técnico para la instalación, configuración y
resolución de problemas por teléfono, ofrecemos los programas de soporte técnico TechConnect.
Para obtener más información, póngase en contacto con el distribuidor o representante de
Rockwell Automation más cercano, o visite la página http://support.rockwellautomation.com.
Asistencia para la instalación

Si se le presenta un problema con un módulo de hardware durante las 24 horas posteriores a la
instalación, revise la información proporcionada en este manual. También puede llamar a un
número especial de servicio de soporte al cliente a fin de obtener ayuda inicial para poner en
marcha el módulo:
Estados Unidos +1-440-646-3434, lunes a viernes, de 8:00 a 17:00 hora oficial del Este de los EE.UU.
Fuera de los Póngase en contacto con el representante local de Rockwell Automation para cualquier
Estados Unidos consulta relacionada con soporte técnico.
Devolución de productos nuevos

Rockwell Automation prueba todos sus productos para asegurarse de que estén en perfecto estado
de funcionamiento cuando se envían de la fábrica. Sin embargo, si el producto no funciona y
necesita devolverlo, siga estos procedimientos.
Estados Unidos Póngase en contacto con el distribuidor. Deberá proporcionar al distribuidor un número de
caso de soporte técnico al cliente (llame al número de teléfono indicado anteriormente para
obtenerlo) a fin de completar el proceso de devolución.
Fuera de los Póngase en contacto con el representante local de Rockwell Automation para obtener
Estados Unidos información sobre el procedimiento de devolución.
Allen-Bradley, Rockwell Automation, SLC, SLC 500 y TechConnect son marcas comerciales de Rockwell Automation, Inc.
Las marcas comerciales no pertenecientes a Rockwell Automation son propiedad de sus respectivas empresas.
Publicación 1746-IN004E-MU-P – Septiembre 2007

Copyright © 2007 Rockwell Automation, Inc. Todos los derechos reservados.
What’s New in
HUMAN MACHINE INTERFACE
Human Machine Interface products are devices that are actuated by a person to
direct the operation of another device and/or indicate the status of an operating
system (equipment or machine). Human Machine Interface products can be
electromechanical devices, for example an emergency stop push button that stops
the movement of a conveyor. Simple LED pilot lights or tower lights can provide
visual indication that a machine is functioning properly. Human Machine Interface
products can also be electronic, for example a touch-screen monitor/display.
Pages
144 & 207
Unibody LED Pilot Lights, Non-Relampable
available in two sizes; 30mm and 22mm, both with full voltage LED
options in 24, 120 and 240 volts, and five color options.
22mm IEC Momentary Non-Illuminated

Reset Push Buttons
designed to actuate the reset function of a Series 320 Overload Relay from
Page 205
outside of the enclosure.
22mm IEC 20V-240V AC/DC Multi-Voltage Light

Module, Relampable
eliminates the headache of matching multiple lights with multiple
Page 209 voltages. The modular design of our light module can be used with
22mm IEC pilot lights, illuminated push buttons, push-to-test lights,
and illuminated selector switches. A c3 Exclusive!
IEC Tower Lights and Accessories

Page 229
stackable design allows up to four modules in a single
assembly.
16mm 20V-240V Multi-Voltage

Pilot Lights, Relampable
eliminates the headache of matching
Page 277 multiple lights with multiple
voltages. A c3 Exclusive!
HUMAN MACHINE INTERFACE
30mm Industrial Pilot Devices
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30 22 16 13 DS EC TB
hazardous
series ner
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122 EVERYTHING UNDER CONTROL

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c3controls’ 30mm Industrial Pilot Devices offer superior quality at an affordable

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are rated Type 4/4X as standard for watertight and corrosion resistance. c3’s pilot
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devices are also listed for Type 1, 2, 3, 3R, 12 and 13 requirements. Our multi-voltage
LED light unit can be operated at any voltage from 20V to 240V AC or DC.
30mm
Industrial PILOT DEVICES
Contact Blocks 124
Push Buttons 126
Special Operators 137
Pilot Lights 140
Selector Switches 146
Legend Plates 150
Accessories 152
Specifications 154
Dimensions 155
Conformity to Standards: Certifications:

UL 508, 1604 UL File #: E68568 (Guide NKCR, NKCR7);
E157436 (Guide NOIV)
CSA C22.2 No. 14, 213 CSA File #: LR47446
IEC 60947-1, 60947-5-1 CE Marked (per EU Low Voltage Directive
2006/95/EC and 93/68/EEC)
NOTE: The scope (range, description, price, specifications,
dimensions, etc.) of the product featured in this section is
subject to change without notice. Refer to www.c3controls.com
for product updates. Visit www.c3controls.com to download product certifications.
30 CS22 D1 DS EC TB GR PS
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B2 | I E C
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d ula
Fused
niteasc t
iec
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iec
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S elect Y o ur c o ntact B l o cs k
eries
30 22
hazardous
Modular Contact Block Configuration
nema
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Standard Rating Designations
nema
Code Description Contact Symbol Color PRICE A600 Rating Designation
SILVER contacts A600 (7,200 VA Make and 720 VA Break),
CBNO Normally Open Contact Block Green/Clear $ 6.00 600V AC Maximum s e r i e s
TB
Maximum Continuous Thermal Current, Ith: 10A
CBNO-IP20 Normally Open Contact Block Green/Clear $ 8.00
P300 Rating Designation
with IP20 Guarded Terminals
P300 (138 VA Make and 138 VA Break),
CBNC Normally Closed Contact Block Red/Clear $ 6.00 250V DC Maximum
CBNC-IP20 Normally Closed Contact Block Red/Clear $ 8.00 Maximum Continuous Thermal Current, Ith: 5A
CBEM Early Make Contact Block White/Clear $ 8.00
CBEM-IP20 Early Make Contact Block White/Clear $10.00 NEW d
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CBNOG Normally Open Contact Block Green/Amber $10.00
CBNOG-IP20 Normally Open Contact Block Green/Amber $12.00
CBNCG Normally Closed Contact Block Red/Amber $10.00
CBNCG-IP20 Normally Closed Contact Block Red/Amber $12.00
CBEMG Early Make Contact Block White/Amber $12.00
CBEMG-IP20 Early Make Contact Block White/Amber $14.00
CBDBG Delayed Break Contact Block Black/Amber $12.00
A
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with IP20 Guarded Terminals Schedule
Our Contact Blocks save you time and money by offering the
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And our heavy-duty construction ensures that these contact blocks stay connected.
Tired of wiring contact blocks in cramped spaces?

Our unique 35 degree angled terminals provide ease of wiring for quick
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All terminal screws have self-lifting captive wire clamps to speed wiring.
Enhanced safety with field installable IP20 terminal

guards are transparent to maintain terminal visibility. Their construction
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NOTE: IP20 terminal guards must be installed before wiring.
For convenient terminal marking our IP20 terminal guards utilize Series
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30
industrial
30 m m S ta n d a r d C o n tac t B l o c k s
3 0 m m I nd u s t r i a l P i l o t D e v i c e s
Our standard contact blocks are stackable 4 deep and up to 2 across
series
30
on most operators for a total of 8 circuits per operator. They are
color coded for instant circuit identification to minimize
wiring errors and to speed the wiring process. You can
hazardous
combine contact block types to achieve your desired function.
Also refer to pages 162-163 for our complete selection of
Hermetically Sealed and Factory Sealed Contact Blocks
in our 30mm H-Line section.
U ni q ue P r o duct Features
c 3 c o n t r o l s m a n u fa c t u r e s t h e m o s t i n n o vat i v e , u s e r - f r i e n d ly
line of C o n ta c t B l o c k s o n t h e m a r k e t t o d ay !
1. Vibration resistant snap-on assembly simplifies
installation.
2. Self-lubricating thermoplastic stroker prevents
1 sticking and corrosive build-up that is often
associated with other competitor products.
3. 35 degree angle plated steel terminal screws with
2 captive pressure plates facilitate wiring and protect
against corrosion.
4. Clear V0 plastic covers resist combustion and aid
in visual confirmation of circuit configuration.
8 5. Stainless steel spring for protection in corrosive
3 4 5 6
environments.
7 6. Built-in self-wiping cleaning action and high point
contact pressure for low-level switching. Silver
contact rivets provide long life in normal
control circuits.
Note: Gold plated contacts are 7. Color-coded body for quick circuit identification
available on standard blocks for dry (green = NO, red = NC, white = EM, black = DB).
circuit applications. The cover will
be gold (amber) in place of clear. 8. Optional IP20 terminal guards protect against
accidental contact with live parts. Can be ordered
separately as an accessory or factory assembled
providing the convenience of a single catalog number.
A va i l a b l e C o n tac t B l o c k s for O r d i n a r y L o cat i o n s
CBNO CBNC CBEM CBDB CBDB-IP20
EVERYTHING UNDER CONTROL
125
30 PS22B D1 DS EC TB GR PS
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t o B uild Y o ur Own P us she r iBe sutt o n
30 22 Simply pick the code number from each of the sections below and combine
them
hazardous to nbuild
ema your part number. See page 6 for more detailed directions.
TB nema
Momentary Push Buttons (Non-Illuminated) NEW d

e
E x p a ndc t
PBO series
TB
Produ g!
I II III IV V VI Offerin
Example: To build one of our most popular Push Buttons, the part
number would be PBO + II + III + IV + V + VI or PB O-FC GN-NO-IP20
I. Operator Type IV. Cap Color V. Contact Block Configuration

Code Description PRIce Code DESCRIPTION Code Description price
PBO Push Button Operator $ 8.40 (Blank) Operator less Cap (Blank) Operator without Contact Blocks —
BK Black NO 1 Normally Open Contact Block $ 6.00
II. Clamp Ring BE Blue NC 1 Normally Closed Contact Block $ 6.00
GN Green EM 1 Early Make Contact Block $ 8.00
Code Description price
GY Grey DB 1 Delayed Break Contact Block $ 8.00
(Blank) Black Polyester (Type 4X) —
RD Red NO/NO 2 Normally Open Contact Blocks $12.00
A Aluminum (Type 4) $ 2.00
WE White NC/NC 2 Normally Closed Contact Blocks $12.00
YW Yellow NO/NC 1 Normally Open and 1 Normally $12.00
III. Cap Type Closed Contact Blocks
(Blank) Operator less Cap — VI. OPtions
FC Flush Cap $ 2.40
Code Description price/PC*
GFC Guarded Flush Cap $ 5.40
IP20 IP20 Guard $ 2.00
XC Extended Cap $ 2.40
*NOTE: When choosing the IP20 option, in order to
GXC Guarded Extended Cap $ 5.40 achieve IP20 protection a terminal guard must be
MC Mushroom Cap $ 8.00 assembled on each contact block configuration,
increasing the price $2.00 for each guard.
JMC Jumbo Mushroom Cap $10.00
SMC Shrouded Mushroom Cap* $12.00
SJC Shrouded Jumbo $14.00
Mushroom Cap*
A
*NOTE: Aluminum clamp rings are NOT an option for Discount
SMC or SJC. Schedule
Rubber Boots
Standard rubber Boots Fluorosilicone Rubber Boots
Rubber Boots Also Available
Code Color price Code Color price
RBBK Black $15.00 HRBBK Black $18.00
Your Secondary Defense for Added Protection. RBGN Green $15.00 HRBGN Green $18.00
Chemicals on gloves, wash down areas and particularly RBRD Red $15.00 HRBRD Red $18.00
harsh climates will do damage to any push button. RBYW Yellow $15.00 HRBYW Yellow $18.00
Utilizing our state-of-the-art rubber boots protect
both the operators and the circuits behind them.
Our Standard Rubber Boots feature a brass ring

that is molded with Neoprene that has been modified
to provide added pliability and protection against dust, freezing and
thawing environments. Example: To build one of our most popular
Push Buttons with a Rubber Boot, replace
II, III & IV (Clamp Ring, Cap Type & Color)
Our Fluorosilicone Rubber Boots feature a nickel-plated brass threaded with the code from the rubber boot chart above.
ring that is insert molded into a special thermoset compound to withstand The part number would be PBO + (code from rubber
most applications in corrosive environments and perform well against boot chart above) + V + VI or PB O-R B GN-NO .
more chemicals and vapors than Hypalon Boots. NOTE: Rubber boots come standard with a built-in clamp ring and
thrust washer. When installing operator we recommend that the
thrust washer be placed behind the panel to prevent rotation.

series
Mo m e n t ary N on-
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| uSsehr iBe u
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30industrial
30 m m M o m e n ta r y N o n - I l l u m i n at e d
series
Push Buttons
c3controls goes the extra step to make sure that our products outlast the competition. 30hazardous
Our 30mm Momentary Non-Illuminated Push Buttons are durable and flexible for a
variety of uses. All c3controls 30mm operators are UL Listed and are rated Type 4/4X as
standard for watertight and corrosion resistance. In addition, operators are also listed for
Type 1, 2, 3, 3R, 12 and 13, and meet global standards requirements.
Product features include:
• Polyester construction for superior corrosion resistance, moisture rejection and
electrical insulation.
• Optional polyester or polished aluminum clamp rings with coarse 16 pitch threads.
• #6 terminal screws with self-lifting captive wire clamps accommodate #22 through
two #12 AWG wires (0.5 - 4mm2) per terminal.
• Operators conveniently mount in a round 1-13/64” (30.5mm) hole that is directly interchangeable with
competitors units and eliminates the labor required for notching.
1. O
ur revolutionary U-Cup seal is infused with a Teflon coating to
eliminate cracking when exposed to harsh conditions such as heat,
dryness and sunlight. The U-Cup seal rides easily along the stroker and
keeps water, oils, dust and other corrosive particles in the air away from
the contact blocks. This U-cup seal also acts like a squeegee and forms
a permanent watertight seal that meets Type 4/4X with or without
a rubber boot. In fact, our push button was the first to be rated Type 4X
without using a rubber boot!
2. O
ur push buttons modular design provides endless options for
appropriate operator interface with a variety of interchangeable cap
types and colors which ultimately will save you time and money by
reducing your inventory.
Some of Our Momentary Non-Illuminated Push Button Operators
Popular
with Polyester Clamp Ring (Type 4x)
Flush Cap Extended Cap
Configurations: Cap Color Catalog Number price Catalog Number price
1NO Black PBO-FCBK-NO $16.80 PBO-XCBK-NO $16.80
Green PBO-FCGN-NO $16.80 PBO-XCGN-NO $16.80
Red PBO-FCRD-NO $16.80 PBO-XCRD-NO $16.80
1NC Black PBO-FCBK-NC $16.80 PBO-XCBK-NC $16.80
S nap - On I P 2 0
Green PBO-FCGN-NC $16.80 PBO-XCGN-NC $16.80
TERMINAL GUARDS
Red PBO-FCRD-NC $16.80 PBO-XCRD-NC $16.80
protect against accidental 1 NO Black PBO-FCBK-NO/NC $22.80 PBO-XCBK-NO/NC $22.80
contact with live parts.
& Green PBO-FCGN-NO/NC $22.80 PBO-XCGN-NO/NC $22.80
See page 152.
1 NC Red PBO-FCRD-NO/NC $22.80 PBO-XCRD-NO/NC $22.80
M ix and M atch A ny C olor and M omentary N on -I lluminated P ush B utton C ap
Flush Cap Guarded Extended Cap Guarded Mushroom Cap Jumbo Shrouded Shrouded Jumbo
Flush Cap
Extended
Flush Cap
(1-1/2” (38mm) dia.) Mushroom Cap
(2-1/4” (57mm) dia.)
Mushroom Cap Mushroom Cap
(1-1/2” (38mm) dia.) (2-1/4” (57mm) dia.)
127
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s ihe s u t t o n s
iec iec
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I ts ’es E asy
ries
30 22 Simply pick the code number from each of the sections below and combine them
to
hazardous build your
n e mpart
a number. See page 6 for more detailed directions. nema
TB
Maintained Push Buttons (Non-Illuminated) NEW d
e
2-Position Push-Pull E x p a ndc t series
TB
Produ g!
PBO PP Offerin
I II III IV V VI VII
number would be PBO + II + PP + IV + V + VI + VII or PB O-PPM C GN-NO
I. Operator Type IV. Cap Type VI. Contact Block Configuration

Code Description price Code Description price Code Description price
PBO Push Button Operator $ 8.40 MC Mushroom Cap — (Blank) Operator without Contact Blocks —
JMC Jumbo Mushroom Cap $ 4.00 NO 1 Normally Open Contact Block $ 6.00
II. Clamp Ring NC 1 Normally Closed Contact Block $ 6.00
Code Description price V. Cap Color EM 1 Early Make Contact Block $ 8.00
(Blank) Black Polyester (Type 4X) — DB 1 Delayed Break Contact Block $ 8.00
Code DESCRIPTION
Y Yellow Polyester (Type 4X) $ 2.00 NO/NO 2 Normally Open Contact Blocks $12.00
BK Black
A Aluminum (Type 4) $ 2.00 NC/NC 2 Normally Closed Contact Blocks $12.00
BE Blue
NO/NC 1 Normally Open and 1 Normally $12.00
GN Green
Closed Contact Blocks
III. Cap function GY Grey
RD Red
Code Description price VII. OPtions
WE White
PP Push-Pull Maintained $26.60
YW Yellow Code Description price/PC*
The 2-Position Push-Pull is maintained in IP20 IP20 Guard $ 2.00
both the push and pull positions. The *NOTE: When choosing the IP20 option, in order to
primary application is “push” to “stop” and achieve IP20 protection a terminal guard must be
assembled on each contact block configuration,
“pull” to “start”. increasing the price $2.00 for each guard.
O = Open X = Closed
Maintained In/Maintained OUt
1 circuit (1 NC) 2 circuit (1 NO/1 NC) 2 circuit (2NC)
A
Out In Out In Out In
NC X O NC X O NC X O Discount
NO O X NC X O
Schedule
S nap - On I P 2 0
TERMINAL GUARDS
protect against accidental
See page 152.
M ix and M atch A ny C olor and P ush -P ull M aintained N on -I lluminated C ap
Jumbo Jumbo Jumbo Jumbo

Mushroom Cap Mushroom Cap Mushroom Cap Mushroom Cap Mushroom Cap Mushroom Cap Mushroom Cap
(1-1/2” (38mm) dia.) (1-1/2” (38mm) dia.) (1-1/2” (38mm) dia.) (2-1/4” (57mm) dia.) (2-1/4” (57mm) dia.) (2-1/4” (57mm) dia.) (2-1/4” (57mm) dia.)

series
Mai n t ai n ed N on-
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N on-
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industrial
30 m m M a i n ta i n e d
series
N o n -I l l u m i n at e d P u s h B u t t o n s
The most rugged Emergency Stop Available
30
hazardous
in the Industry!
All c3controls 30mm operators are UL Listed and are rated Type 4/4X as
standard for watertight and corrosion resistance. In addition, operators
are also listed for Type 1, 2, 3, 3R, 12 and 13, and meet global standards
requirements.
• Polyester construction for superior corrosion resistance, moisture
rejection and electrical insulation.
• Optional polyester or polished aluminum clamp rings with coarse
16 pitch threads that easily thread on and won’t cross thread or strip.
• All cap types are secured by the clamp ring once installed for tamper
protection, unlike snap-on/snap-out caps used by others.
• #6 terminal screws with self-lifting captive wire clamps accommodate
#22 through two #12 AWG wires (0.5 - 4mm2) per terminal.
• Operators conveniently mount in a round 1-13/64” (30.5mm) hole that is directly
interchangeable with competitors units and eliminates the labor required for notching.
We Put The Metal On The Inside — Where It Counts!

c3controls Emergency Stops contain a solid brass detent mechanism and are the best-
engineered, most reliable heavy-duty emergency stop buttons
in the world. This rugged design, which comes standard with
a polyester clamp ring or optional aluminum clamp ring, ensures
reliable operation in emergency applications, providing
safe interruption of circuits, and much longer life
when compared to any competitor’s product. A
stainless steel version is also available for corrosive
environments (see pages 166-167).
Some of Our Popular Configurations:

2-Position Push-Pull Maintained Non-Illuminated Operators
with Polyester Clamp Ring (Type 4X)
1 Circuit (1NC) 2 Circuit (1 NO/1 NC) 2 Circuit (2 NC)
Color Catalog Number price Catalog Number price Catalog Number price
Black PBO-PPMCBK-NC $41.00 PBO-PPMCBK-NO/NC $47.00 PBO-PPMCBK-NC/NC $47.00
Green PBO-PPMCGN-NC $41.00 PBO-PPMCGN-NO/NC $47.00 PBO-PPMCGN-NC/NC $47.00
Red PBO-PPMCRD-NC $41.00 PBO-PPMCRD-NO/NC $47.00 PBO-PPMCRD-NC/NC $47.00
Yellow PBO-PPMCYW-NC $41.00 PBO-PPMCYW-NO/NC $47.00 PBO-PPMCYW-NC/NC $47.00
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30 22
hazardous
Simply pick the code number from each of the sections below and combine
them to nbuild
TB nema

e
E x p a ndc t
2-Position Push-Twist Release series
TB
Produ g!
Offerin
PTR TMC
I II III IV V VI
number would be PTR + II + TMC + IV + V + VI or PTR -TM C GN-NO
I. Operator Type III. Cap Type V. Contact Block Configuration

Code Description price Code Description price Code Description price
PTR Push-Twist Release $30.00 TMC Twist Mushroom Cap $ 8.00 (Blank) Operator without Contact Blocks —
NO 1 Normally Open Contact Block $ 6.00
II. Clamp Ring IV. Cap Color NC 1 Normally Closed Contact Block $ 6.00
Code Description price EM 1 Early Make Contact Block $ 8.00
Code DESCRIPTION
(Blank) Black Polyester (Type 4X) — DB 1 Delayed Break Contact Block $ 8.00
BK Black
Y Yellow Polyester (Type 4X) $ 2.00 NO/NO 2 Normally Open Contact Blocks $12.00
BE Blue
A Aluminum (Type 4) $ 2.00 NC/NC 2 Normally Closed Contact Blocks $12.00
GN Green
NO/NC 1 Normally Open and 1 Normally $12.00
GY Grey
The linear push off twist to release style Closed Contact Blocks
RD Red
operator requires a “twist” for the “out” or
WE White
“on” position and a linear “push” for the VI. OPTIONS
“in” or “off” position. The twist mushroom YW Yellow
cap is marked with arrows identifying the Code Description price/PC*
direction for the twist release. IP20 IP20 Guard $ 2.00
*NOTE: When choosing the IP20 option, in order to
O = Open X = Closed achieve IP20 protection a terminal guard must be
increasing the price $2.00 for each guard.
Out In Out In Out In

NC X O NC X O NC X O
NO O X NC X O
Discount
Schedule A
2-Position Push-Twist Release Maintained Non-Illuminated Operators
Color Catalog Number price Catalog Number price Catalog Number price
Black PTR-TMCBK-NC $44.00 PTR-TMCBK-NO/NC $50.00 PTR-TMCBK-NC/NC $50.00
Green PTR-TMCGN-NC $44.00 PTR-TMCGN-NO/NC $50.00 PTR-TMCGN-NC/NC $50.00
Red PTR-TMCRD-NC $44.00 PTR-TMCRD-NO/NC $50.00 PTR-TMCRD-NC/NC $50.00
Yellow PTR-TMCYW-NC $44.00 PTR-TMCYW-NO/NC $50.00 PTR-TMCYW-NC/NC $50.00
A vailable C ap C olors for 2-P osition and 3-P osition M aintained N on -I lluminated P ush B uttons
Twist Twist Twist Twist Push-Pull Push-Pull Push-Pull

Mushroom Cap Mushroom Cap Mushroom Cap Mushroom Cap Mushroom Cap Mushroom Cap Mushroom Cap
(1-1/2” (38mm) dia.) (1-1/2” (38mm) dia.) (1-1/2” (38mm) dia.) (1-1/2” (38mm) dia.) (1-1/2” (38mm) dia.) (1-1/2” (38mm) dia.) (1-1/2” (38mm) dia.)

series
Mai n t ai n ed N on-
I EC
I llum
N on-
i naFused
t ed | P
| uSsehr iBe u
s t DS2
tons
30
industrial
I t ’ s E asy t o B uild Y o ur Own P us h B utt o n
series
them to build your part number. See page 6 for more detailed directions.
30
hazardous

e
3-Position Push-Pull E x p a ndc t
Produ g!
PP Offerin
I II III IV V VI
number would be I + PP + III + IV + V + VI or PPMIRD-NC-DB
I. Clamp Ring IV. Mushroom Cap/Color VI. OPtions

Code Description price Code DESCRIPTION price Code Description price/PC*
(Blank) Black Polyester (Type 4X) — BK Black $ 8.00 IP20 IP20 Guard $ 2.00
Y Yellow Polyester (Type 4X) $ 2.00 BE Blue $ 8.00 *NOTE: When choosing the IP20 option, in order to
*achieve IP20 protection a terminal guard must be
A Aluminum (Type 4) $ 2.00 GN Green $ 8.00 *assembled on each contact block configuration,
GY Grey $ 8.00 *increasing the price $2.00 for each guard.
II. Operator Type RD Red $ 8.00

WE White $ 8.00 The 3-Position Push-Pull device is available
YW Yellow $ 8.00
in two basic styles. One version features
PP Push-Pull Maintained $27.00 the “out” position as momentary, the
“center” position as maintained, and the
V. Contact Block Configuration “in” position as maintained. The other
III. Operator Function
Code Description price version features the “center” position as
Code Description (Blank) Operator without Contact Blocks —
maintained while the “out” and “in”
MI Momentary Out, Maintained positions are momentary.
NC-DB 1 Normally Closed and $14.00
Center, Maintained In 1 Delayed Break Contact Blocks
AC Momentary Out, Maintained NO-NC 1 Normally Open and $14.00
Center, Momentary In 1 Normally Closed Contact Blocks
O = Open X = Closed
Momentary Out, Maintained Momentary Out, Maintained
Center, Maintained In Center, Momentary In
Out Center In Out Center In

NC X O O NC X O O
A
DB X X O DB X X O
NO O O X NO O O X
Discou n t
Schedu l e
NC X O O NC X O O

3-Position Push-Pull Maintained Non-illuminated Operators
Momentary Out, Maintained Center, Momentary Out, Maintained Center
S nap - On I P 2 0 Maintained In Momentary In
TERMINAL GUARDS Color Catalog Number price Catalog Number price
Black PPMIBK-NC-DB $49.00 PPACBK-NC-DB $49.00
protect against accidental
Green PPMIGN-NC-DB $49.00 PPACGN-NC-DB $49.00
See page 152. Red PPMIRD-NC-DB $49.00 PPACRD-NC-DB $49.00
Yellow PPMIYW-NC-DB $49.00 PPACYW-NC-DB $49.00
See b o t t o m o f pa g e 130 for C ap C o l o r options.

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I ste’rsi e s E asy t o B uild Y o ur Own P uss h B utt o n
eries
30 22
hazardous
them to nbuild
TB nema
Momentary Push Buttons (Illuminated)* NEW d

e
E x p a ndc ts e r i e s
TB
Produ g!
I II III IV V VI VII VIII Offerin
number would be I + II + III + IV + V + VI + VII + VIII or FV LUI20-IPB C GN-NO-IP20
*Note: Our momentary illuminated push buttons must be ordered as an assembled part. Contact blocks may be ordered separately.
I. Basic Illuminated Push III. Lamp Type/color VI. Lens Color

Button Operator
Code Color price Code DESCRIPTION
Code Description price LED AR Amber
FVLU Full Voltage $26.00 LA Amber $10.00 BE Blue
TFLU Transformer (50/60 Hz) $38.00 LB Blue $10.00 CR Clear
RLU Resistor $32.00 LG Green $10.00 GN Green
RTLU Dual Input Remote Test $35.00 LR Red $10.00 RD Red
LW White $10.00 WE White
II. Voltage based on INCANDESCENT YW Yellow
Operator Type
(Blank) Clear‡ —
Code Description ‡NOTE: Incandescent bulbs VII. Contact Block Configuration
are not an option for RLU480.
Full Voltage
F Clear Flashing Bulb* $ 4.00 Code Description price
6 6V AC/DC (Blank) Operator without Contact Blocks —
*NOTE: Incandescent flashing
12 12V AC/DC bulbs available for any 6V full NO 1 Normally Open Contact Block $ 6.00
24 24V AC/DC voltage or transformer application.
NC 1 Normally Closed Contact Block $ 6.00
120 120V AC/DC NEON†
EM 1 Early Make Contact Block $ 8.00
Transformer NG Green —
DB 1 Delayed Break Contact Block $ 8.00
120 120V AC NR Red —
NO-NO 2 Normally Open Contact Blocks $12.00
†NOTE: Only Available in FVLU120,
240 240V AC NC-NC 2 Normally Closed Contact Blocks $12.00
†RLU240 and RLU480.
277 277V AC NO-NC 1 Normally Open and 1 Normally $12.00
NL No Lamp – $ 1.00
480 480V AC Closed Contact Blocks
Resistor
IV. Clamp Ring
120 120V AC/DC VIII. options
240 240V AC/DC Code Description price
480 480V AC/DC (LED & Neon only) (Blank) Black Polyester (Type 4X) —
Dual Input Remote Test A Aluminum (Type 4) $ 2.00 *NOTE: When choosing the IP20 option, in order to
6 6V AC/DC achieve IP20 protection a terminal guard must be
assembled on the light module and each contact block
12 12V AC/DC V. Lens Type
configuration, increasing the price $2.00 for each guard.
24 24V AC/DC Code Description price
IP20 terminal guards are not available for RTLU.
120 120V AC/DC IPBC Illuminated Push Button Lens $ 8.00
IPBCM Illuminated Push Button $12.00
Mushroom Lens S ee page 153 for L amp
GIPBC Guarded Illuminated Push $12.00 R eplacement C hart and page
Button Lens* 154 for L amp T echnical D ata .
SIPBCM Shrouded Illuminated Push $16.00
Button Mushroom Lens*
*NOTE: Aluminum clamp rings are not an option for
*GIPBC or SIPBCM.
Discount
Schedule A
Mix and M at c h A n y C o l o r and M o m e n ta r y I l l u m i n at e d P u s h B u t t o n L e n s
Push Button Lens Push Button Lens Push Button Lens Guarded Push Mushroom Lens Mushroom Lens Shrouded
Button Lens (1-1/2” (38mm) dia.) (1-1/2” (38mm) dia.) Mushroom Lens
(1-1/2” (38mm) dia.)
Revision 04.14.10

series
Mo m e nt a r yI EC
I llum
N on-
i naFused
t ed | P
| uSsehr iBe u
s t DS2
tons
30
industrial
30 m m M o m e n ta r y I l l u m i n at e d
series
Push Buttons
c3controls goes the extra step to make sure that our products outlast the 30
hazardous
competition. Our 30mm Momentary Illuminated Push Buttons are durable
and flexible for a variety of uses. All c3controls 30mm operators are UL Listed
and are rated Type 4/4X as standard for watertight and corrosion resistance.
In addition, operators are also listed for Type 1, 2, 3, 3R, 12 and 13, and
meet global standards requirements.
• Polyester construction for superior corrosion resistance, moisture rejection
and electrical insulation.
• Optional polyester or polished aluminum clamp rings.
• Full voltage lights incorporate a unique insulated socket design to
minimize accidental contact during lamp change.
• All lights use miniature bayonet base lamps to provide reliable lamp secureness.
• Available with Incandescent, Neon, or our LED lamps with leakage protection.
• #6 terminal screws with self-lifting captive wire clamps accommodate #22 through two #12 AWG wires (0.5 - 4mm2) per terminal.
• Operators conveniently mount in a round 1-13/64” (30.5mm) hole that is directly interchangeable with competitors units
and eliminates the labor required for notching.
1. O
ur revolutionary U-Cup seal is infused with a Teflon coating to eliminate
cracking when exposed to harsh conditions such as heat, dryness and sunlight.
The U-Cup seal rides easily along the stroker and keeps water, oils, dust and
other corrosive particles in the air away from the contact blocks. This U-cup
seal also acts like a squeegee and forms a permanent watertight seal that meets
Type 4/4X standards.
2. A
ll frictional parts are molded with an internal self lubricant to provide outstanding
wear without troublesome greases used by others.
3. O
ur rugged Lexan™ caps can resist high impact for reliable performance in most
environments even in high temperature ambients.

D ual I nput
Momentary Illuminated Push Button Operators R em o te T est
PUsh button Lens mushroom Lens Our unique Dual Input Remote light
Lens Color Catalog Number price Catalog Number price unit can be used as an illuminated push
Full Amber FVLU120-IPBCAR-NO-NC $46.00 FVLU120-IPBCMAR-NO-NC $50.00 button while also permitting the testing
of a number of lights from a single push
Voltage Green FVLU120-IPBCGN-NO $40.00 FVLU120-IPBCMGN-NO $44.00
button. A diode circuit isolates the test
Red FVLU120-IPBCRD-NC $40.00 FVLU120-IPBCMRD-NC $44.00
supply from the normal supply.
Trans- Amber TFLU120-IPBCAR-NO-NC $58.00 TFLU120-IPBCMAR-NO-NC $62.00 The schematic
former Green TFLU120-IPBCGN-NO $52.00 TFLU120-IPBCMGN-NO $56.00 TEST L1 1LS
shown
1CR L2
Red TFLU120-IPBCRD-NC $52.00 TFLU120-IPBCMRD-NC $56.00 represents COMMON

NORMAL
Resistor Amber RLU120-IPBCAR-NO-NC $52.00 RLU120-IPBCMAR-NO-NC $56.00 a typical 3CR PS
TEST COMMON
Green RLU120-IPBCGN-NO $46.00 RLU120-IPBCMGN-NO $50.00 dual input NORMAL
Red RLU120-IPBCRD-NC $46.00 RLU120-IPBCMRD-NC $50.00 application. 2LS TEST SOL
COMMON
LED Amber TFLU120LA-IPBCAR-NO-NC $68.00 TFLU120LA-IPBCMAR-NO-NC $72.00 NORMAL
Green FVLU120LG-IPBCGN-NO $50.00 FVLU120LG-IPBCMGN-NO $54.00 TEST
Red FVLU120LR-IPBCRD-NC $50.00 FVLU120LR-IPBCMRD-NC $54.00

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Maintained Push Buttons (Illuminated) NEW d

e
E x p a ndc t
2-Position Push-Pull P r o d u sge! r i e s
TB
Offerin
PPM IMC
I II III IV V VI VII VIII IX
Example: To build one of our most popular Push Buttons, the part number
would be I + PPM + III + IV + V + IMC + VII + VIII + IX or FV PPM 120-IM C GN-NO
I. Basic Illuminated Push IV. Lamp Type/color VI. Lens Type

Button Operator
Code Color price Code Description price
Code Description price LED IMC Illuminated Push Button $12.00
FV Full Voltage — LA Amber $10.00 Mushroom Lens
TF Transformer (50/60 Hz) $12.00 LB Blue $10.00
RL Resistor — LG Green $10.00 VII. Lens Color
LR Red $10.00 Code DESCRIPTION
II. Operator Type LW White $10.00 AR Amber
Code Description price INCANDESCENT BE Blue
PPM Push-Pull Maintained $45.00 (Blank) Clear‡ — CR Clear
‡NOTE: Incandescent bulbs
are not an option for RLPPM480. GN Green
III. Voltage based on F Clear Flashing Bulb* $ 4.00 RD Red
Operator Type *Note: Incandescent flashing WE White
bulbs available for any 6V full
Code Description voltage or transformer application.
Full Voltage NEON† VIII. Contact Block Configuration
6 6V AC/DC NG Green — Code Description price
12 12V AC/DC NR Red — (Blank) Operator without Contact Blocks —
24 24V AC/DC †NOTE: Only Available in FVPPM120,
120 120V AC/DC †RLPPM240 and RLPPM480.
NC 1 Normally Closed Contact Block $ 6.00
Transformer NL No Lamp – $ 1.00
120 120V AC
DB 1 Delayed Break Contact Block $ 8.00
240 240V AC V. Clamp Ring NO-NO 2 Normally Open Contact Blocks $12.00
277 277V AC
Code Description price NC-NC 2 Normally Closed Contact Blocks $12.00
480 480V AC
(Blank) Black Polyester (Type 4X) — NO-NC 1 Normally Open and 1 Normally $12.00
Resistor
A Aluminum (Type 4) $ 2.00 Closed Contact Blocks
120 120V AC/DC
240 240V AC/DC
S ee page 153 for L amp IX. OPtionS
480 480V AC/DC (LED & Neon only)
R eplacement C hart and page Code Description price/PC*
The 2-Position Push-Pull is maintained in 154 for L amp T echnical D ata . IP20 IP20 Guard $ 2.00
both the push and pull positions. The S ee page 135 for C ircuit *NOTE: When choosing the IP20 option, in order to
primary application is “push” to “stop” D iagram C hart .
*achieve IP20 protection a terminal guard must be
*assembled on each contact block configuration,
and “pull” to “start”. increasing the price $2.00 for each guard.
D i sco u n t
Schedule A
A va i l a b l e L e n s C o l o r s for 2-P o s i t i o n and 3-P o s i t i o n M a i n ta i n e d I l lu m i n at e d P u s h B u t t o n s
(1-1/2” (38mm) dia.) (1-1/2” (38mm) dia.) (1-1/2” (38mm) dia.) (1-1/2” (38mm) dia.) (1-1/2” (38mm) dia.) (1-1/2” (38mm) dia.)
Revision 04.14.10

series
Mai n t a i nedI EC
I llum
N on-
i naFused
t ed | P
| uSsehr iBe u
s t DS2
tons
30 industrial
30 m m M a i n ta i n e d I l l u m i n at e d
series
Push Buttons
c3controls goes the extra step to make sure that our products outlast the competition. 30 hazardous
Our 30mm Maintained Illuminated Push Buttons are durable and flexible for
a variety of uses. All c3controls 30mm operators are UL Listed and are rated
Type 4/4X as standard for watertight and corrosion resistance. In addition,
operators are also listed for Type 1, 2, 3, 3R, 12 and 13, and meet global
standards requirements.
• Optional polyester or polished aluminum clamp rings with coarse
16 pitch threads that easily thread on and won’t cross thread or strip.
• Full voltage lights incorporate a unique insulated socket design to minimize accidental contact during lamp change.
• All lights use miniature bayonet base lamps to provide reliable lamp secureness.
• Available with Incandescent, Neon or our LED lamps with leakage protection.
• #6 terminal screws with self-lifting captive wire clamps accommodate #22 through two #12 AWG wires (0.5 - 4mm2) per terminal.
• Operators conveniently mount in a round 1-13/64” (30.5mm) hole that is directly interchangeable with competitors units
and eliminates the labor required for notching.
1. O
ur seal is infused with a coating to eliminate cracking
when exposed to harsh conditions such as heat, dryness
and sunlight. This seal also acts as a light reflector because
it is white which increases light output and improves
visibility from all angles.
2. A
ll frictional parts are molded with an internal self lubricant
to provide outstanding wear without troublesome greases
used by others.
3. O
ur rugged Lexan™ caps can resist high impact for reliable performance in most
environments even in high temperature ambients.
2-P o s i t i o n P u s h -P u l l M a i n ta i n e d I l lu m i n at e d 3-P o s i t i o n P u s h -P u l l M a i n ta i n e d I l lu m i n at e d
O p e r at o r s C i r c u i t D i ag r a m C h a rt O p e r at o r s C i r c u i t D i ag r a m C h a rt
O = Open X = Closed O = Open X = Closed
Momentary Out, Maintained Momentary Out, Maintained
Center, Maintained In Center, Momentary In
Out Center In Out Center In

Out In Out In Out In NC X O O NC X O O
DB X X O DB X X O
NC X O NC X O NC X O
NO O O X NO O O X
NO O X NC X O
NC X O O NC X O O

2-Position Push-Pull Maintained Illuminated Operators
Type Catalog Number price Catalog Number price Catalog Number price
Transformer TFPPM120-IMCRD-NC $75.00 TFPPM120-IMCRD-NO-NC $81.00 TFPPM120-IMCRD-NC-NC $81.00
Full Voltage FVPPM120-IMCRD-NC $63.00 FVPPM120-IMCRD-NO-NC $69.00 FVPPM120-IMCRD-NC-NC $69.00
Resistor EVERYTHING UNDER CONTROL
RLPPM120-IMCRD-NC $63.00 RLPPM120-IMCRD-NO-NC $69.00 RLPPM120-IMCRD-NC-NC $69.00
135
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TB nema
NEW
Maintained 3-Position Push-Pull Push Buttons (Illuminated) ed
E x p a ndc t
u
P r osd e rg i! e s
IMC
TB
Offerin
I II III IV V VI VII VIII IX
Example: To build one of our most popular Push Buttons, the part number
would be I + II + III + IV + V + IMC + VII + VIII + IX or FV M I120-IM C R D -NC -D B
I. Basic Illuminated Push IV. Lamp Type/color VII. Lens Color

Button Operator
Code Color price Code DESCRIPTION
Code Description price LED AR Amber
FV Full Voltage — LA Amber $10.00 BE Blue
TF Transformer (50/60 Hz) $14.00 LB Blue $10.00 CR Clear
RL Resistor — LG Green $10.00 GN Green
LR Red $10.00 RD Red
II. Operator Function LW White $10.00 WE White
Code Description price INCANDESCENT
MI Momentary Out, Maintained $45.00 (Blank) Clear‡ — VIII. Contact Block Configuration
Center, Maintained In are not an option for RL480. Code Description price
AC Momentary Out, Maintained $45.00 F Clear Flashing Bulb* $ 4.00 (Blank) Operator without Contact Blocks —
Center, Momentary In *NOTE: Incandescent flashing
NC-DB 1 Normally Closed and $14.00
voltage or transformer application. 1 Delayed Break Contact Blocks
III. Voltage based on NO-NC 1 Normally Open and $14.00
Operator Type NEON†
1 Normally Closed Contact Blocks
NG Green —
Code Description
NR Red —
Full Voltage †NOTE: Only Available in FV120, RL240 IX. OPtionS
6 6V AC/DC †and RL480.
12 12V AC/DC NL No Lamp – $ 1.00
24 24V AC/DC *NOTE: When choosing the IP20 option, in order to
120 120V AC/DC V. Clamp Ring achieve IP20 protection a terminal guard must be
Transformer
Code Description price increasing the price $2.00 for each guard.
120 120V AC
(Blank) Black Polyester (Type 4X) —
240 240V AC
A Aluminum (Type 4) $ 2.00 S ee page 153 for L amp
277 277V AC
480 480V AC
R eplacement C hart and page
VI. Lens Type 154 for L amp T echnical D ata .
Resistor
120 120V AC/DC Code Description price S ee page 135 for C ircuit
240 240V AC/DC IMC Illuminated Push Button $12.00 D iagram C hart .
480 480V AC/DC (LED & Neon only) Mushroom Lens
The 3-Position Push-Pull device is available in two basic styles.

One version features the “out” position as momentary, the
“center” as maintained, and the “in” position as maintained.
The other version features the “center” position as maintained
while the “out” and “in” positions are momentary.
Discount
Schedule A
Some of Our Popular 3-Position Push-Pull Maintained Operators
Configurations: Momentary Out, Maintained Center, Momentary OUt, maintained Center,
Maintained In Momentary In
Type Catalog Number price Catalog Number price
See bottom o f pag e 134 for Transformer TFMI120-IMCRD-NC-DB $85.00 TFAC120-IMCRD-NC-DB $85.00
Lens Color options. Full Voltage FVMI120-IMCRD-NC-DB $71.00 FVAC120-IMCRD-NC-DB $71.00
Resistor RLMI120-IMCRD-NC-DB $71.00 RLAC120-IMCRD-NC-DB $71.00
Revision 04.14.10

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I EC N on- Fused
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tors
30industrial
Reset Push Button Cable Pull Operators
series
Our unique Reset Push Button
mounts in a standard
1-13/64” (30.5mm) hole
Our unique low-energy cable pull operators are available in four styles and are UL Listed for Type 1, 2, 3, 3R,
4/4X, 12 and 13 requirements. We also offer an optional polished aluminum clamp ring – add prefix
“A” to catalog code and increase the price $2.00. Our cable pull operators are reverse spring biased to hazardous
hold
30
and accepts either 20 hex contact blocks in the operated position until a force (varies by operator) is applied to the included eyebolt.
head bolts or 20 thread Contact operation is opposite of normal (i.e., CBNO is held closed and opens only when the eyebolt is
rod to provide adjustable pulled). Units are available with or without contact blocks and can be supplied in Type 4X surface mounting
extension and save on all rod enclosures as a custom order (not available for guaranteed same day shipping). See pages 289-298 for a
cutting and fitting labor. complete selection of our enclosures.
Universal styles include two bolts to cover 1” to 3”
(25.4mm to 76.2mm) space from cover to overload Momentary Cable Heavy-Duty Momentary Cable Pull
reset rod. It is rated Type 4/4X as standard. Pull Operator Operator
Constructed to Constructed of solid brass
Code Description price withstand corrosive to provide the most
RPB Reset Push Button $ 9.00 environments. It reliable operation.
RPB-B RPB w/Bolts $10.00 holds contact blocks It holds contact
(1/4-20 x 1-3/4” & 3”) in the operated blocks in the
position until a 4 - 6 operated position
RPB-W RPB w/Washers $10.00 pound force is applied to the included eyebolt.* until a 13 pound
RPB-BW RPB w/Bolt & Washer Set $11.00 force is applied to the included eyebolt.*
RPB BOLTS 2 Bolts (1/4-20 x 1-3/4” & 3”) $ 1.00
RPB WASHERS Washer Set $ 1.00 Code Description price Code Description price
Special bolt lengths available — please consult factory CPO Operator Only $44.00 HDCPO Operator Only $50.00
(not available for guaranteed same day shipping). CPO-NO With CBNO held closed $50.00 HDCPO-NO With CBNO held closed $56.00
CPO-NC With CBNC held open $50.00 HDCPO-NC With CBNC held open $56.00
Alternate Action Block Booted Momentary Cable Pull Push-Pull Maintained Cable Pull
Operator Operator
Our snap-on Alternate Action Block mounts in Provides protection in the most severe environments, Operating head is provided with a latch detent
position of a standard contact block to provide such as when sleet, freeze and thaw conditions are mechanism to hold the operator in the pulled or
alternate “push-on/push-off” contact action. prevalent. It holds contact blocks in the operated “out” position when operated. It holds contact
It may be used with any momentary position until a 4 - 6 pound force is applied to the blocks in the operated position until a 4 - 6 pound
push button or momentary included eyebolt.* force is applied to the included eyebolt. Requires a
illuminated push manual reset after actuation. Also available in solid
button operator. stainless steel as a custom order
NOTE: Action Block (not available for guaranteed
comes standard using an same day shipping)
Early-Make contact block. please consult the
factory.*

AABEM Alternate Action Block $18.00 Code Description price Code Description price
CPORB4 Operator only with $60.00 PPCPO Operator Only $50.00
Type 4X Boot PPCPO-NO With CBNO held closed $56.00
Wobble Stick Note: Not available with aluminum clamp ring. PPCPO-NC With CBNC held open $56.00
Designed primarily for use with pendant stations,

*Note: The c3controls Cable Pull Switch is a “pull operated” switch designed to be operated by pulling on a rope or cable. It is not
the wobble stick may be mounted in oil tight or
designed to the Machine Directives for Emergency Devices for Safeguarding Machinery. It does not offer direct drive, positive break/
watertight stations. The unit has spring return positive transfer contacts. It is a spring operated momentary device that operates “slow make/slow break” normally open and normally
action to center and may be operated from any closed contact blocks. Pulling the eyebolt collapses an internal spring, which allows contact blocks mounted on the rear of the operator
angle. It is rated Type 4/4X as standard. We also to open or close and actuate the intended circuit. Releasing the eyebolt allows the internal spring to return and depress the contact
offer an optional polished aluminum clamp ring – blocks to their original state. The device is designed to provide in excess of 1 million mechanical operations and is frequently applied
add prefix “A” to catalog code and increase in overhead door applications.
the price $2.00.
NOTE: Our Wobble Stick is
a linear device similar to a
Discoun t
Sche d ul e A
push button. It is not a
joystick or directional.
S nap - On I P 2 0 T E R M I N A L
G U A R D S protect against accidental contact
with live parts, see page 152. Available for use
Code Description price with the special operators featured on this page,
WS-NO/NC w/1 NO & 1 NC $32.00 excludes reset push button.
WS-NO-NO/NC-NC w/2 NO & 2 NC $44.00
137
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OS 2 | I E C N
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| oPot
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i ei s
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al perators
iec
series
I t ’ sse r iEe sasy t o B uild Y o ur Own P o tenti o meter
series
them
hazardous to nbuild
TB nema
Potentiometer Operators
POTO series
I II III IV
Example: To build one of our most popular
TB
Potentiometer Operators, the part number would be
POTO + II + III + IV or P OT O5 K -T BW
I. OPERATOR TYPE III. Resistance IV. Terminal Block

CODE DESCRIPTION price CODE DESCRIPTION price CODE DESCRIPTION price
POTO Potentiometer Operator $36.00 (Blank) Operator only — (Blank) Operator only —
1k 1k Potentiometer $14.00 TBW Terminal Block installed $10.00
2.5k 2.5k Potentiometer $14.00 and wired
II. Clamp Ring
5k 5k Potentiometer $14.00
CODE DESCRIPTION price Terminal block kit may be ordered
10k 10k Potentiometer $14.00
(Blank) Black Polyester (Type 4X) — Special order values available — please consult factory separately (part number TBK, price $6.00)
A Aluminum (Type 4) $ 2.00 (not available for guaranteed same day shipping).
1” or installed and wired at the factory to
2 1/8”
the potentiometer operator.
1 5/8”
D i sco u n t
Schedule A
1 2 3
1 9/16”
WIRING DIAGRAM
L e g end P lates f or P OT enti o meter
Operat o rs are available for same day shipping. Panel Thk. shown
4.8mm (3/16")
See pages 150-151 for complete selection.
2
1 3
2 is the common
Clockwise
knob rotation 1 2 is decreasing
as seen from resistance ( )
the front of
the panel 3 2 is increasing
resistance ( )

series
Pot ent i om
I ECetNer
on-
s Fused
| S p e c i|a lS eOrpi e sr aDS2
tors
30
industrial
30 m m P o t e n t i o m e t e r O p e r at o r s
series
Our single-turn Potentiometer Operators utilize standard 2 watt potentiometers with 1/4” (6.4mm)
bushing and 7/8” (22.5mm) long slotted shafts. A 5/64” allen wrench is required for installation.
All c3controls 30mm operators are UL Listed and are rated Type 4/4X as standard for watertight
30
hazardous
and corrosion resistance. In addition, operators are also listed for Type 1, 2, 3, 3R, 12 and 13, and
meet global standards requirements. CSA File # LR-4744609.
• Polyester construction for superior corrosion resistance,
moisture rejection and electrical insulation.
• Optional polyester or polished aluminum clamp rings.
• Standard 2 watt potentiometer.
• #6 terminal screws with self-lifting captive
wire clamps accommodate #22 through two
#12 AWG wires (0.5 - 4mm2) per terminal.
• Operators conveniently mount in a round
1-13/64” (30.5mm) hole that is directly
interchangeable with competitors units.
1. O
2. A
ll frictional parts are molded with an internal self-lubricant to provide
outstanding wear without troublesome greases used by others that attracts
dust and other particles in the area.
3. T hree point terminal block and hardware.
139
30 PS22L D1 6 13 DS EC TB GR PS
S 2 || I E C N o n- Fused
ielroi t
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industrial iec iec
series
I ste’r s
ies
E asy t o B uild Y o ur Own P il soe t Light
ries
them
hazardous to nbuild
TB nema
Pilot Lights NEW d

e
PLL E x p a ndc t s e r i e s
TB
Produ g!
I II III IV V VI VII Offerin
Example: To build one of our most popular Pilot Lights, the part
number would be I + II + III + IV + PLL + VI + VII or FV LU120LG-PLLGN
I. Basic Pilot Light Operator Iii. Lamp Type/color IV. Clamp Ring
Code Description price Code Color price Code Description price
FVLU Full Voltage $26.00 LED (Blank) Black Polyester (Type 4X) —
TFLU Transformer (50/60 Hz) $38.00 LA Amber $10.00 A Aluminum (Type 4) $ 2.00
RLU Resistor $32.00 LB Blue $10.00
RTLU Dual Input Remote Test $35.00 LG Green $10.00 V. Lens Type
LR Red $10.00
II. Voltage based on LW White $10.00
Operator Type PLL Pilot Light Lens $ 6.00
INCANDESCENT
Code Description (Blank) Clear‡ —
‡NOTE: Incandescent bulbs VI. Lens Color
Full Voltage are not an option for RLU480.
6 6V AC/DC Code DESCRIPTION
F Clear Flashing Bulb* $ 4.00
12 12V AC/DC *Note: Incandescent flashing AR Amber
bulbs available for any 6V full BE Blue
24 24V AC/DC
voltage or transformer application.
120 120V AC/DC CR Clear
NEON†
Transformer GN Green
NG Green —
120 120V AC RD Red
NR Red —
240 240V AC WE White
†NOTE: Only Available in FVLU120,
277 277V AC RLU240 and RLU480.
480 480V AC NL No Lamp – $ 1.00 VII. OPtionS
Resistor Code Description price
120 120V AC/DC IP20 IP20 Guard $ 2.00
240 240V AC/DC S ee page 153 for L amp
NOTE: IP20 terminal guards are not available for RTLU.
R eplacement C hart and page
154 for L amp T echnical D ata .
Dual Input Remote Test
6
12
6V AC/DC
12V AC/DC
Discount
Schedule A
24 24V AC/DC
120 120V AC/DC D ual I nput R em o te T est
240 240V AC/DC
TEST L1 1LS 1CR L2
Our unique Dual Input Remote light unit can
be used as a pilot light while also permitting the COMMON
testing of a number of lights from a single push NORMAL
button. A diode circuit isolates the test supply from 3CR PS
TEST COMMON
the normal supply. The schematic shown represents NORMAL

a typical dual input application. 2LS TEST SOL
COMMON
NORMAL
TEST
A va i l a b l e L e n s C o l o r s for Pilot Lights
Revision 04.14.10

series
I EC N on- Fused || P
Sielroite sL iDS2
ghts
30
industrial
30 m m P i l o t L i g h t s
series
30
Our 30mm Pilot Lights and Illuminated Push-To-Test Pilot Lights,
when utilized with our LED lamps provide leakage protection,
long-lasting life and high quality with tremendous hazardous
resistance to shock and vibration. Our reflection
technology and state-of-the-art Led lamps improve
visibility from all angles. c3controls LED lamps last
100,000 hours — that’s 11.4 years! Combine these
LEDs with our full voltage, transformer or resistor
packages for optimum durability. All c3controls 30mm
operators are UL Listed and are rated Type 4/4X as standard for
watertight and corrosion resistance. In addition, operators are also listed for
Type 1, 2, 3, 3R, 12 and 13, and meet global standards requirements.
• Full voltage lights incorporate a unique insulated socket design to minimize Exclusive!
accidental contact during lamp change.
Multi-Voltage Light!
• All lights use miniature bayonet base lamps to provide reliable lamp secureness. See page 143.
• Available with Incandescent, Neon, or our LED lamps with leakage protection.
• #6 terminal screws with self-lifting captive wire clamps accommodate
#22 through two #12 AWG wires (0.5 - 4mm2) per terminal.
• Operators conveniently mount in a round 1-13/64” (30.5mm) hole that is directly interchangeable
with competitors units and eliminates the labor required for notching.
1. C
ompact, thin design is also vibration resistant.
2. O
ur seal is infused with a coating to eliminate cracking when exposed to harsh
conditions such as heat, dryness and sunlight. This seal also acts as a light reflector
because it is white which increases light output and improves visibility from all angles.
3. O
ur rugged Lexan™ lenses provide better visibility and can resist high impact for
reliable performance in most environments, even in high temperature ambients.
4. W
e utilize premium 130V incandescent and LED lamps for improved,
long-lasting life.
Some of Our Popular Pilot Lights with Polyester Clamp Ring (Type 4X)
Configurations: Catalog Number

FVLU120LG-PLLGN
Description price
Full Voltage 120V Green LED w/Green Lens $42.00
FVLU120LR-PLLRD Full Voltage 120V Red LED w/Red Lens $42.00
FVLU120LA-PLLAR Full Voltage 120V Amber LED w/Amber Lens $42.00
141
30 PS22L D1 DS EC TB GR PS
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S 2 || IPu sh
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N-o
Tn-
o- Fused
Test
ielroi t
iec
es ights
iec
I t ’ s E asy t o B uild Y o ur Own P il o t Light

them
hazardous to nbuild
TB nema
Push-To-Test Pilot Lights* NEW d

e
E x p a ndc t
PTT Produ g! series
I II III IV V VI
Example: To build one of our most popular Pilot Lights, the part number
VII VIII Offerin
TB
would be I + PTT + III + IV + V + VI + VII + VIII or FV PTT120-IPB C R D
*Note: Our push-to-test pilot lights must be ordered as an assembled part.
I. Basic Push-to-Test Operator IV. Lamp Type/color VI. Lens Type

Code Description price Code Color price Code Description price
FV Full Voltage $26.00 LED IPBC Illuminated Push Button Lens $ 8.00
TF Transformer (50/60 Hz) $38.00 LA Amber $10.00 IPBCM Illuminated Push Button $12.00
RL Resistor $32.00 LB Blue $10.00 Mushroom Lens
LG Green $10.00 GIPBC Guarded Illuminated Push $12.00
II. Operator Type Button Lens*
LR Red $10.00
SIPBCM Shrouded Illuminated Push $16.00
Code Description price LW White $10.00
Button Mushroom Lens*
PTT Push-To-Test $21.00 INCANDESCENT *Note: Aluminum clamp rings are not an
(Blank) Clear‡ — *option for GIPBC or SIPBCM.
III. Voltage based on are not an option for RLPTT480.
Operator VII. Lens Color
F Clear Flashing Bulb* $ 4.00
Code Description *NOTE: Incandescent flashing Code DESCRIPTION
Full Voltage voltage or transformer application.
AR Amber
6 6V AC/DC NEON† BE Blue
12 12V AC/DC NG Green — CR Clear
24 24V AC/DC NR Red — GN Green
120 120V AC/DC †NOTE: Only Available in FVPTT120, RD Red
Transformer RLPTT240 and RLPTT480. WE White
120 120V AC NL No Lamp – $ 1.00 YW Yellow
240 240V AC
277 277V AC V. Clamp Ring VIII. OPtionS
480 480V AC Code Description price Code Description price
Resistor (Blank) Black Polyester (Type 4X) — IP20 (3) IP20 Guards* $ 6.00
120 120V AC/DC A Aluminum (Type 4) $ 2.00 *NOTE: Includes guards for light module and both
240 240V AC/DC contact blocks.
Push-To-Test Pilot Lights combine an S ee page 153 for L amp

illuminated push button with normally R eplacement C hart and
open and normally closed contact blocks
page 154 for L amp
factory wired for three-point wiring in
standard push-to-test circuits.
T echnical D ata . Discount
Schedule A
Some of Our Popular Configurations: Wirin g D ia g ram
Push-To-Test Pilot Lights w/Polyester Clamp Ring (Type 4X) Customer connections Test
Catalog Number Description price of line and test power
FVPTT120-IPBCAR Full Voltage 120V w/Incandescent Lamp & Amber Lens $55.00 supplies. Light unit is Line
FVPTT120-IPBCGN Full Voltage 120V w/Incandescent Lamp & Green Lens $55.00 powered by the line
circuit. Depressing the
FVPTT120-IPBCRD Full Voltage 120V w/Incandescent Lamp & Red Lens $55.00
lens cap will disconnect
the line and connect Common
S e e b o t t o m o f pag e 132 f o r P u s h -T o -T e s t the test supply, confirm-
X2 X1
Pilot Light Lens Options. ing bulb status. Push-To-Test
Light Operator
Revision 04.14.10

series
I EC
Mult
Nion-
- Volt
Fused
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Sielroite sL iDS2
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30
industrial
I t ’ s E asy t o B uild Y o ur Own P il o t Light
series
30
hazardous
20-240V Multi-Voltage Pilot Lights NEW d

e
E x p a ndc t
30MV20-240 LW PLL Produ g!
I II III IV V VI VII Offerin
Example: To build one of our most popular Pilot Lights, the part number would
be 30MV20-240 + II + LW + IV + PLL + VI + VII or 30M V 20-240D LW-PLLR D
I. Basic Operator IV. Clamp Ring VI. Lens Color

Code Description price Code Description price Code DESCRIPTION
30MV20-240 Multi-Voltage Pilot Light $60.00 (Blank) Black Polyester (Type 4X) — AR Amber
A Aluminum (Type 4) $ 2.00 BE Blue
II. LED Lamp Function CR Clear
V. Lens type GN Green
RD Red
D Standard — Code Description price
WE White
F Flashing $10.00 PLL Pilot Light Lens $ 6.00
c3controls LED lamps last 100,000 VII. OPtionS

III. Lamp Type/Color
hours — that’s 11.4 years! Code Description price
Code Description
LW LED White Discount
Schedule A
U ni q ue P r o duct Features Exclusive!

Eliminate the headache of matching specific
lamps with light units!
With our state-of-the-art, super-bright integral white LEDs and printed
circuit boards, this c3controls indicating light unit can be operated
at any voltage from 20V to 240V AC or DC without losing light
intensity. All you have to do is pick your lens color. An optional
flashing unit is also available. This compact design is also rated
Type 4/4X as standard. All of this is achieved with just one light unit,
reducing your inventory!

MULTI-VOLTAGE PILOT LIGHTS with POLYESTER clamp ring (TYPE 4X)
Catalog Number Description price
30MV20-240DLW-PLLAR Multi-Voltage 20-240V w/ White LED and Amber Lens $66.00
30MV20-240DLW-PLLGN Multi-Voltage 20-240V w/ White LED and Green Lens $66.00
30MV20-240DLW-PLLRD Multi-Voltage 20-240V w/ White LED and Red Lens $66.00
A va i l a b l e L e n s C o l o r s for M u lt i -V o lta g e P i l o t L i g h t s
143
30 PS22L D1 DS EC TB GR PS
industrial 6E C1
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I ts e’ rsi e sE asy t o B uild Y o ur Own P il o t Light
series
them
hazardous to nbuild
TBnema
Unibody Pilot Lights (Non-Relampable) NEW t

30UNR PNL P r o d u cg ! series
I II III IV V
Example: To build one of our most popular pilot lights, the part number
Offerin
TB
would be 30UNR + II + III + PNL + V or 30UNR-120LR-PNLRD
I. Operator TYPE III. LED COLOR IV. Lens Type

Code Description price Code Description Code Description
30UNR Unibody Light Unit, $18.00 LA Amber PNL Pilot Light Lens,
Non-Relampable LB Blue Non-Relampable
LG Green
II. FULL Voltage LR Red V. Lens Color
LW White
Code Description Code Description
24 24V AC/DC AR Amber
c3controls integral LED lamps last
120 110 ~ 130V AC/DC BE Blue
60,000 hours — that’s 6.8 years!
240 220 ~ 240V AC CR Clear
GN Green
RD Red
D i sco u n t
Schedule A S ee page 154 for L amp
T echnical D ata .

Unibody PILOT LIGHTS, Non-Relampable
Catalog Number Description price
30UNR-24LR-PNLRD 30mm Unibody Non-Relampable LED Pilot Light, $18.00
24V AC/DC, Red LED, Red Lens
30UNR-24LG-PNLGN 30mm Unibody Non-Relampable LED Pilot Light, $18.00
24V AC/DC, Green LED, Green Lens
30UNR-120LR-PNLRD 30mm Unibody Non-Relampable LED Pilot Light, $18.00
120V AC/DC, Red LED, Red Lens
30UNR-120LG-PNLGN 30mm Unibody Non-Relampable LED Pilot Light, $18.00
120V AC/DC, Green LED, Green Lens
30UNR-120LA-PNLAR 30mm Unibody Non-Relampable LED Pilot Light, $18.00
120V AC/DC, Amber LED, Amber Lens
A va i l a b l e L e n s C o l o r s for Unibody Pilot Lights
Revision 09.02.09

series
I EC N on-
U niFused
b ody || P
Sielroite sL iDS2
ghts
30
industrial
30 m m U n i b o d y N o n - R e l a m pa b l e
series
Pilot Lights
Our 30mm Unibody Pilot Lights were designed with simplicity in function to save you 30
hazardous
valuable time and money. This full voltage light features integral LED lamps that
provide great light output and leakage protection. Available in 24, 120 and 240 volts
and five lens color options. Wiring is made easy by utilizing rear access captive
mounting screws with side wire entry. All c3controls 30mm operators are UL Listed
and are rated Type 4/4X as standard for watertight and corrosion resistance. In
addition, operators are also listed for Type 1, 2, 3, 3R, 12, 13, IP65, and meet
global standards requirements.
• Vibration resistant compact design.
• Terminal screws with self-lifting captive wire clamps accommodate
#22 through two #14 AWG wires (0.5 – 2mm2) per terminal.
• Operators conveniently mount in a round 1-13/64” (30.5mm) hole that is
directly interchangeable with competitors units and eliminates the labor
required for notching.
1. High-tech integral LED lamps offer the latest and most

current technology providing leakage protection, great
light output and increased visibility from side views –
and lasts up to 60,000 hours!
2. Compact, low power consumption energy saving design.
3. DC devices are bi-polar design, functionality is independent
of which lead is connected to each terminal.
4. Rugged Lexan™ lenses provide better visibility and can resist high impact for reliable
performance in most environments – even in high temperature ambients.
5. Low behind the panel depth to allow mounting into shallow enclosures.
6. IP20 guarded terminals prevent accidental contact with live parts.
145
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I ts ’es E asy t o B uild Y o ur O w n S elect os r
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Selector Switches NEW d

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E x p a ndc t series
TB
Produ g!
I II III IV V* VI* VII Offerin
Example: To build one of our most popular Selector Switches, the part
number would be I + II + III + IV + V + VI + VII or S S O3-S H WE-NO/ NO
*Note: Contact block configurations are based on circuit designations (see charts below).
I. Basic Selector Switch IV. Handle Insert Color VI. Contact Block
Operator Function Configuration (Right Side)
Code DESCRIPTION
Code Pos./Function price BE Blue Code Description price
SSO2 2/Maintained $12.00 GN Green (Blank) Operator without Contact Blocks —
SROLR 2/Spring Return, L to R $21.00 GY Grey NO 1 Normally Open Contact Block $ 6.00
SRORL 2/Spring Return, R to L $21.00 RD Red NC 1 Normally Closed Contact Block $ 6.00
SSO3 3/Maintained $12.00 WE White EM 1 Early Make Contact Block $ 8.00
SROLC 3/Spring Return, L to C $21.00 YW Yellow DB 1 Delayed Break Contact Block $ 8.00
SRORC 3/Spring Return, R to C $21.00 NO-NO 2 Normally Open Contact Blocks $12.00
SROLRC 3/Spring Return, L & R to C $21.00 V. Contact Block NC-NC 2 Normally Closed Contact Blocks $12.00
SSO4 4/Maintained $12.00 Configuration (Left Side) NO-NC 1 Normally Open and 1 Normally $12.00
SRO43 4/Spring Return, Pos. 4 to 3 $21.00 Closed Contact Blocks
SRO1243 4/Spring Return, Pos. 1 to 2 $21.00
and Pos. 4 to 3 (Blank) Operator without Contact Blocks —
VII. OPtionS
NC 1 Normally Closed Contact Block $ 6.00 Code Description price/PC*
II. Clamp Ring IP20 IP20 Guard $ 2.00
Code Description price DB 1 Delayed Break Contact Block $ 8.00 *NOTE: When choosing the IP20 option, in order to
achieve IP20 protection a terminal guard must be
(Blank) Black Polyester (Type 4X) — NO-NO 2 Normally Open Contact Blocks $12.00 assembled on each contact block configuration,
A Aluminum (Type 4) $ 2.00 NC-NC 2 Normally Closed Contact Blocks $12.00 increasing the price $2.00 for each guard.
NO-NC 1 Normally Open and 1 Normally $12.00

III. Handle Type Closed Contact Blocks

SH Standard $ 5.00
SL Lever $ 5.00
Each operating handle is black with a

factory assembled color insert.
Discount
Schedule A
Contact Block Selection for 2-Position Selector Switches
Circuit Handle Position Block Catalog Mounting
desig. Left Right Number Position O = Open X = Closed
A O X CBNO EITHER
B X O CBNC EITHER Contact Block Selection for 4-Position Selector Switches
Circuit Handle Position Block Mounting
Contact Block Selection for 3-Position Selector Switches desig. Left Lt. cnt. Rt. cnt. Right Cat. # Position
Circuit Handle Position Block Catalog Mounting I X O O O CBNO LEFT
desig. Left Center Right Number Position J O X O O CBNC RIGHT
C X O O CBNO LEFT K O O X O CBNC LEFT
D O X O CBNC EITHER L O O O X CBNO RIGHT
E O O X CBNO RIGHT M O X X X CBDB LEFT
F O X X CBDB LEFT N X O X X CBEM RIGHT
G X O X CBEM EITHER O X X O X CBEM LEFT
H X X O CBDB RIGHT P X X X O CBDB RIGHT

series
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S e l e c|t oSre rSi ewsi tDS2
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30
industrial
30 m m S e l e c t o r S w i t c h e s
With our unique universal cam design, c3controls Selector Switches offer multiple
series
30
functions in a single device eliminating the need to install separate devices to
perform individual functions based on contact block configuration. All operators
feature polyester housings, are UL Listed, and are rated Type 4/4X as standard for
hazardous
watertight and corrosion resistance. In addition, operators are also listed for
Type 1, 2, 3, 3R, 12 and 13, and meet global standards requirements. Add-on
contact blocks are available for up to 8 circuits per operator. See pages 124-125
for our complete line of 30mm standard contact blocks.
Handle Positions
2-Position 3-Position 4-Position
Save time & money - with c3controls, one cam does it all!
1. O
ne-Cam does it all vs. our competitors who need up to fifteen cams to perform the same function. This One-Cam design eliminates
the need for multiple cam configurations and selector switch configuration nightmares, saving time, inventory, money, and ensuring
100% cam selection configuration accuracy.
2. O
ur revolutionary U-Cup seal is infused with a Teflon coating to eliminate cracking when exposed to harsh
conditions such as heat, dryness and sunlight.
3. A
ll frictional parts are molded with an internal self-lubricant to provide outstanding wear
and smooth cam operations without troublesome greases used by others that attracts dust
and other particles in the area.

2-Position selector switch operators with polyester clamp ring (Type 4X)
Contact Contact Block Handle Position Type of Maintained Spring Return from Spring Return from
Symbol Mounting Pos. O=Open X=Closed Operator Position Right to Left left to right
Viewed from front of operator Left Right Catalog # price Catalog # price Catalog # price
1 NO Either O X STANDARD SSO2-SHWE-NO $23 SRORL-SHWE-NO $32 SROLR-SHWE-NO $32
LEVER SSO2-SLWE-NO $23 SRORL-SLWE-NO $32 SROLR-SLWE-NO $32
1 NC EITHER X O STANDARD SSO2-SHWE-NC $23 SRORL-SHWE-NC $32 SROLR-SHWE-NC $32

LEVER SSO2-SLWE-NC $23 SRORL-SLWE-NC $32 SROLR-SLWE-NC $32
3-Position selector switch operators with polyester clamp ring (Type 4X)
Contact Contact Block Handle Position Type of Maintained Spring Return from Spring Return from Spring Return From
Symbol Mounting Pos. O=Open X=Closed Operator Position LEFT TO CENTER RIGHT TO CENTER Left or Right to center
Viewed from front of
operator Left Center Right Catalog # price Catalog # price Catalog # price Catalog # price
NO/NO LEFT X O O STANDARD SSO3-SHWE-NO/NO $29 SROLC-SHWE-NO/NO $38 SRORC-SHWE-NO/NO $38 srolrc-shWE-NO/NO $38
RIGHT O O X LEVER SSO3-SLWE-NO/NO $29 SROLC-SLWE-NO/NO $38 SRORC-SLWE-NO/NO $38 srolrc-sLWE-NO/NO $38
Mix and M at c h A n y I n s e r t C o l o r and Selector Switch Handle
Standard Handle EVERYTHING

Standard HandleStandard Handle UNDER
Lever Handle CONTROL
Lever Handle Lever Handle
147
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I t ’ s s eEr iasy
es
t o B uild Y o ur Own S elect o r S w itc h
series
30 22 Simply pick the code number from each of the sections below and combine them to build your
part
hazardous number.
n e m See
a page 6 for more detailed directions. nema
TB
Keyed Selector Switches NEW d
e
E x p a ndc t series
TB
Produ g!
I II III IV* V* VI Offerin
Example: To build one of our most popular Keyed Selector Switches,
the part number would be I + II + III + IV + V + VI or K OS S 2K A -NO
*Note: Contact block configurations are based on circuit designations (see page 146 for circuit designation charts).
I. Clamp Ring III. Key removal Position V. Contact Block

Configuration (Right Side)
Code Description price Code Removal Position
(Blank) Black Polyester (Type 4X) — KA All Code Description price
A Aluminum (Type 4) $ 2.00 KR Right Only (Blank) Operator without Contact Blocks —
KL Left Only NO 1 Normally Open Contact Block $ 6.00
II. Keyed Selector Switch KC Center Only NC 1 Normally Closed Contact Block $ 6.00
Operator Function KLR Left & Right Only EM 1 Early Make Contact Block $ 8.00
Code Pos./Function Avail. Key price KLC Left & Center Only DB 1 Delayed Break Contact Block $ 8.00
removal KRC Right & Center Only NO-NO 2 Normally Open Contact Blocks $12.00
position(s) NC-NC 2 Normally Closed Contact Blocks $12.00
KOSS2 2/Maintained KA,KR,KL $52.00 IV. Contact Block NO-NC 1 Normally Open and 1 Normally $12.00
KOSRRL 2/Spring Return, R to L KL $60.00 Configuration (Left Side) Closed Contact Blocks
KOSRLR 2/Spring Return, L to R KR $60.00 Code Description price
KOSS3 3/Maintained KA,KR,KL,KC, $52.00 VI. OPTIONS
(Blank) Operator without Contact Blocks —
KLR,KLC,KRC
NO 1 Normally Open Contact Block $ 6.00 Code Description price/PC*
KOSRLC 3/Spring Return, L to C KC,KR,KRC $60.00
NC 1 Normally Closed Contact Block $ 6.00 IP20 IP20 Guard $ 2.00
KOSRRC 3/Spring Return, R to C KC,KL,KLC $60.00 *NOTE: When choosing the IP20 option, in order to
KOSRLRC 3/Spring Return, L & R to C KC $60.00 achieve IP20 protection a terminal guard must be
DB 1 Delayed Break Contact Block $ 8.00 assembled on each contact block configuration,
KOSS4 4/Maintained* KA $52.00
*NOTE: Please consult factory for special key removal
NO-NO 2 Normally Open Contact Blocks $12.00 increasing the price $2.00 for each guard.
positions (not available for guaranteed same day shipping). NC-NC 2 Normally Closed Contact Blocks $12.00
A
NO-NC 1 Normally Open and 1 Normally $12.00 Discoun t
Closed Contact Blocks Schedule
Keyed Switch Options

Alternate Key Combinations: Up to 9 different key combinations (CC series) are available. To order locks keyed differently,
please consult factory or specify on order and increase the price $28.00 per operator.
Master Keys: A master key is available that works in all 9 CC series key combinations. To order, specify part number MK1250
($20.00 per set of two master keys).
Extra or Replacement Keys: Available for standard keyed selector switches only. To order, specify part number ES201 ($4.00 per set of two keys).
NOTE: Two keys come standard with each operator.
Key Positions
2-Position 3-Position 4-Position

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S e l e c|t oSre rSi ewsi tDS2
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30industrial
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30 m m K e y e d S e l e c t o r S w i t c h e s
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30 2
30
c3controls Keyed Selector Switches offer multiple functions in a single device eliminating the
need to install separate devices with individual functions based on contact block configuration.
All operators feature polyester housings and all locks are premium quality brass for superior hazardous
hazardous
corrosion resistance. Keys are made of extra heavy brass for long life. Our Keyed Selector
Switches are UL Listed and are rated Type 4/4X as standard. In addition, operators are also
listed for Type 1, 2, 3, 3R, 12 and 13, and meet global standards requirements. We also
offer you the opportunity to choose the appropriate clamp ring for your specific work
environment; polyester clamp rings, which are designed to provide you with a modern
appearance, or polished aluminum clamp rings for those who prefer a shiny rugged
metal appearance. Add-on contact blocks are available for up to 8 contacts per
operator. See pages 124-125 for our complete line of 30mm standard contact blocks.
Save time & money - with c3controls,

one cam does it all!
1. O
ne-Cam does it all vs. our competitors who need up to fifteen cams to perform
the same function. This One-Cam design eliminates the need for multiple
cam configurations and selector switch configuration nightmares, saving time,
inventory, money, and ensuring 100% cam selection configuration accuracy.
2. O
3. A
ll frictional parts are molded with an internal self-lubricant to provide outstanding wear and smooth cam
operations without troublesome greases used by others that attract dust and other particles in the area.

2-Position Keyed selector switch Operators with polyester clamp ring (Type 4X)
Contact Contact Block Handle Position Type of Maintained Spring Return from Spring Return from
Symbol Mounting Pos. O=Open X=Closed Operator Position Right to Left left to right
Viewed from front of operator Left Right Catalog # price Catalog # price Catalog # price
1 NO Either O X Key Removal Pos
L KOSS2KL-NO $58 KOSRRLKL-NO $66 — —
R KOSS2KR-NO $58 — — KOSRLRKR-NO $66
L & R KOSS2KA-NO $58 — — — —
1 NC EITHER X O Key Removal Pos
L KOSS2KL-NC $58 KOSRRLKL-NC $66 — —
R KOSS2KR-NC $58 — — KOSRLRKR-NC $66
L & R KOSS2KA-NC $58 — — — —
3-Position Keyed selector switch Operators with polyester clamp ring (Type 4X)
Contact Contact Block Handle Position Type of Maintained Spring Return from Spring Return from Spring Return from
Symbol Mounting Pos. O=Open X=Closed Operator Position LEFT TO CENTER RIGHT TO CENTER Left or Right to center
Viewed from
front of operator Left Center Right Catalog # price Catalog # price Catalog # price Catalog # price
NO/NO LEFT X O O Key Rem Pos
RIGHT O O X L koss3kl-no/no $64 — — kosrrckl-no/no $72 — —
R koss3kr-no/no $64 kosrlckr-no/no $72 — — — —
C koss3kc-no/no $64 kosrlckc-no/no $72 kosrrckc-no/no $72 kosrlrckc-no/no $72
Key Rem Pos
L & R koss3klr-no/no $64 — — — — — —
L & C koss3klc-no/no $64 — — kosrrcklc-no/no $72 — —

R & C koss3krc-no/no $64 kosrlckrc-no/no $72 — — — —
149
30 LS22 DP1 3 DS EC TB GR PS
industrial 6| C1
S2 | IE N o n- Fused
eeg
rei end
iec
s lates
iec
I t ’ s E asy t o B uild Y o ur Own L e g end P late

30 22 TB
Simply pick the code number from each of the sections below and combine them to build your
part number. See page 6 for more detailed directions.
hazardous nema nema
Legend plates feature 2 lines of text with approximately 16 characters per line. Upper case
Legend Plates is standard unless specified.
*The tall legend plate (LPT) features 3 lines of text with approximately 16 characters per
I II III series
TB
line and the Potentiometer legend plate comes standard with a scale and one or two lines
of text, see chart D below.
I. STANDARD LEGEND PLATE TYPE II. FACE AND LETTER COLOR

CODE DESCRIPTION price CODE Face Color Letter Color
LP Standard 2”h x 2”w $2.00 AL Aluminum Black
LPN Narrow 2”h x 1-3/4”w $2.00 (Blank) Black White
LPS Short 1-3/4”h x 2”w $2.00 BE Blue White
LPT *Tall 2-1/4”h x 2”w $2.50 GN Green White
LPR Standard Round 2-25/64” Dia. $3.50 RD Red White
LPRM Medium Round 2-3/4” Dia. $4.00 WE White Black
LPRJ Jumbo Round 3-3/4” Dia. $4.50 YW Yellow Black
III. LEGEND DESIGNATION

A. Push Buttons and Lights B. 2-Position Selector C. 3-Position Selector
CODE DESCRIPTION CODE LEGEND LEFT LEGEND RIGHT CODE LEGEND LEFT LEGEND CENTER LEGEND RIGHT
00 (Blank) 00 (Blank) (Blank) 00 (Blank) (Blank) (Blank)
01 AUTO
50 AUTO HAND 92 AUTO OFF HAND
02 CLOSE
68 AUTO MANUAL 93 AUTO MAN OFF
31 CYCLE START
100 CYCLE STOP 51 DOWN UP 80 DOWN OFF UP
03 DOWN 63 FAST SLOW 81 FWD AUTO REV
102 EMERGENCY 52 FWD REV 82 FWD OFF REV
04 EMERGENCY STOP 83 HAND OFF AUTO
53 HAND AUTO
06 FAST 94 HIGH OFF LOW
101 FAULT 73 HIGH LOW
99 JOG OFF AUTO
07 FORWARD 54 INCH RUN
90 LOCAL OFF REMOTE
08 HAND 75 LEFT RIGHT
32 HIGH 84 MANUAL OFF AUTO
70 LOCAL REMOTE
33 IN 89 OFF RUN START
55 MANUAL AUTO
09 INCH 85 OFF START RUN
56 OFF ON
10 JOG 86 OFF 1 2
38 JOG FORWARD 57 ON OFF 95 OPEN OFF CLOSE
39 JOG REVERSE 58 OPEN CLOSE 91 RAISE OFF LOWER
34 LOW 65 PULL START PUSH STOP 96 SLOW OFF FAST
35 LOWER 66 PUSH OFF PULL ON 97 SUMMER OFF WINTER
11 MANUAL
64 PUSH ON PUSH OFF 98 UP OFF DOWN
26 MOTOR RUN
12 OFF 67 PUSH TO STOP PULL TO START 87 1 OFF 2
13 ON 71 RAISE LOWER 88 1 2 3
14 OPEN 59 REV FWD
36 OUT 60 RUN JOG D. Potentiometer
27 OVERLOAD 69 SLOW FAST CODE DESCRIPTION
15 POWER OFF
61 START STOP 40 Blank Legend 0 - 10
16 POWER ON
30 PUSH TO RESET 62 STOP START 41 “SPEED” 0 - 10
17 PUSH TO TEST 74 SUMMER WINTER 43 Blank Legend 0 - 100
37 RAISE 72 UP DOWN 44 “SPEED” 0 - 100
18 RESET
19 REVERSE
N ot finding what you need in
a standard plate ?
Popular Configurations:
20 RUN We offer Special and Custom Engraving up to
21 SLOW Legend Plates
12” x 24” (304.8mm x 609.6mm). Please
22 START consult factory or see page 151 for details. Catalog NO. Designation price
23 STOP While our standard legend plates are available LPRYW-04 EMERGENCY STOP $3.50
24 TEST for same day shipping, our special and custom
29 TRIP legend plates are not. LPT-83 HAND OFF AUTO $2.50
25 UP D isco u nt
Sch e du le A LP-41 SPEED 0 - 10 $2.00

series
I EC N on- Fused
| L|e gSeend
rieP
s lDS2
ates
30 industrial
F e at u r e B e n e f i t s
series
All Legend Plates are a 2-ply laminated plastic, laser engraved for a permanent and quality appearance and feature 2 lines of text with
approximately 16 characters per line. Upper case is standard unless specified. The Potentiometer legend plate comes standard with a scale
and one or two lines of text.
30 hazardous
I t ’ s E asy t o B uild Y o ur Own L e g end P late

Special Legend Plates
I II III
I. STANDARD LEGEND PLATE TYPE II. FACE AND LETTER COLOR
Upon receipt of your
CODE DESCRIPTION price CODE Face Color Letter Color
order, legend plates will be
LP Standard 2”h x 2”w $2.00 AL Aluminum Black set up as specified and a
LPN Narrow 2”h x 1-3/4”w $2.00 (Blank) Black White proof will be sent to you prior
LPS Short 1-3/4”h x 2”w $2.00 BE Blue White to production to ensure accuracy.
LPT *Tall 2-1/4”h x 2”w $2.50 GN Green White
While our standard legend plates are
LPR Standard Round 2-25/64” Dia. $3.50 RD Red White available for same day shipping, our special
LPRM Medium Round 2-3/4” Dia. $4.00 WE White Black and custom legend plates are not.
LPRJ Jumbo Round 3-3/4” Dia. $4.50 YW Yellow Black
To order, submit your drawing to:
*The tall legend plate (LPT) features 3 lines of text with 16
characters per line.
III. LEGEND DESIgnation Mail: c3controls
Attn: Customer Care
CODE DESCRIPTION price
P.O. Box 496
SP Special Legend $7.00
Beaver, PA 15009
D i sco u n t
Schedule A Note: $3.00 each when ordering 3 or more of the
same exact legend plate. Fax: 724.775.5283
Email: legendplates@c3controls.com
To help simplify your order process, templates are available by calling our
factory at 724.775.7926 o r r e f e r e nc e o n e o f t h e d r a w i n g s o n p a g e 160.
CUSTOM LEGEND P L ATES

• Available in 2-ply 12” x 24” (304.8mm x 609.6mm) sheets
of laminated plastic for custom laser engraving.
To order, submit your drawing to:
• Add your Corporate Logo! Send us your corporate logo
electronically to promote your company image in a clean Mail: c3controls
professional legend plate. Attn: Customer Care
P.O. Box 496
• Initial Set-Up Fee Per Legend Plate: Beaver, PA 15009
$25/hour (minimum fee $25.00). Fax: 724.775.5283
• $1.00/Square Inch (minimum $9.00). Email: legendplates@c3controls.com
• Design services available. Consult factory for details and
hourly rate.
(Sample custom plate)
• While our standard legend plates are available for same day
shipping, our special and custom legend plates are not.
151
30 AS22 D1 6 13 DS EC TB GR PS
S 2 | I E C N o n- Fused
cc
e r ieesss o r i e s
industrial iec iec
Extended Clamp Rings Lock off attachments Push Maintained Flush

and extended Caps
series series c3controls offers a wide variety of 30mm corrosive series
30 22 TB
AECR resistant lock-off attachments for maintained and Use with a secondary
momentary push buttons and selector switches. standard cap and
hazardous nema Our LOAX, LOAM and LOAP lock-offs permit nema mechanical
locking operators in the interlock to
depressed position. Our provide two
LOAFC lock-off covers and button momentary/
ECR locks the operator so its s e r i e s maintained operation
TB
LECR EECR
position cannot be changed or use on adjacent operators with
We offer four types of 30mm extended clamp rings and features a 1/4” (6.4mm) mechanical interlock to provide two-button
that guard against accidental operation. Use our diameter padlocking hasp. maintained/maintained operation. Comes with our
Extended Clamp Rings (ECR or AECR) with flush standard polyester clamp ring. An optional polished
caps, our Clear Guarded Clamp Ring (EECR) with aluminum clamp ring is also available, add prefix
illuminated push buttons and our Large Extended LOAFC “A” to catalog code and increase the price $2.00.
Clamp Ring (LECR) with flush or extended caps, Color Flush Extended price
which also provides easier access to your push Code Code
buttons. LOAX/LOAM/LOAP Black PMFCBK PMXCBK $22.00
FOR USE WITH non-illuminaTED CAPS Green PMFCGN PMXCGN $22.00
Code Fits price
Code Description price Red PMFCRD PMXCRD $22.00
LOAX Standard Extended Cap $16.00
ECR Extended Ring $ 3.00 Yellow PMFCYW PMXCYW $22.00
LOAM Standard Momentary $16.00
LECR Large Extended Ring $ 5.00 Mushroom Cap
AECR Aluminum Extended Ring $ 5.00 LOAP Push-Pull Maintained $16.00 Mechanical Interlock
FOR USE WITH illuminaTED LENS Mushroom Cap (PPMC) or
Push Maintained Extended Our Mechanical Interlock features
Code Description price Cap (PMXC) a 2” (50.8mm) center and can be
EECR Guarded Clear Polyester Ring $ 4.00 LOAFC Most Push Buttons and $25.00 used to interlock two adjacent
Selector Switches operators. This may also be
used to interlock a two-unit
Panel Gaskets maintained/momentary
assembly. NOTE: Factory
Our panel gaskets guard attachment installation recommended.
are constructed
of Neoprene for Our PPGD guards against
long life and low accidental operation and is Code Description price
compression set and made of a high strength MI 30mm Mechanical Interlock $12.00
provide a watertight polyester material.
seal. Panel gaskets are
supplied to accommodate IP20 Terminal guards
different panel thickness. In order to meet
Type 4/4X requirements, at least one 1/16” (1.6mm)
Code Fits price NEW t
gasket must be used. Note: All c3controls 30mm PPGD Maintained Push Buttons $20.00 P r o d u cg !
operators are provided with gaskets. Offerin

PG2 1/16” (1.6mm) Gasket $ 0.50 Hole Plug
PG6 3/16” (4.8mm) Gasket $ 0.50 Use to seal unused panel holes.
Our hole plug comes with
additional sealing panel gaskets Our IP20 terminal guards protect against accidental
THrust & Trim Washers to ease installation and is rated contact with live parts and can be ordered separately
Type 4X. as an accessory or factory installed providing the
Anti-rotation device convenience of a single catalog number. NOTE: IP20
for use with 30mm terminal guards must be installed before wiring. For
push buttons, Code Description price factory installed guards, refer to the operator page to
selector switches determine the appropriate part number. For terminal
HP 30mm Grey Hole Plug $ 4.00
and pilot lights to marking convenience, our guards can be utilized with
provide additional Series WTB2 markers (see page 332).
protection from
Code Fits price
rotation and aid in Clamp ring wrench
alignment. This product is optional with c3controls CBIP20 Standard Contact Blocks $ 2.00
gasket technology. To simplify tightening and FVIP20 Full Voltage Illuminated $ 2.00
loosening of standard Push Button Operators, Pilot
Code Description price polyester and aluminum Lights, Push-To-Test Light
TTW 30mm Anti-Rotation Washers $ 1.00 1-3/8” (34.9mm) octagonal Modules and Multi-Voltage
clamp rings. Won’t scratch Pilot Lights
your lens or panel. MLIP20 Resistor & Transformer $ 2.00
Momentary Illuminated
Code Description price Push Button Operators and
D isco u nt
Sch e du le A CRW 30mm Clamp Ring Wrench $10.00 Pilot Lights
Revision 07.29.10

series
I EC N on- Fused | A
S cc
erei esss oDS2
ries
30
industrial
LED, Incandescent & Neon Replacement lamps Lamp Removal Tool
series
c3controls offers a full range of lamp options in a miniature bayonet base for direct interchangeability which
provides flexibility in choosing the best lamp for each installation application. Multiple voltage options in
Incandescent, LED and Neon lamps are available. Please refer to the chart at the bottom of the page to determine
30
Used to facilitate the removal
of lamps particularly in
illuminated push buttons hazardous
the appropriate replacement lamp based on your operator voltage. For lamp technical data, see page 154. and push-to-test operators.
LED Lamps Di scoun t

Sc he d ul e C
LED
I II III
To order LED Lamps, the part Code Description price
number would be LED + II + III LRT Lamp Removal Tool $ 4.00
I. Lamp Type II. Voltage III. Lamp Color

Code Description price Code Description Code DESCRIPTION
LED LED Lamp $14.00 6 6V AR Amber
12 12V BE Blue
Our LED lamps feature built-in 24 24V GN Green
leakage protection. 130 130V RD Red
WE White
Incandescent Lamps Neon Lamps
Discount
Schedule A
Code Voltage price Code Voltage Color price
NOTE: Discount Schedule A
FVB6 6V $ 2.00 FVB120NG 120V Green $ 2.00 does not apply to Lamp
FVB12 12V $ 2.00 FVB120NR 120V Red $ 2.00 Removal Tool.
FVB24 24V $ 2.00
FVB55 55V $ 4.00
FVB120 120V $ 4.00
FVB6F *6V Flashing $ 6.00
*NOTE: There may be a 5-15 second
delay before flashing begins.
30mm Replacement Lamp Reference Chart (for reference only - Use charts above to order)
Operator Code Operator Voltage LED (all colors) Incandescent Neon

FVLU6 Full Voltage 6V AC/DC LED6 FVB6 or FVB6F —
FVLU12 Full Voltage 12V AC/DC LED12 FVB12 —
FVLU24 Full Voltage 24V AC/DC LED24 FVB24 —
FVLU120 Full Voltage 120V AC/DC LED130 FVB120 FVB120NG or FVB120NR
TFLU120 Transformer 120V AC LED6 FVB6 or FVB6F —
RLU120L Resistor 120V AC/DC* LED24 — —
RLU120I Resistor 120V AC/DC* — FVB55 —
RLU240L Resistor 240V AC/DC* LED24 — —
RLU240I Resistor 240V AC/DC* — FVB120 —
RLU240N Resistor 240V AC/DC* — — FVB120NG or FVB120NR
RLU480N Resistor 480V AC/DC* — — FVB120NG or FVB120NR
RTLU6 Dual Input 6V AC/DC LED6 FVB6 —
*NOTE: Lamps are unique to Resistor Light Units. Refer to side of light unit for correct replacement lamp part number.
153
30 S22 D1 6 13 DS EC TB GR PS
S 2 | I|E C N o n- Fused
p
erec
i ei s
fications
industrial iec iec
30mm Industrial Pilot Devices

30 22 TB
ELECTRICAL RATINGS
Industry Current Draw Lamp Shock & Leakage
Lamp
hazardous n e m aNumber Rated Volts Lumens (MSCD) Design Life (Hrs.) (mA) Type n eVibration
ma Protection
FVB6 1866 6.3V 0.65 5,000 250 Incandescent Very Good N/A
FVB12 756 14V 0.31 15,000 80 Incandescent Good N/A
series
TB
FVB120 ** 130V 0.36 10,000 20 Incandescent Good N/A
LED6 ** 6V 100,000 50 LED Excellent 14 mA
Varies w/ Color
LED12 ** 12V Varies w/ Color 100,000 <20 LED Excellent 4 mA
2000 mcd
LED24 ** 24V 2000 mcd
Typical 100,000 <20 LED Excellent 4 mA
LED130 ** 120/130V 100,000 <10 LED Excellent 2 mA
FVB120NG — 95-135V Typical (Glows) 25,000 <5 Neon/Green Very Good N/A
FVB120NR — 95-135V Typical (Glows) 25,000 <5 Neon/Red Very Good N/A
30UNR-24L ** 24V AC/DC Varies w/ Color 60,000 <18 LED* Excellent <3 mA
30UNR-120L ** 110-130V AC/DC 2000 mcd 60,000 <18 LED* Excellent <3 mA
30UNR-240L ** 220-240V AC Typical 60,000 <18 LED* Excellent <3 mA
*Specify lamp color when ordering.
**Designates a lamp design optimized for c3controls Illuminated devices. See LED replacement lamps on page 153.
Dielectric Strength (Terminal to Ground) 2200V for 1 Minute
Standard Contacts Utilization Category
IEC UL Make Rating Break Rating Ith-Thermal Current
AC AC-15 A600 7200VA 720VA 10A
DC DC-13 P300 138VA 138VA 5A
Note: For AC voltage below 72V AC the max. allowed switching current is 10A = Ith. For DC voltages below 28V DC the max. allowed switching current is 5A =Ith.
For switching applications below 24V/40mA - Hermetic REED contacts are recommended. Hermetic Reeds are also excellent in environments containing
chemical vapors, oxidizing agents, and explosive gases. Please refer to the HAZARDOUS section of the Series 30 devices for more information. Available
on c3controls’ 30MM products only.
Environmental Ratings Operating Forces Materials

TYPE 1, 2, 3, 3R, 4/4X, 12, 13, and IP65 Pushbuttons (Operator Only) Thermoplastic Polyester and Polyester
Operating Temperature Momentary 1.3 lbs. [5.8 N] Blends (UV Stabilized for outdoor use)
-40 to +131° F ( -40 to +55° C ) Illuminated Momentary 2.8 lbs. [12.4 N] Operator Housings
Storage Temperature Maintained 4 to 6 lbs. [17.9~26.7 N] Operator Caps and Handles -
-40 to +185° F ( -40 to +85° C ) Non-Illuminated (Glass Reinforced Grades)
Illuminated Maintained 4.6 lbs. [20.5 N]
Mounting Rings and Nuts
Operating environments below freezing Reset Push Button 1.5 lbs. [6.7 N]
temperatures are assumed to be absent of Thrust Washer
Selector Switches Trim Washer
freezing liquids or pollutants.
Maintained 1.7 in-lbs [.19 Nm] High Impact Polycarbonate
Momentary 1.7 in-lbs [.19 Nm] (UV Stabilized for outdoor use)
Key Operated 1.7 in-lbs [.19 Nm] Pilot Light Lens
Terminal & Wiring Consideration
Cable Pull Transparent PB and Mushroom Caps
Wire- AWG 22-12 CU Custom Polymers
Standard 4 to 6 lbs. [17.9~26.7 N]
(Copper Only – Solid & Stranded) [.5 ~ 4 mm2 ]
Heavy Duty 13 lbs. [57.8 N] Certain CAM and Bearing parts are
One or Two wires permitted per termination Teflon, Silicone, & Moly-Disulfide
Recommended Tightening Torque Push-Twist Release 4.7 lbs. [20.9 N] Impregnated for improved wearability
7 lb-in (+3.0/-0.0 lb-in) — [ .8 Nm ] Potentiometer Fluorosilicone and Thermoplastic
2 Watt ”J” Series 3-12 in-oz. [.11 Nm Max.] Neoprene Boot Accessories
( 300° Rotation ) Seals
Standard Contact Blocks 1 lb. [4.45 N] Neoprene Gaskets
Mechanical Design Life Cycles
Indicating Lights Refer to the appropriate Thermoplastic – Molded Neoprene
Push Buttons Lamp Data and alloy derivitives
Momentary 5,000,000 Multi-Voltage Light 20-240 VAC/VDC BUNA N – Rubber – Teflon Coated
Maintained 250,000 (Burden .65W max.) Thermoplastic – Elastomer Molded Seals
Selector Switches 500,000 Transformer 2 VA Fluorosilicone – Boots
All Other Devices 250,000 Metal: Brass & Stainless Steel
Standard Contact Blocks 10,000,000 Push Pull Bushings
Indicating Lights – Refer to the appropriate Lamp Data Internal tubes for Maintained Devices
Detents for Maintained Devices
Springs (Stainless Steel throughout)
Aluminum
Optional Mounting Nut
RoHS Compliance
For RoHS compliance documentation by
product, refer to www.c3controls.com

series
I EC N on- Fused || SDeirmi e sn sDS2

ions
30
industrial
Momentary & Maintained Non-Illuminated Push Buttons
series
Fully-assembled operators come standard with one 3/16” (4.8mm) and three 1/16” (1.6mm) gaskets.
7/8"
N on -I lluminated O perator (22.5mm)
See mounting gasket specifications chart #3 on page 160.
M omentary F lush C ap M omentary G uarded F lush C ap
30
hazardous
( shown with F lush C ap ) blocks

1-1/2"
Add'l
7/16" 1-9/16" 11/16”
1-9/16”
7/16" (39.7mm) (17.5mm)
(38.1mm)
7/8" (11.1mm) (39.7mm)
(11.1mm)
(22.5mm)
Add'l 1-9/16"
1-1/2" blocks 7/16" 1-11/16"
7/16" (11.1mm) (39.7mm)
(11.1mm) (38.1mm) (42.9mm)
1-11/16”
(42.9mm)
1-11/16"
Panel Thk. shown (42.9mm)
3/16" (4.8mm)
Panel Thk. shown

3/16" (4.8mm) M omentary E xtended C ap M omentary G uarded
23/32" E xtended C ap
(18.3mm) 1-9/16" 11/16” 1-9/16”
(39.7mm)
(17.5mm)
(39.7mm)
1-11/16"
(42.9mm)
1-11/16”
(42.9mm)
M omentary S tandard M omentary 2-1/4” (57.2 mm )

R ubber B oot M omentary 1-1/2” (38 mm ) J umbo M ushroom C ap
1-3/16" M ushroom C ap
(20.6mm) 1-9/16" 1-3/8" 1-9/16"
(39.7mm) 1-9/16" (34.9mm) (39.7mm)
1-3/8" (39.7mm)
(34.9mm)
1-1/2" 1-5/8" 1-5/8"

(38.1mm) (41.3mm) 1-11/16" 2-1/4"
1-9/16" (57.2mm) (41.3mm)
(39.7mm) (42.9mm)
M omentary F luorosilicone M omentary 1-1/2” (38 mm )

R ubber B oot S hrouded M ushroom C ap M omentary 2-1/4” (57.2 mm )
13/16" 1-9/16" ø1-7/8” 1-7/16” S hrouded J umbo M ushroom C ap
(20.6mm) (39.7mm) (ø45.2mm) (36.5mm) 1-7/16"
(36.5mm)
1-9/16" 1-11/16"
(39.7mm) (42.9mm)
2-5/8"
(66.7mm) 1-5/8"
(41.3mm)
1-3/16”
(30.2mm)
1-9/16"
(39.7mm)
2-P osition P ush -P ull 2-P osition P ush -P ull M aintained
Maintained 1-1/2” (38 mm ) 2-1/4” (57.2 mm ) J umbo M ushroom C ap
Mushroom Cap 1-3/16" 2-P osition P ush -T wist M aintained
(30.2mm)
In Dim.
1-9/16"
(39.7mm)
1-1/2” (38 mm ) M ushroom C ap
1-7/16" 1-9/16"
(36.5mm) (39.7mm)
Out Dim. 1-9/16”
1-7/16” (39.7mm)
(36.5mm)
1-5/8"
1-5/8" (41.3mm)
(41.3mm)
1-5/8”
(41.3mm)
1-3/16"
(30.2mm) 1-7/16"
In Dim. (36.5mm)
In Dim.

Revision 02.17.10
155
30 DS22 D1 6 13 DS EC TB GR PS
im
e r ieenss i o n s
industrial iec iec
Momentary Illuminated Push Buttons

30 22 TB
I lluminated F ull V oltage , T ransformer , R esistor I lluminated F ull V oltage O perators

hazardousand n -I
D ual enput
m a O perators ( shown with IPBC)
2-3/16" ( shownnwith
e m IPBCM)
a
1-1/2" (55.6mm)
1-1/4"1-1/4" 1-5/8"1-5/8" 1-3/4"1-3/4"
(38.1mm) 1-5/8"2-3/16" 1-3/4" (31.8mm) (41.3mm) (44.5mm)
(55.6mm)
(41.3mm) (31.8mm) (41.3mm) (44.5mm)
1-1/2" (44.5mm)
(38.1mm) 1-5/8" 7/8" 1-3/4" s e 7/8"
7/8" ries
TB
(41.3mm) (22.5mm) (44.5mm)
Add'l (22.5mm)
(22.5mm)
7/8" 1-9/16" Add'l Add'l 1-5/8"1-5/8"
blocks
(22.5mm) 1-9/16"
1-5/8" (39.7mm)
(39.7mm) blocksblocks (41.3mm)
(41.3mm)
Add'l
blocks (41.3mm)
1-5/8"
(41.3mm)
PanelPanel
Thk. shown
Thk. shown
3/16" 3/16"
(4.8mm)
(4.8mm)
Panel Thk. shown
3/16" (4.8mm)
Panel Thk. shown
3/16" (4.8mm) I lluminated G uarded L ens (GIPBC)
I lluminated S hrouded
1-11/16”
M ushroom L ens (SIPBCM) (42.9mm)
1-3/4” 1-1/2”
1-7/16” 1-1/2” (44.5mm) 1-5/8” TABLE 1- MOUNTING
(39.1mm) (41.3mm)
(36.5mm) (39.7mm) PANEL THICKNESS
1-15/16” 1/16" 4
(49.2mm) 1/8" 3
1-5/8” 3/16" 2
(41.3mm) 1/4" 1
1-9/16” * REMOVE ONE ADDITI
WHEN USING A LEGE
(39.7mm)
Panel Thk. shown

3/16” (4.8mm)
NOTES:
2 & 3 Position Push-Pull Maintained Illuminated Push Buttons 1) MOUNTING HOLE IN PANEL - ÿ1-3/16
3) MOUNTING HOLE SPACING (FOR STAN

Fully-assembled operators come standard with one 3/16” (4.8mm) and three 1/16” (1.6mm) gaskets. 2) CHOICE OF ALUMINUM OR PLASTIC C
I lluminated F ull V oltage O perator I lluminated T ransformer and R esistor O perators

( shown with IMC) ( shown with IMC) TOLERANCE:
.XX +/- 0.02

.XXX +/- 0.005
1-7/16" 2-1/16" 3-1/16" (77.8mm) .XXXX +/- 0.001
1-7/16"
ANGLES +/- 0.5 DEG
(52.4mm)
P
(36.5mm)
UNLESS OTHERWISE
(36.5mm)
SPECIFIED Descripti
2-1/16" 2-1/8" 30mm
(52.4mm) (54mm) This drawing is the property of c3controls. The drawing
7/8" Drawn B
(22.5mm) 06
Date:
7/8"
1-9/16" Add'l 1-5/8" (22.5mm)
(39.7mm) blocks (41.3mm) Add'l 1-5/8"
block (41.3mm)
Panel Thk. 2-1/8"

(3/16" (4.8mm) shown) (54mm) Panel Thk.
/16" 2-1/16" (3/16" (4.8mm) shown)
5mm) (52.4mm) 3-1/16" (77.8mm)
1-7/16"
(36.5mm) 2-1/16" 2-1/8"
7/8" (52.4mm) (54mm)
(22.5mm)
Add'l 1-5/8"
blocks 7/8"
(41.3mm) (22.5mm)
Add'l 1-5/8"
block (41.3mm)
Panel Thk. 2-1/8"
(3/16" (4.8mm) shown) (54mm)
Panel Thk.
(3/16" (4.8mm) shown)
Reset Push Button Alternate Action Block

Fully-assembled operators come standard with one 3/16” (4.8mm)
and three 1/16” (1.6mm) gaskets. 11/16”
2-3/16”
See mounting gasket specifications chart #3 on page 160. (17.5mm)
(55.6mm)
1-3/8"
(34.9mm)
7/16"
(11.1mm) 1-11/16”
(42.9mm)
1/2"
(12.7mm)
Travel

series

ions
30industrial
Wobble stick GUARD ATTACHMENT
Fully-assembled operators come standard with one 3/16” (4.8mm) PPGD series
30
and three 1/16” (1.6mm) gaskets.
ø1-15/16”
1-1/2” (ø49.5mm)
1-9/16” ø1-3/16” hazardous
(39.7mm)
3-3/16” MULTIPLE (39.4mm) (ø30.5mm)
(80.96mm) GASKETS
7/8”
1-9/16” (22.2mm)
(39.7mm) ADD PER 1-15/16” 1-3/4”
CONTACT (49.5mm) (45.2mm)
1-5/8” 1-5/8”
(41.3mm) (41.3mm) 1” 2 1/8”
ø1-3/16”
(ø80.96mm) 1 5/8”
MOUNTING HOLE
1/4”
(6.3mm)
1 2 3
Potentiometer with & without Terminal Block 1 9/16”
P otentiometer O perator P otentiometer O perator
( shown without T erminal B lock ) ( shown with T erminal B lock ) Panel Thk. shown W iring D iagram
4.8mm (3/16")
1” 2-1/8”
1-5/8" (25.4mm) 1-5/8” 2
(41.3mm) (54mm)
2 (41.3mm) 1
1" 1-3/4" 1 3
(25.4mm) (44.5mm) 1-9/16"
(39.7mm) 1-9/16” 0
(39.7mm)
1-3/8" 2 is the common
(34.9mm) Clockwise
knob rotation 1 2 is decreasing
1-9/16" as seen from resistance ( )
(39.7mm) the front of
Panel Thk. shown the panel 3 2 is increasing
3/16" (4.8mm) B 1 2 3
resistance ( )
1-5/16" Panel Thk. shown
(33.3mm) 3/16” (4.8mm)
2
Contact Blocks 1
1 3
C ontact B lock A600 (AC) Rating Designation:

& 0
C ontact B lock A600 (7200 VA Make
( shown with IP20 T erminal G uard )
11/16" and 720 VA Break),
2 IS THE COMMON
(17.5mm) LOCATION FOR
7/8"
(22.5mm) 15/16" 7/8" M6 TERMINAL 600V AC Maximum,
CLOCKWISE
KNOB ROTATION 1 ‘ 2 IS DECREASING
(24.5 mm) (21.6 mm) BLOCK MARKER Maximum
AS SEEN FROM Continuous
RESISTANCE (” &)
7/8" THE FRONT OF
Thermal Current, Ith: 10A
1-3/8" (22.5mm) THE PANEL 3 ’ 2 IS INCREASING
RESISTANCE (‘ )
(34.9mm) P300 (DC) Rating
Designation:
1-5/8" P300 (138 VA Make
1-11/16" 5/16" 5/16" (41.1 mm)
(42.9mm) (7.9mm) (7.9mm) and 138 VA Break),
250V DC Maximum,
Maximum Continuous
A
Thermal Current, Ith: 5A
Cable Pull Operators

P.O. BOX 496 BEAVER, PA 15009 www.c3controls.com
See mounting gasket specifications chart #3 on page 160. 1" Description:
(25.4mm)
P ush -P ull M aintained C able P ull O perator
This drawing is the property of controls. The drawing may
31/32"
M omentary and
not be copied, used or
c3 disclosed, for any purpose
except as authorized in writing (787.4mm)
30mm
Contact Block and IP-20 Gaurd Ouline Drawing
7/8"
(22.5mm) H eavy D uty by controls.
c3
Drawn By:
B. Johnson
Drawing Number:
Add'l C able P ull
block 2 Date:
1/4/20081 Scale:
1:1 30P10046-OD
2-3/8" 1/2"
(60.3mm) (12.7mm) 1-9/16" O perators
(39.7mm)
Fully Extended
1-5/8" M omentary 1-13/16" 1-5/16"
(41.3mm) (46mm)
B ooted C able (33.3mm)
1/4" P ull O perator

(6.4mm) Panel Thk. shown 1-7/16"
Throw
3/16" (4.8mm) (36.5mm)
157
im
e r ieenss i o n s
industrial iec iec
series series
maintained flush & extended push button caps
series
30 22
hazardous nema
See mounting gasket specifications chart #3 on page 160. TB nema
M aintained F lush P ush B utton C ap
M aintained E xtended
( shown with an operator and 7/8"
(22.5mm) P ush B utton C ap
contact block ) Add'l
block 1-9/16" s e r i e s1-1/2"
TB
1-3/8" 1-1/2"
(34.9mm) (38.1mm) (39.7mm)
(38.1mm)
1-3/8" 1-5/8" 1-3/8"

(34.9mm) (41.3mm) (34.9mm)
Panel Thk. shown

3/16" (4.8mm)
Pilot Lights
Fully-assembled operators come standard with one 3/16” (4.8mm) and two 1/16” (1.6mm) gaskets.
F ull V oltage P ilot L ight O perator T ransformer & R esistor P ilot L ight D ual I nput
( shown with PLL and IP20 T erminal O perators ( shown with PLL P ilot L ight O perator
G uard ) and IP20 T erminal G uard ) ( shown with PLL)
1-7/8”
(47.3mm) 1-7/64”
(28.2mm) 2-11/64” 2-3/16"
11/16” 25/128” 1-1/16"
1-3/4” (55.1mm) (5mm) (55.6mm)
(17.7mm) (44.4mm) (27mm)
1-1/16” 1-5/8" (41.3mm) 7/8"
1-13/16” (22.5mm)
(46mm) (27.1mm)
Add'l
1-5/8” blocks 1-5/8"
(41.2mm) (41.3mm)
1” 3/16” IP20 Terminal

(25.4mm) (4.7mm) Guard
Panel Thk. shown 1-3
3/16" (4.8mm) (44.5
Multi-Voltage Pilot Light UNIBODY Pilot Lights

Fully-assembled operators come standard with four 1/16” (1.6mm) gaskets.
See mounting gasket specifications chart #2 on page 160. F ull V oltage U nibody P ilot L ight O perator
M ulti -V oltage P ilot L ight 1-9/16”

11/16”
( shown with PLL and IP20 T erminal G uard ) (17.3mm) (39.6mm)
ø51/64”
(ø20.2mm)
1-1/64”
(25.8mm) 2-1/128”
1-5/8” 25/128” ø1-3/32”
(51mm) (5mm)
(41.2mm) (ø27.7mm)
1-3/8”
1-5/8” (34.8mm)
X1 X2
(41.2mm)
IP20 Terminal
3/16” Guard
1-1/128” (4.7mm)
(25.5mm)
Panel Thk. shown
3/16” (4.8mm)
V isit w w w . c 3 c o ntr o ls . c o m t o
d o w nl o ad C ad dra w in g s

s2-1/2"
eries
30
1-1/4"

(31.8mm) (63.5mm)
ions
industrial
1-1/4" 2-1/2"
(31.8mm) (63.5mm)
Push-To-Test Pilot Lights
series
30
Panel Thk.
Fully-assembled operators come standard with one 3/16” (4.8mm) and three 1/16” (1.6mm) gaskets. (3/16" (4.8mm) shown)

hazardous
F ull V oltage , T ransformer & R esistor F ull V oltage , T ransformer & R esistor
P ush -T o -T est O perators ( shown with IPBC) P ush -T o -T est O perators ( shown with IPBCM)
Panel Thk. 1-3/4"
1-1/2" 2-1/2" 1-3/4" (3/16" (4.8mm) shown)
(38.1mm) (163.5mm) (44.5mm) 1-1/4" 2-1/2" (44.5mm)
(31.8mm) (63.5mm)
1-5/8" 1-5/8"
(41.3mm) (41.3mm)
1-3/4"
Panel Thk. (44.5mm)
(3/16" (4.8mm) shown)
G uarded L ens S hrouded M ushrooms L ens Panel Thk.

1-5/8"
(3/16"(41.3mm)
(4.8mm) shown)
1-11/16” 1-1/2” 1-7/16” 1-3/4”
(42.9mm) (39.7mm) (36.5mm) (44.45mm)
ø1-15/16”
(ø49.2mm)
1-9/16” 1-5/8”
(39.7mm) (41.3mm) 1-3/4"
(44.5mm)
1-5/8"
(41.3mm)
Selector switches
S elector S witch O perator S elector S witch L ever K eyed S elector S witch O perator
( shown with standard handle ) H andle
31/32" 2-7/32" 1-17/32"
1-1/8" (787.4mm) 1-39/64"
1-7/16" (56.2mm) (38.9mm) (40.8mm)
(28.6mm) (36.5mm) 7/8"
(22.5mm)
Add'l 1-1/8"
block (28.6mm)
7/8"
1-5/8" (22.5mm) 1-39/64"
(41.3mm) Add'l (40.8mm)
contacts
1-5/8"
(41.3mm) 1-3/8" Panel Thk. shown
(34.9mm) 3/16" (4.8mm)
1" (25.4mm) Swing Radius 1-3/8"
(34.7mm)
Panel Thk. shown
1/4" (6.4mm)
lock-off attachment
5-7/64"
(129.8mm) 2-11/16"
(68.1mm)
2-11/16"
(68.1mm)
1-15/32”
(37.5mm) 1-21/32”
CAVITY (42mm)
2” 1-55/64" HEIGHT
(50.9mm) (47mm)
ø1-7/32” 37/64”
(ø30.7mm) (14.7mm)
3/16”
(4.7mm)
159
im
e r ieenss i o n s
industrial iec iec
LEgend Plates
30 22
hazardous
STANDARD LEGEND PLATE
WITH n WAY
BREAK-A e mPaOSITIONING
LP-SP LP-SP LP-SP n e m a
TB LP-SP
FOR OPTIONAL THRUST WASHER ACCESSORY STANDARD NARROW SHORT TALL
2”
ø1-3/64" 2" 1-3/4” (50.8mm) 1/16”
(50.8mm) 1/16” (44.5mm) 1/16” 2”
3/16" s e r1/16”
ies (1.6mm)
TB
(ø30.5mm) (4.9mm) (1.6mm) (1.6mm) (50.8mm) 16 CHARACTERS
16 CHARACTERS 16 CHARACTERS 16 CHARACTERS
1/16” 16 CHARACTERS 16 CHARACTERS 16 CHARACTERS (1.6mm) 16 CHARACTERS
(1.6mm) 2” 2” 2-1/4”
(50.8mm) (50.8mm) 1-3/4” (57.2mm)
9/16” (44.5mm)
8 CHAR.
8 CHAR.
8 CHAR.
8 CHAR.
8 CHAR.
8 CHAR.
23/32”
A (18.2mm) (14.1mm)
3/4” 3/4” 3/4”

(19.1mm) (19.1mm) 3/4” (19.1mm)
(19.1mm)
3/16”
(4.5mm)
B
LP-40-SP LP-43-SP LP-40-SP LP-40-SP
POT POT SHORT TALL
2”
2" 2” (50.8mm) 1/16”
(50.8mm) 1/16” (50.8mm) 1/16” 2” (1.6mm)
(1.6mm) (1.6mm) (50.8mm) 1/16”
(1.6mm)
2” 2” 2-1/4”
(50.8mm) (50.8mm) 1-3/4” (57.2mm)
(44.5mm)
0 10 0 100 0 10 0 10
3/4” 3/4” 3/4” 3/4”

(19.1mm) (19.1mm) (19.1mm) (19.1mm)
LPR-SP LPRM-SP LPRJ-SP

STANDARD ROUND MEDIUM ROUND JUMBO ROUND
ø3-3/4”
ø2-3/4” (ø95mm)
ø2-13/32” (ø70mm) 1/16”
(ø61mm) (1.6mm)
1/16” 1/16”
(1.6mm) (1.6mm)
MOUNTING GASKETS
Mounting Gaskets Chart #1 Mounting Gaskets chart #2 Mounting Gaskets chart #3

Panel thickness # of Gaskets Needed Panel thickness # of Gaskets Needed Panel thickness # of Gaskets Needed
in decimals 3/16” & 1/16” in decimals 3/16” & 1/16” in decimals 3/16” & 1/16”
(4.8mm) (1.6mm) (4.8mm) (1.6mm) (4.8mm) (1.6mm)
less than .080 1 3 less than .080 1 2 less than .080 1 5
.080 – .132 1 2 .080 – .132 1 1 .080 – .132 1 4
.133 – .185 1 1 .133 – .185 0 3 .133 – .185 1 3
.186 – .238 0 3 .186 – .238 0 2 .186 – .238 1 2
.239 – .291 0 2 .239 – .291 0 1 .239 – .291 1 1
.292 – .344 0 1 Note: Remove one 1/16” (1.6mm) gasket when using a .292 – .344 0 3
Note: Remove one 1/16” (1.6mm) gasket when using a legend plate. Note: Remove one 1/16” (1.6mm) gasket when using a
legend plate. legend plate.
MOUNTING HOLE PATTERN
A
MOUNTING HOLE PATTERN
SPACING A B
Minimum 2” (50.8mm) 2” (50.8mm)
Standard 2-1/14” (57.2mm) 2-1/14” (57.2mm)
B ø1-3/16”
(ø30.2mm)

CBE Range
Q–Series Miniature Circuit Breakers
Product Type QL QY QZ QDC

Standard Ampere Ratings (A) 0.1 – 63 (1 pole) 0.1 – 60 (UL 1077) 0.1 – 63 (1 pole)
0.1 – 50 (2 poles) 5 – 50 (IEC 60947-2) 0.1 – 50 (2 poles)
0.1 – 25 20 – 100 (2p parallel) 20 – 100 (2p parallel)
110 – 150 (3p parallel) 110 – 150 (3p parallel)
Number of Poles 1, 2, 3, 1+N, 3+N 1, 2 1, 2, 3, 1+N, 3+N 1, 2
2, 3p parallel 2, 3p parallel
2 poles in series 2 poles in series
Rated Voltage (V) 120V AC (1p) 80V DC 120V AC (1p) 80V DC
120/240V AC(2p) *125V DC (1, 2p & 2p 240V AC (1p) *125V DC (1, 2p & 2p
240V AC (1p) parallel) 240/415V AC (2, 4p) parallel)
240/415V AC 2, 4p) *250V DC (2p in series) 277V AC (1p) *250V DC (2p in series)
277/480V AC (2, 3p)
Approvals VDE (EN 60947-2) 6kA (240/415V AC) 10kA 3kA (240/415V AC) 10kA
√ √ √ √
& CE
Interrupt. cULus (UL489_CSA) 10kA (120/240V AC)
Capacity UL489A 10kA
(kA) cURus 5kA (1p, 120V ac)
(UL1077_CSA) √ √ 5kA (277/480V
√ ac) √
Mounting Dual Mounting
Options (DIN & Mini)
√ √ √ √
DIN Rail
√ √ √ √
Surface Clip
√ √
Plug-in
Tripping curves 1, 3, 9, KM, OP OP, U2, 1, 9 1, 2, 3, 9, OP OP, U2, 1, 9
Resistance to shock IEC 60068-2-27, 5G/30ms half sine wave
Vibration IEC 77/IEC 60068-2-6, 3G/10-150Hz
Operating temperature -40°C to +65°C
Optional Accessories – Aux. switch – Trip alarm
– Aux. switch + trip alarm – Bus bar
– Handle lock
Features – Compact 13mm/module width – Hydraulic-magnetic technology
– Precision tripping – Suitable for isolation
– Temperature independent trip point – Mid trip handle
* Polarity Sensitive
CBE Range
Range
QL QY QDC
Features - AC circuit breaker - DC circuit breaker - DC circuit breaker
- UL 489 Listed - UL 489A listed - VDE and CE Approved
- VDE, CSA, CE Approved - VDE & CE Approved - One and two pole units
- One and two pole units - One and two pole units - Current ratings up to 150A
- Current ratings up to 25A - Current ratings up to 150A - 80V DC 125V DC and
- 80V dc & 125V DC 250V DC (250V DC 2 poles
in series)
74 65
(2.91) (2.56)
17.9
(0.7)
66 60 13 26 39
(2.6) (2.36) (0.51) (1.02) (1.54)
(0.86)
22.5
(0.94)
25.9
(1.12)
28.5
135 (5.32)
151 (5.95)
(3.65)
(2.81)
(2.24)
92.8
71.4
(1.77)
57
45
19
(0.75) 44 13
(1.73) (0.51)
32
(1.26)
63.8
5 45 (2.51) NOTE: DIMENSIONS IN BRACKETS ARE IN “INCHES”
5.0
(0.2) (1.77) (0.2)
73
QY/QDC, 2 2&& 33POLES
QY / QDC, POLES
BRIDGED IN PARALLEL
64.8
(2.55)
(2.87) BRIDGED IN PARALLEL
DUAL MOUNT DIN RAIL MOUNT
QZ
Features - AC circuit breaker
- UL 1077 Recognized
- VDE, CE, CSA certified
- One, two and three pole units
- Current ratings up to 60A
74 65
(2.91) (2.56)
(0.78)
19.9
66 60 13 26 39
(2.6) (2.36) (0.51) (1.02) (1.54)
(0.86)
22.5
(0.94)
25.9
(1.12)
28.5
(3.81)
(2.81)
(2.24)
96.8
71.4
(1.77)
57
45
19
(0.75) 44 13
(1.73) (0.51)
32
(1.26)
63.8
5 45 (2.51) NOTE: DIMENSIONS IN BRACKETS ARE IN “INCHES”
5.0
(0.2) (1.77) (0.2)
73
64.8 (2.87)
(2.55)
DUAL MOUNT DIN RAIL MOUNT

CBE Range
Auxiliary switch,Trip alarm, Combo
Features - AC and DC voltages
- UL 489 listed
(5A, 250V AC; 0.5A, 80V DC Auxiliary; 0.5A, 125V DC Trip alarm)
- IEC 60947-5-1 approved
(5A, 250V AC; 0.5A, 110V DC Auxiliary; 0.5A, 125V DC Trip alarm)
- Factory fitted
- Compact 6.5mm width
- Attached to right hand side of circuit breaker
- Available on Dual and DIN rail mounting
30.3 31.3
(1.19) (1.23) TRIP ALARM Q. CONNECTORS
6.5 25.2 26.2
20.1 21.1
(0.256) (0.99) (1.03)
(0.79) (0.83)
(0.08)
5.5
2
(N/O)16
(N/C)18
(C)15
(N/O)16
(N/C)18
(C)15
(0.22)
(0.02)
0.5
(1.77)
(2.24)
45.0
57.0
AUX SWITCH Q. CONNECTORS

14(N/O)
14(N/O)
12(N/C)
12(N/C)
11(C)
11(C)
(0.11)
2.8
(0.28)
(0.02)
9.7 10.7
0.5
19.5 20.3 21.3
31.9 (0.38) 32.9 (0.42)
(0.77) (0.8) (0.84)
(1.26) (1.3)
DIN RAIL MOUNT DUAL MOUNT
Standard Time Delay Curves

1000 1000 1000 1000
OPERATING OPERATING OPERATING
CHARACTERISTICS CHARACTERISTICS CHARACTERISTICS OPERATING
CHARACTERISTICS
AMBIENT TEMPERATURE AMBIENT TEMPERATURE AMBIENT TEMPERATURE
100 100 100 100
MINUTES
MINUTES
MINUTES
MINUTES
30˚C 30˚C 30˚C AMBIENT TEMPERATURE

30˚C
CURVE 1 CURVE 2 CURVE 3
CURVE 9
10 10 10 10
1 1 1 1
TRIPPING TIME
TRIPPING TIME
TRIPPING TIME
TRIPPING TIME
10 10 10 10
1 1 1 1
SECONDS
SECONDS
SECONDS
SECONDS
0.1 0.1 0.1 0.1
0.01 0.01 0.01 0.01
0.001 0.001 0.001 0.001

1000
1200
1500
2000
2500
3000
4000
5000
1000
1200
1500
2000
2500
3000
4000
5000
1000
1200
1500
2000
2500
3000
4000
5000
1000
1200
1500
2000
2500
3000
4000
5000
100
105
130
150
200
300
400
500
100
105
130
150
200
300
400
500
100
105
130
150
200
300
400
500
100
105
130
150
200
300
400
500
(%) RATED CURRENT (%) RATED CURRENT (%) RATED CURRENT (%) RATED CURRENT
1000 1000 1000

OPERATING
CHARACTERISTICS
OPERATING
OPERATING
CHARACTERISTICS INTERNAL IMPEDANCE
CHARACTERISTICS
100 AMBIENT TEMPERATURE 100 100
AMBIENT TEMPERATURE
30˚C vs CURRENT RATING
MINUTES
MINUTES
MINUTES
CURVE U2 DC
30˚C (4% RIPPLE FACTOR)
CURVE OP
CURVE KM AMBIENT TEMPERATURE INSTANTANEOUS DC
30˚C (4% RIPPLE FACTOR) 10
10 10 10
INTERNAL IMPEDANCE [Ohms]
1 1 1
1
TRIPPING TIME
TRIPPING TIME
TRIPPING TIME
10 10 10
0.1
1 1 1
SECONDS
SECONDS
SECONDS
0.1 0.1 0.1 0.01
0.01 0.01 0.01

0.001
1 2 5 6 10 15 20 25 30 35 40 50
CURRENT RATINGS [Amps]

0.001 0.001 0.001
AC
1000
1500
2000
2500
3000
4000
5000
1000
1200
1500
2000
2500
3000
4000
5000
1000
1500
2000
2500
3000
4000
5000
100
125
150
200
300
400
500
100
105
130
150
200
300
400
500
105
130
150
200
300
400
500
DC
(%) RATED CURRENT (%) RATED CURRENT (%) RATED CURRENT

CBE Range
Example codes: QY-1(13)-D-U2-20A-B1
Long Code QDC-2(13)-DM-U2-50A-B2
Group 1: Frame Code Frequency Approvals QL-A-2(13)-D-9-25A
Type QL AC UL 489
QY DC UL489A,VDE, CE QZ-N-AT-4(13)-DM-2-60A
QZ AC CURus,VDE,CE
QDC DC EN 60947-2, CE
Group 2: Code Description Comments
N Neutral Leave blank if
S Switch not applicable
Group 3: Auxiliary Code Description Comments
A Auxiliary Switch Leave blank if
T Trip Alarm not applicable
AT Auxiliary Switch + Trip Alarm
Group 4: Number Code Description Comments
of Poles 1 Single Pole
2 Double Pole
3 Triple Pole
4 Four Pole
Group 5: Module Code Description Comments
width 13 13mm
18 18mm
19 19.5mm
26 26mm
Group 6: Mounting Code Description Comments
D DIN – 45mm Escutcheon
DM Dual Mount – DIN & Mini-Rail, 57mm Escutcheon
P1 Plug-in, DIN
Code
P2 Plug-in, Dual Mount
Group 7: Time Code Description Comments
Delays 1 Curve 1
2 Curve 2
3 Curve 3
9 Curve 9
U2 Curve U2
KM Curve KM
OP Instantaneous
Group 8: Current Code Description Comments
Ratings 0.1 0.1A
0.2 0.2A
0.5 0.5A
01 1A
1.5 1.5A
02 2A
2.5 2.5A
03 3A
04 4A
05 5A
06 6A
10 10A
15 15A
16 16A For other ratings
20 20A consult factory
25 25A
30 30A
32 32A
35 35A
40 40A
45 45A
50 50A
60 60A
63 63A
70 70A
80 80A
100 100A
125 125A
150 150A
Group 9: Code Description Comments
B0 80V DC Bottom Connected (Positive at bottom) Leave blank if
B1 125V DC Bottom Connected (Positive at bottom) not applicable
B2 250V DC Bottom Connected (Positive at bottom)
T3 250V DC with + and – connecting terminals at top
Z DC – Bridged (Link not supplied)
A member of the Group

June 2007/June Viljoen Print Design Print
South Africa Germany USA Australia

CBI-electric: low voltage CBI-electric: Europe CBI-electric: North America CBI-electric: Australia
Tripswitch Drive Elandsfontein Postfach 101240 D-86882 35E Uwchlan Ave Suite 328 821 Springvale Road Mulgrave Melbourne
Gauteng South Africa Landsberg Germany Exton PA 19341 USA Victoria 3170 Australia
Tel: +27 11 928 2000 Tel: +49 8191 9472900 Tel: +91 610 524 9949 Tel: +61 3 9560 3522
Fax: +27 11 392 2354 Fax: +49 8191 94729011 Fax: +91 610 524 9945 Fax: +61 3 9562 0420
E-mail: cbi@cbi-electric.com E-mail: office@cbibreakers.de E-mail: info@cbibreakers.com E-mail: heinelec@heinelec.com.au
Website: www.cbi-electric.com Website: www.cbibreakers.com Website: www.cbibreakers.com Website: www.heinemannelectric.com.au
30mm Contact Blocks (0 items) Industrial controls by c3controls Page 1 of 1
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30mm Industrial : Contact Blocks
PRODUCTS
PILOT DEVICES (Push To configure and order your parts, please select each of the options described in the righ
Buttons, Switches, List Prices Shown, Please Call for Your Factory Direct Discou
Indicators) Configure your item h
Product Features
30mm Industrial Pilot Catalog Reference:
Devices 1 Contact Configuratio
Page 124-125 Operate multiple control
Contact Blocks Discount Sched: A Choose Here Now
circuits from a single pilot
Push Buttons device - most operators can
be stacked up to 4 deep,
2 Contact Option:
Pilot Lights providing a total of 8
circuits per operator in any ----------
combination.
Selector Switches
Self-lubricating 3. Please enter the de
Special Operators thermoplastic stroker 1
prevents sticking and
Accessories corrosive build-up.
Contact blocks can be wired

Replacement Lamps
outside the tight space of
the control panel and then
Standard Legend Plates simply "snap-on" to the
operator.
MOTOR CONTROL
(Contactors, OLR, MPCB, 35-degree angled terminals
Photos represent the general
Starters) provide ease of wiring for
category, and will not change as
PROGRAMMABLE RELAYS quick installation.
you select options.
GP RELAYS / ELECTRONIC
TIMERS
TERMINAL BLOCKS (IEC &
NEMA)
TOWER LIGHTS
WIRING/CABLE DUCT
CAM SWITCHES
DISCONNECT SWITCHES
PROXIMITY SENSORS
ENCLOSURES
© 2008 c3controls,
all rights reserved
These are some of the c3controls part numbers that apply to this page :
CBNO, CBNOG, CBNO-IP20, CBNO-IP20, CBNC, CBNCG, CBNC-IP20, CBNC-IP20, CBEM, CB
IP20, CBDB, CBDBG, CBDB-IP20, CBDB-IP20
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30mm Indicating Lights (0 items) Industrial controls by c3controls Page 1 of 2
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30mm Industrial : Pilot Lights: Indicat
PRODUCTS
Product Features
Devices 1 Operator Type:
Page 140-141 Compact, thin design is also
Pilot Lights Discount Sched: A Choose Here Now
vibration resistant.
Indicating Lights
Our seal is infused with a
Push-To-Test 2 Voltage (based on o
coating to eliminate
Multi-Voltage cracking when exposed to ----------
Unibody harsh environments. The
seal also acts as a light
MOTOR CONTROL 3 Lamp Type / Color:
reflector to increase light
(Contactors, OLR, MPCB,
output and visibility. ----------
Starters)
PROGRAMMABLE RELAYS Rugged Lexan lenses
GP RELAYS / ELECTRONIC provide better visibility and 4 Clamp Ring:
TIMERS can resist high impact in ----------
TERMINAL BLOCKS (IEC & most environments.
Photos represent the general
NEMA)
category, and will not change as
TOWER LIGHTS you select options. 5 Lens Type:
WIRING/CABLE DUCT ----------
CAM SWITCHES
DISCONNECT SWITCHES
6 Lens Color:
PROXIMITY SENSORS
----------
ENCLOSURES
7. Please enter the de

1
https://www.c3controls.com/30mm-indicating-lights.cfm 3/28/2008
30mm Push Button Switch, Maintained, Non-Iluminated (0 items) Industrial controls by c... Page 1 of 2
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30mm Industrial : Push Buttons : Main
PRODUCTS Non-Iluminated : 2-Position : Push-Pu
Product Features
Page 128-129 Our E-Stops contain a solid
Push Buttons Discount Sched: A Push Button
brass detent mechanism
Maintained ensuring reliable operations
in emergency applications,
Non-Illum, 2- 2 Clamp Ring:
providing safe interruption
Position Push-Pull Choose Here Now
of circuits, and much longer
Non-Illum, 2-Position life when compared to any
Push-Twist-Release competitor's product.
3 Cap Function:
Non-Illum, 3-Position
Push-Pull All cap types are secured ----------
by the clamp ring once
Illuminated, 2-
installed for tamper
Position
protection. 4 Cap Type:
Illuminated, 3- Photos represent the general ----------
Position category, and will not change as The 2-position push-pull is
MOTOR CONTROL you select options. maintained in both the
(Contactors, OLR, MPCB, push and pull positions. The 5 Cap Color:
Starters) primary application is
"push" to "stop" and "pull" ----------
PROGRAMMABLE RELAYS
to "start".
GP RELAYS / ELECTRONIC
TIMERS Operators are UL Listed and 6 Contact Block Config
TERMINAL BLOCKS (IEC & are rated for Type 1, 2, 3, ----------
NEMA) 3R, 4/4X, 12 and 13, and
TOWER LIGHTS meet global standards
requirements. 7. Please enter the de
WIRING/CABLE DUCT
CAM SWITCHES 1
DISCONNECT SWITCHES
PROXIMITY SENSORS
ENCLOSURES
https://www.c3controls.com/30mm-maintained-non-illuminated.cfm 3/28/2008
30mm Pushbutton Switch, Momentary, non-Illuminated (0 items) Industrial controls by c... Page 1 of 2
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30mm Industrial : Pushbuttons: Mome
PRODUCTS Non-Illuminated
Product Features
Page 126-127 U-Cup seal is infused with a
Push Buttons Discount Sched: A Push Button Operator
Teflon coating to eliminate
Momentary cracking when exposed to
harsh conditions and acts
Non-Illuminated 2 Clamp Ring:
like a squeegee and forms
Illuminated a permanent watertight Choose Here Now
MOTOR CONTROL seal.
(Contactors, OLR, MPCB,
Modular design provides 3 Cap Type:
Starters)
PROGRAMMABLE RELAYS endless options for ----------
appropriate operator
GP RELAYS / ELECTRONIC interface with a variety of
TIMERS interchangeable cap types 4 Cap Color:
TERMINAL BLOCKS (IEC & and colors. ----------
NEMA) Photos represent the general
TOWER LIGHTS category, and will not change as Operators are UL Listed and
you select options. rated for Type 1, 2, 3, 3R,
WIRING/CABLE DUCT 5 Contact Block Config
4/4X, 12 and 13, and meet
CAM SWITCHES ----------
global standards
DISCONNECT SWITCHES requirements.
PROXIMITY SENSORS
6. Please enter the de
ENCLOSURES
1
© 2008 c3controls,
all rights reserved
https://www.c3controls.com/30mm-pushbutton-momentary-non-illuminated.cfm 3/28/2008
CYCLOPS
Y or Z – Purge Indicator
User’s Manual
This page intentionally left blank
Information in this document is subject to change without notice. All terms mentioned
in this manual that are known to be trademarks have been appropriately capitalized.
Purge Solutions acknowledges all trademark(s) and the rights of the trademark(s) owned
by the company referred to herein.
12450 Galveston Rd, Suite C, Webster, TX. 77598, USA

Phone: 832-368-7166
Fax: 281-992-5726
E-mail: info@purgesolutions.com
Web site: http://www.purgesolutions.com
Release Date: 12-August-2002

Document Number: DO-10011-N
© Copyright 2002 by Purge Solutions
All rights reserved
Revision Record
Rev. Description Date
A Initial Release 12-Aug-02
B Web Site Changes 02-Jan-03
C Add 12 DC Powered Model 23-Mar-03
D Several Revisions 07-Dec-03
E Several Revisions 14-Mar-04
F Several Revisions 29-June-04
G Several Revisions 14-Dec-04
H Several Revisions 27-May-05
I Added Recommended UL Power Supply Requirements 06-Jan-06
J Revised Options and Illustrations 01-Mar-06
K Revised Initial and Maintenance Start Up Procedures 13-Jan-07
L Revised Illustrations 24-Jan-08
M Revisions Per Certification Updates and New Product Offerings 23-Aug-08
N Revisions Per New Purge Gas Inlet Kits Procedures 21-Aug-09
O Several Revisions 11-Nov-09
Copyright Notice:
This document contains information proprietary to Purge Solutions with all rights
reserved worldwide. Any reproduction or disclosure of this publication, or any part thereof,
to persons other than Purge Solutions personnel or customers is strictly prohibited, except
by written permission of Purge Solutions. Unauthorized use, disclosure, reproduction, or
translation of this publication will result in Purge Solutions exercising maximum possible
legal action against all persons and/or organizations involved.
Disclaimer:
Purge Solutions makes every effort to ensure the accuracy and completeness of this
manual. However, we cannot be responsible for errors, omissions, or any loss of data as
the results of errors or omissions. We therefore make no representations or warranties
with respect to the contents hereof. Further, Purge Solutions reserves the right to revise
this publication and to make changes in the content hereof, without obligation to notify any
person or organization of such revision or changes.
Shipment Arrival Procedures:

This shipment has been thoroughly inspected at the factory prior to its delivery to the
carrier. After the shipment is picked up by the carrier, it becomes their responsibility.
When the shipment arrives, make certain that it is undamaged and complete.
Patent Notice:
Manufactured under United States, Worldwide Patents, and Patents Pending.
Trademark Information:
Purge Solutions and its logo(s) are trademark(s) of Purge Solutions.
i
Table of Contents
Legal Notices and Revision History Inside
front cover
Section 1 Section 5
How To Use This Manual 1 Start Up Procedures 18
Safety Considerations 1 Initial Start Up 21
Label Definition Table 2 Maint/Service Start Up 26
Locating Information 2
General Safety 3
General Precautions 3 Section 6
Electrical Power 4
System Location 4 Documents 32
Purge Systems 4 Drawing, Flow Diagram 33
Drawing, Mounting 34
Drawing, Wiring 35
Section 2
Specifications 5 Section 7
Features Table 5
N/O Conditions Table 5 Options 37
Utility Req. Table 6
Environmental Con. Tab. 6
Section 8
Getting Help 41
Section 3
Introduction 8
Description 8 Section 9
Warranty 12 Index 42
Section 4
Installation 13
Mounting 13
Electrical Power 16
Power Source Table 16
Power Connection Table 17
Alarm Signal Installation 17
Alarm Source Table 17
Alarm Connection Table 17
1
Section 1
How to Use This Manual
Safety Considerations:
This chapter includes important information that must be read and understood by
all persons installing, using, or maintaining this equipment. While this manual is
designed to aid personnel in the correct and safe installation, operation, and
maintenance of the systems described. Personnel must consider all actions and
procedures for potential hazards or conditions that may not have been anticipated in the
written procedures. If a procedure cannot be performed safely, it must not be
performed until appropriate actions can be taken to ensure the safety of equipment and
personnel. The procedures in this manual are not designed to replace or supersede
required or common sense safety practices. All safety warnings listed in any
documents applicable to equipment and parts used in or with the system described in
this manual must be read and heeded before commencing work on any part of the
system.
NOTE: Refer to all ATEX, CEC, IECEx or NEC / NFPA certificates for any
Special Conditions of Use. If the sign “X” is placed after the certificate
number, it indicates that the equipment or protective system is subject to
special conditions for safe use specified in the schedule of the certificate.
WARNING: Failure to follow appropriate safety procedures or

inappropriate use of the equipment described in this manual can lead
to injury of personnel or equipment damage.
2
The following symbols are used throughout this manual to alert users to potential
hazards or important information. Failure to heed the warnings and cautions listed
herein can lead to injury and equipment damage.
Document Label Definitions Used To

Indicate Potential Hazards
Symbol Label Description
Consists of conditions, practices, or procedures
WARNING: that must be observed to prevent personal injury.
Consists of conditions, practices, or procedures

CAUTION: that must be observed to prevent injury or
equipment damage.
Risk of electric shock or high temperature parts
CAUTION: may result in injury if proper precautions are not
taken.
Emphasizes important or essential information.

NOTE:
Locating Information:
NOTE: In the interest of completeness, manuals and drawings

included with the system may provide information pertaining to
options not included with your equipment. Information in application
notes supersedes general information in these documents.
Information can be located in this manual using any of the following
aids.
1. Table of Contents
2. Index
3. Getting Help
3
General Safety and Operating Information:

This section contains general safety and operating information applicable to
electrical equipment installed within hazardous locations. This information must be
understood by all persons installing, using, or maintaining the electrical equipment. This
information is designed to aid personnel in safe installation, operation, and maintenance
of the CYCLOPS Y or Z – Purge Indicator. It is not designed to replace or limit
appropriate safety measures applicable to work performed by personnel. Any additional
safety and operating measures that are required must be determined by and followed
by personnel performing work on the electrical equipment.
WARNING: Deviation from the specified instruction or procedure
steps can result in equipment malfunction, equipment damage, or
injury to personnel.
WARNING: Return unit to factory for any repairs or replacement of

parts, customer not permitted. This will void all warranties and
hazardous area certification(s).
General Precautions:
Protective eyewear (glasses with side shields or goggles as appropriate) must
be worn when servicing any part of electrical equipment. Hot components should be
allowed to cool before servicing if possible. Other appropriate equipment or clothing
must be used as required by the type of work performed. All applicable regulations and
procedures must be followed for the work performed. Before beginning any work on
the equipment, carefully consider all the potential hazards and ensure that appropriate
measures are taken to prevent injury to personnel or equipment damage.
CAUTION: Electrical equipment components may be hot even when
power is not applied. Take appropriate precautions to prevent injury
from contact with hot items.
CAUTION: Applicable permits must be obtained and appropriate

precautions must be taken to prevent possible injury to personnel or
equipment damage when installing or maintaining this equipment.
4
Electrical Power:
The CYCLOPS Z – Purge Indicator uses AC power of 115 or 230 volts and DC
power of 12 or 24. The AC power is converted to DC. The CYCLOPS Y – Purge
Indicator uses DC power of 12 or 24. Appropriate precautions must be taken to prevent
sparks that may ignite combustible materials that may be present in the Purge
Indicator’s environment. Precautions must also be taken to prevent electrical shock if
the electrical equipment’s enclosure being monitored by the CYCLOPS Y or Z – Purge
Indicator is opened.
The power to the CYCLOPS Y or Z – Purge Indicator must be free from noise,
surges, sags, and spikes for proper operation of the purge indicator. AC power circuit
breakers and wiring must be sized properly for the required current. All wiring
installations must meet applicable electrical codes.
System Location:
The CYCLOPS Y and Z – Purge Indicator must be installed in a suitable
location. The CYCLOPS Y and Z – Purge Indicator must not be installed in an area
classification for which it is not rated and must be protected from temperature extremes.
The CYCLOPS Y and Z – Purge Indicator should not be mounted in an area with
potentially high vibration. The CYCLOPS Y and Z – Purge Indicator must be attached
securely and appropriately to the wall of the electrical equipment’s enclosure being
monitored per the mounting instructions page 13. The CYCLOPS Y and Z – Purge
Indicator must be mounted in a location to permit adequate viewing of green indicator
light and to permit proper purge exhaust venting.
Purge Systems:
Electrical equipment may use purging to ensure safe operation when installed
within a hazardous location. The protective gas purge supply must be clean, dry, and
free from hydrocarbons or corrosive materials. All protective gas purge supply
pressures must be set correctly and all electrical equipment enclosure doors must be
closed securely. Purged enclosures must not be opened unless power is removed from
the electrical equipment or the area is known to be non-hazardous.
CAUTION: Electrical equipment enclosures being monitored by
CYCLOPS Y or Z – Purge Indicator must not be opened unless power
is removed from the electrical equipment or the area is known not to
contain explosive materials.
5
Section 2
Specifications
Features
Certified for installation and use in ATEX, IECEx and CE marked for
Type Y – Purge, II 2 G Ex e mb ib [py] IIC T6
For Zone 1 gas hazardous areas
Type Y - Purge, II 2 D Ex tD A21 IP66 79°C
For Zone 1 dust hazardous areas
Type Z – Purge, II 3 G Ex nA nL [pz] IIC T6
For Zone 2 gas hazardous areas
Type Z - Purge, II 3 D Ex tD A22 IP66 79°C
For Zone 2 dust hazardous areas
Certified for installation and use to CEC and NEC / NFPA for
Type Y – Purge, Class 1, Division 1, Group A,B,C,& D, T6, hazardous areas
Type Z – Purge, Class 1, Division 2, Group A,B,C,& D, T6, hazardous areas
Monitors one pressure point
Normal Operating Conditions

Power Manually applied to the electrical equipment within
the enclosure being monitored by purge indicator.
Manual Dilution Cycle Time To Typically, dilution cycle time is to ensure that at
Energizing Electrical Equipment least five (5) times the volume of free space in the
enclosure of protective gas supply is exchanged
before power is applied to the electrical
equipment. Ten (10) times volumes for motors,
generators and other rotating electrical machinery.
CYCLOPS Y and Z – Purge Green indicator light remains on to show purge
Indicator, Minimum Pressure pressure being maintained above 0.20 inches
H2O (0.50 mbar) in electronics enclosure being
monitored.
WARNING: The number of exchanged volumes may be higher in some

situations.
6
Utility Requirements
Purge Protective Gas Supply 20 psig (1.4 Bar) minimum (Suggested to
Pressure to Pressure Regulator compensate for enclosure leak rate)
Purge Protective Gas Supply Water and oil-free, -40°F (-40°C) dew point,
Quality particles  5µ, ISA grade hydrocarbon free
Power (CYCLOPS Z – Purge 12VDC, 24VDC, 115VAC or 230 VAC, 50/60 Hz
Indicator)
Power (CYCLOPS Y – Purge 12VDC or 24VDC, 50/60 Hz
Indicator) with proper I.S. Barrier (with proper I.S. Barrier installed)
Mains Supply Fluctuation Not to Exceed 10%
Environmental Conditions
Operating Temperature Range -40°F to 150°F (-40°C to 65°C)
Used and Mounted For Indoor and Outdoor Use
Casing Material Specifications

Anodized Aluminum Weight 2.48 lbs. (1.13 kg)
316 Stainless Steel Weight 6.70 lbs. (3.04 kg)
Anodized Aluminum Protection NEMA 4 (IP66)
316 Stainless Steel Protection NEMA 4X (IP66)
NOTE: Purge Solutions is NOT responsible for any misuse

or improper installation of product, assumes no liability for
special or consequential damages caused by use or misuse
or improper installation of its products sold and assumes
no liability for injury from use or misuse or improper
installation of its products or attached products.
7
CYCLOPS Z – Purge Indicator

Model Number Matrix
Voltage Material Model Number
12VDC Anodized Aluminum PSCZ - 1A
24VDC Anodized Aluminum PSCZ - 2A
115VAC Anodized Aluminum PSCZ - 3A
230VAC Anodized Aluminum PSCZ - 4A
12VDC 316 Stainless Steel PSCZ - 1S
24VDC 316 Stainless Steel PSCZ - 2S
115VAC 316 Stainless Steel PSCZ - 3S
230VAC 316 Stainless Steel PSCZ - 4S
CYCLOPS Y – Purge Indicator

Model Number Matrix
Voltage Material Model Number
12VDC Anodized Aluminum PSCY - 1A
24VDC Anodized Aluminum PSCY - 2A
12VDC 316 Stainless Steel PSCY - 1S
24VDC 316 Stainless Steel PSCY - 2S
NOTE: Only 12VDC and 24VDC CYCLOPS Y – Purge Indicators can be

installed in order to meet hazardous area certification requirements for
intrinsic safety and must be installed per drawing number DO-11108-B,
which can be found on page 39 of this manual.
8
Section 3
Introduction
Description:
Type Z purging reduces the classification within a protected electronics
enclosures from Division 2 or Zone 2 to nonhazardous. Failure to maintain pressure
within the protected enclosure shall be detected by an alarm or indicator at the
electronics enclosure. The dilution purge time shall be a manual operation and once
the electronics enclosure has been purged of ignitable or flammable concentrations,
only positive pressure of at least 0.20 inches H2O (0.50 mbar) is required to be
maintained within the electronics enclosure and it is not necessary to remove power
from the protected equipment upon the loss of purge pressure.
Type Y purging reduces the classification within the protected electronics
enclosures from Division 1 or Zone 1 to Division 2 or Zone 2. Therefore, all equipment
in the protected electronics enclosures shall be approved for Division 2 or Zone 2
hazardous area locations. Failure to maintain pressure within the protected electronics
enclosure shall be detected by an alarm or indicator both at the purged electronics
enclosure and at a location always monitored. The dilution time shall be a manual
operation and once the electronics enclosure has been purged of ignitable or flammable
concentrations, positive pressure of at least 0.20 inches H2O (0.50 mbar) is required to
be maintained within the electronics enclosure and it is not necessary to remove power
from the protected equipment upon the loss of purge pressure.
The CYCLOPS Z – Purge Indicator is used to provide safe monitoring of electrical
equipment in Division 2 and Zone 2 hazardous areas. The CYCLOPS Y – Purge
Indicator is used to provide safe monitoring of electrical equipment in Division 1 and
Zone 1 hazardous areas. Both units can be used to prevent the possibility of fire or
explosion inside the enclosure of energized electrical equipment, a protective gas
supply is used to dilute potentially flammable materials to an acceptable level, creating
a safe area for the electrical equipment within the enclosure. Positive pressure
prevents the ingress of flammable materials in the surrounding atmosphere from
entering into the enclosure, as long as positive pressure is maintained. After the
enclosure is purged, power may be manually applied to the protected electrical
equipment.
The CYCLOPS Y and Z – Purge Indicator provides an objective evidence of the
presence of adequate positive purge pressure within the electrical equipment enclosure.
A normally open differential pressure switch continuously compares the pressure inside
the monitored electronics enclosure with respect to the atmospheric pressure
surrounding the electronics enclosure. When the monitored electronics enclosure
register’s a pressure of at least 0.20 inches H2O (0.50 mbar) above the reference
atmospheric pressure a manually controlled dilution time cycle may then begin.
Typically, a minimum dilution time cycle is specified to ensure that at least five times the
volume of free space in the electronics enclosure is exchanged before power is
9
manually applied to the electrical equipment. (The number of exchanged volumes may
be higher in some situations). After the manual dilution time cycle has elapsed and the
monitored electronics enclosure pressure is being maintained above 0.20 inches H2O
(0.50 mbar), power may be manually applied to the electrical equipment within the
purged electronics enclosure.
The CYCLOPS Y and Z – Purge Indicator is designed to indicate the presence
of purge pressure from one pressure reference point. Several electronics enclosures
can be installed in series with purge gas being introduced into the first electronics
enclosure and the CYCLOPS Y or Z – Purge Indicator monitoring the last electronics
enclosure in the series; multiple electronics enclosures can now be monitored using
only one CYCLOPS Y or Z – Purge Indicator. The pressure inside the monitored
electronics enclosures must maintain at least 0.20 inches H2O (0.50 mbar) higher than
the atmospheric pressure surrounding the electronics enclosure. This ensures that
hazardous materials are not going to ingress into the pressurized and now protected
electronics enclosures. If any of the electronics enclosures installed in the series door
is opened, pressure will show to be below the required 0.20 inches H2O (0.50 mbar) in
all electronics enclosures.
The exhaust vent which comes as part of the CYCLOPS Y or Z – Purge
Indicator casing, can exhaust purge gas from enclosures with volumes up to 15 cubic
feet (425 liters). For enclosure with volumes above 15 cubic feet (425 liters) and up to
200 cubic feet (5,663 liters) an additional exhaust vent will be required to properly vent
the larger volume of purge gas from the enclosure safely. For proper selection of
components for your purge application, refer to the Purge System Selection Wizard,
which can be found on the home page of our web site www.purgesolutions.com.
The CYCLOPS Y or Z – Purge Indicator uses two different purge methods to
dilute the electronics enclosure and maintain at least 0.20 inches H2O (0.50 mbar);
continuous dilution or leakage compensation. Continuous dilution is a method of
maintaining pressure in an electronics enclosure in which after the electronics enclosure
has been diluted below the required lower explosive limit (LEL) the protective gas is
passed continuously through the electronics enclosure at a pressure above that of the
required 0.20 inches H2O (0.50 mbar) and discharged to the outside atmosphere
through an exhaust vent. The same volume of purge gas is maintained during and after
the dilution time cycle. Continuous dilution is normally used for maintaining and
controlling heat buildup from the electronics within the pressurized enclosure by
continuously exchanging purge gas through the electronics enclosure to atmosphere.
Purge Solutions offers three sizes of continuous dilution models a Small Continuous
Dilution Purge Gas Inlet Kit for enclosures with a volume up to 15 cubic feet (425 liters),
a Medium Continuous Dilution Purge Gas Inlet Kit for enclosures with volumes up to 75
cubic feet (2,125 liters) and a Large Continuous Dilution Purge Gas Inlet Kit for
enclosures with volumes up to 200 cubic feet (5,663 liters). All three Small, Medium
and Large Continuous Dilution Purge Gas Inlet Kits are available in materials of
anodized aluminum or 316 stainless steel.
10
The second purge method offered by Purge Solutions leakage compensation,

which allows a higher volume of protective gas supply to be manually selected to speed
up dilution time of potentially flammable materials to an acceptable level, permitting a
more-rapid application of initial power, or restoration of power to protected electrical
equipment, after service. When the dilution cycle has elapsed, the large volume of
purge gas can be manually turned off. A volume of purge gas larger than the leak rate
of the electronics enclosure will be introduced into the now protected electronics
enclosure to maintain at least 0.20 inches H2O (0.50 mbar). Leakage compensation is
normally used to conserve purge gas when utilities are at a premium. Purge Solutions
offers three sizes of leakage compensation models a Small Leakage Compensation
Purge Gas Inlet Kit for enclosures with a volume up to 15 cubic feet (425 liters), a
Medium Leakage Compensation Purge Gas Inlet Kit for enclosures with volumes up to
75 cubic feet (2,125 liters) and a Large Leakage Compensation Purge Gas Inlet Kit for
enclosures with volumes up to 200 cubic feet (5,663 liters). All three Small, Medium
and Large Leakage Compensation Purge Gas Inlet Kits are available in materials of
anodized aluminum or 316 stainless steel.
For installations that require a back-up pressure relief vent for the purged
enclosure, Purge Solutions offers three sizes of back-up pressure relief vent kits. A
Small Back-Up Vent for enclosures with a volume up to 15 cubic feet (425 liters),
Medium Back-Up Vent for enclosures with volumes up to 75 cubic feet (2,125 liters) and
a Large Back-Up Vent for enclosures with volumes up to 200 cubic feet (5,663 liters).
All three Small, Medium and Large Back-Up Vents are constructed of 316 stainless
steel with an option of mounting on the top or side of an enclosure.
For purged electronic enclosures monitored by a CYCLOPS Y or Z – Purge
Indicator, which has electrical components with higher surface temperatures than the
temperature class of the hazardous area in which the electrical equipment is located,
Purge Solutions offers a Back-Up Purge Gas Kit, which is used in the event that the
initial protective gas supply is lost, a back-up source of bottled protective gas is
automatically applied to the protected enclosure. Electrical equipment protected with
this feature is allowed to cool adequately, while preventing the ingress of flammable
materials in the surrounding atmosphere from entering into the electronics enclosure as
long as positive pressure is maintained.
For purged enclosures using the Back-Up Purge Gas Kits, a Protective Gas
Loss Indicator can be installed for remote protective bottled gas purge supply
monitoring. By installing a Protective Gas Loss Indicator on the protective back-up
bottled purge gas supply line, an alarm signal will be sent if the protective back-up
bottled purge gas supply has been depleted, when bottled gas is used as a back-up gas
source.
WARNING: Failure to heed the following information may lead to
injury of personnel or equipment damage.

11
WARNING: Failure to allow adequate cooling of electrical equipment

components with hot surfaces before opening the purged enclosure
can lead to injury of personnel or equipment damage.
NOTE: In the interest of completeness, included in this manual with

the CYCLOPS Y or Z – Purge Indicator information is additional
information pertaining to options not included with your equipment.
For applications were compressor gas is not available or has oil, which can
introduce hydrocarbons into the purge enclosure, Purge Solutions offers a Purge Gas
Supply Blower. The Purge Gas Supply Blower will be mounted in a non-hazardous
area, were the blower fan within the system, will move up to 131 CFM (3,709 LPM)
purge air through a 2 inch diameter (50.8 mm diameter) tube to the enclosure located
within the hazardous area. The Purge Gas Supply Blower is constructed of 316
stainless steel and is available in 115VAC or 230VAC.
NOTE: The Purge Gas Supply Blower is not certified for hazardous area
installation and use Purge Gas Supply Blower must be installed and
used within a non-hazardous area.
12
Warranty:
Purge Solutions products are warranted free from defects in material and
workmanship at the time of shipment for one year thereafter. Any claimed defects with
Purge Solutions products must be reported within the warranty period and warranty
subject to inspection by Purge Solutions. All warranty inspections are to be performed
Purge Solutions facility. Customer shall ship with shipping charges paid by the
customer to Purge Solutions facility.
After inspection by Purge Solutions, a quotation of proposed work required will
be sent to the customer. Purge Solutions shall be liable only to replace or repair, at its
option, free of charge, products which are found by Purge solutions to be defective in
material or workmanship, and which are reported to Purge Solutions within the warranty
period as provide previously. This right to replacement shall be customer’s exclusive
remedy against Purge Solutions. Shipment of repaired or replaced products from Purge
Solutions facility shall be F.O.B. Purge Solutions facility.
Purge Solutions shall not be liable for labor charges or other losses or
damages of any kind or description, including but not limited to, incidental, special or
consequential damages caused by defective products. This warranty shall be void if
product specifications provided by Purge Solutions are not followed concerning
methods of installation, operation, usage, storage or exposure to harsh conditions
(including, but not limited to, temperature and humidity levels outside the approved
ranges).
Materials and / or products furnished by Purge Solutions by other suppliers
shall carry no warranty except that supplier’s warranties as to materials and
workmanship. Purge Solutions disclaims all warranties, expressed or implied, with
respect to such products.
Limitations on Warranties: The express warranties set forth herein constitute
the only warranties with respect to the products sold in connection herewith. Purge
Solutions makes no representation or warranty of any kind, express or implied (either in
fact or by operation of law), with respect to the products, whether as to their
merchantability, fitness for a particular purpose or otherwise. No employee, agent or
representative of Purge Solutions has any authority to bind Purge Solutions to any oral
or written representation or warranty concerning the Products over and above that
stated herein, except by written amendment signed by Purge Solutions and customer.
13
Section 4
Installation
WARNING: Before attempting to install the CYCLOPS Y or Z –
Purge Indicator, review all the material and all safety information in
this manual and all other applicable documents.
WARNING: Applicable permits must be obtained and appropriate

equipment damage when installing the CYCLOPS Y or Z – Purge
Indicator.
Mounting:
Review all of the material in this manual prior to installing the CYCLOPS Y or Z –
Purge Indicator to the enclosure it will be monitoring. If you have any questions, please
contact your local Purge Solutions representative or the factory (refer to Getting Help
page 41). For installing the CYCLOPS Y or Z – Purge Indicator to an enclosure and for
attaching and routing of wires for power and alarm signals, refer to Installation Flow
Diagram drawing number DO-11007-F page 33, Mounting Hole Template drawing
number DO-11008-C page 34, Wiring Diagram drawing number DO-11009-E page 35
or CYCLOPS Y Intrinsically Safe Wiring Diagram for Div 1 & Zone 1 Installations
drawing number DO-11108-B page 36.
Step 1:
Make sure that area surrounding the enclosure to be monitored by the CYCLOPS
Y or Z – Purge Indicator is known to be non-hazardous.
Step 2:
Make sure that all power is removed from the electrical equipment located in the
enclosure where the CYCLOPS Y or Z – Purge Indicator will be installed.
14
Step 3:
Choose a mounting location for the CYCLOPS Y or Z – Purge Indicator on the
enclosure in a location farthest from the protective supply gas inlet in order to allow
proper enclosure dilution, refer to Installation Flow Diagram (drawing number DO-
11007-F, page 33) for possible mounting location. The chosen location should also
permit adequate viewing of the green indicator light and proper purge exhaust venting.
Step 4:
Use Mounting Hole Template (drawing number DO-11008-C, page 34) to
accurately locate the mounting holes. Use the Mounting Hole Template to draw and
print a 1 to 1 scale drawing. Tape the 1 to 1 drawing to the outside of enclosure. The
required hole locations can then be transferred and / or marked using the centers of the
holes as shown on the 1 to 1 drawing.
Step 5:
Drill or punch all holes, per the sizes and locations specified on the Mounting
Hole Template (drawing number DO-11008-C, page 34).
Step 6:
Before mounting the CYCLOPS Y or Z – Purge Indicator install the o-ring
provided into its appropriate groove. Next, line up CYCLOPS Y or Z – Purge Indicator
on the outside of enclosure, aligning the CYCLOPS Y or Z – Purge Indicator to the
mounting holes produced in Step 5.
Step 7:
Using the five (5) each stainless steel, 1/4–20 UNC x 1/2 long screws, flat and
split lock washers provided, mount the CYCLOPS Y or Z – Purge Indicator to enclosure.
Tighten bolts until the o-ring seal is completely compressed against the surface of the
enclosure.
Step 8:
Connect 16 AWG, three-conductor wire (refer to Power Source Specifications
page 16) for power to the CYCLOPS Y or Z – Purge Indicator. Use Wiring Diagram
(drawing number DO-11009-F, page 35) for wire terminal strip locations.
15
Step 9:
Connect 20 AWG, two-conductor wire (refer to Power Source Specifications
page 16) for alarm signal to the CYCLOPS Y or Z – Purge Indicator. Use Wiring
Diagram drawing number DO-11009-F, page 35 for wire terminal strip locations.
Step 10:
After routing and terminating the wires into the terminal strips on the CYCLOPS
Y or Z – Purge Indicator, secure these wires using proper lead dress.
16
Electrical Power Installation:

NOTE: Refer to Power Source Specifications, Power Connection
table, and Wiring Diagram number DO-11009-F, page 36 for
connecting power to the CYCLOPS Y or Z – Purge Indicator.
Power Source Specification

115 Volt Model: 85 to 160 VAC, 47 to 63 Hz
230 Volt Model: 130 to 265 VAC, 47 to 63 Hz
12 Volt Model: 11 to 17 VDC, polarity-protected
24 Volt Model: 19 to 28 VDC, polarity-protected
Use 16 AWG stranded, 3 conductor copper or tin-plated copper power wire rated for
at least 250 VAC, of the required length.
WARNING: This apparatus must be earth grounded! Refer

to Figure 1 for proper ground connection details.
Figure 1
CAUTION: Electrical power must be free of spikes, sags, surges, or
electrical noise.

17
Power Connection
WIRE TERMINAL NUMBER
Hot 1 or + Supply Terminal Block – 1
Position – 1
Neutral or Hot 2 Terminal Block – 1
Or Return Position – 2
Ground, Earth, or Chassis Terminal Block – 1
Position – 3
Alarm Signal Installation:

NOTE: The CYCLOPS Y and Z – Purge Indicator provides a dry alarm
contact for use by the customer. For hook-up and use the alarm
contact provided by the Purge Indicator, consult the following Alarm
Source Specifications, Alarm Connection table, and Wiring Diagram
drawing number DO-11009-F, page 35.
Alarm Source Specifications

Alarm Contact is rated for 265V AC/DC, 150mA max.
Use 20 AWG solid, two conductor copper or tin-plated copper power wire rated for at
least 300 V at the required length.
Alarm Connection
ALARM TERMINAL TERMINAL NUMBER
Loss of Purge Pressure; Open on Alarm (Standard).
Closed on Alarm (Optional) Terminal Block – 2
Closed (Standard) Open (Optional) when pressure in Position – 1
enclosure being monitored is at or above 0.20 inches
H2O or (0.50 mbar).
Return for position one Terminal Block – 2
Position – 2

18
Section 5
Startup Procedures
Continuous Dilution Initial Startup Procedure:
The following procedure should be performed when initially starting up a system
using a Continuous Dilution purge gas inlet system and to calculate the manual dilution
time for any purged electrical equipment that uses the CYCLOPS Y or Z – Purge
Indicator to monitor the electrical equipment enclosure purge pressure.
WARNING: Do not open the electrical equipment enclosure in a

hazardous area even when de-energized unless area has been
properly tested and is known to not contain explosive materials.
WARNING: Before initially starting the equipment, electrical power

wiring must be checked for correct size and routing.
Step 1:
Make sure that area surrounding the CYCLOPS Y or Z – Purge Indicator and the
electronics enclosure the CYCLOPS Y or Z – Purge Indicator will be monitoring is
known to be non-hazardous.
Step 2:
After it has been assured that area surrounding the CYCLOPS Y or Z – purge
Indicator and the electronics enclosure the CYCLOPS Y or Z – Purge Indicator will be
monitoring is known to be non-hazardous, open electronics enclosure door.
19
Step 3:
After opening electronics enclosure door, install Continuous Dilution Purge Gas
Inlet Kit per installation instructions located in Options Users Manual page 13.
Step 4:
With electronics enclosure door still open, turn on purge protective gas supply to
electronics enclosure by turning the Continuous Dilution Purge Gas Inlet Kit shutoff
valve to the ON position and verify that enclosure is being supplied with purge gas.
Step 5:
After it has been verified that the enclosure is being supplied with purge gas,
turn off purge gas supply pressure to electronics enclosure at Continuous Dilution Purge
Gas Inlet Kit pressure regulator.
Step 6:
With protective gas supply pressure off at Continuous Dilution Purge Gas Inlet
Kit regulator, close and latch electronics enclosure door.
Step 7:
With electronics enclosure door closed and latched, apply power to electrical
equipment in enclosure, which should also apply power to the CYCLOPS Y or Z –
Purge Indicator.
WARNING: DO NOT TURN ON POWER TO ELECTRICAL
EQUIPMENT LOCATED IN ENCLOSURE CYCLOPS Y or Z – PURGE
INDICATOR WILL BE MONITORING PURGE PRESSURE, UNLESS
AREA HAS BEEN PROPERLY TESTED AND IS KNOWN NOT TO
CONTAIN EXPLOSIVE MATERIALS.
Step 8:
With power applied to the CYCLOPS Y or Z – Purge Indicator, raise the pressure
of the purge protective gas using the Continuous Dilution Purge Gas Inlet Kit pressure
regulator until the CYCLOPS Y or Z – Purge Indicator green light comes on.
20
Step 9:
With the CYCLOPS Y or Z – Purge Indicator green light on, turn off the
protective gas supply to electronics enclosure at purge gas shutoff valve on the
Continuous Dilution Purge Gas Inlet Kit manifold.
Step 10:
With protective gas supply turned off at Continuous Dilution Purge Gas Inlet Kit
shutoff valve, record the pressure reading on the Continuous Dilution Purge Gas Inlet
Kit pressure gauge. The recorded pressure will be used to calculate the purge dilution
time before power can be applied to electronics within the purged enclosure. Only the
pressure recorded when the Continuous Dilution Purge Gas Inlet Kit shutoff valve is in
the OFF position should be used to calculate the dilution time required before power
can be connected to the electronics with in the enclosure.
Step 11:
After recording the pressure reading on the Continuous Dilution Purge Gas Inlet
Kit pressure gauge, which will be used to calculate the purge dilution time before power
can be applied to electronics within the purged enclosure, turn on protective gas supply
to electronics enclosure by turning the Continuous Dilution Purge Gas Inlet Kit shutoff
valve to the ON position.
Step 12:
With purge protective gas being supplied to electronics enclosure and
CYCLOPS green indicator light illuminated, start the manual dilution time cycle. The
manual dilution time cycle must be long enough to ensure that at least five (5) times the
volume of free space in the electronics enclosure of purge protective gas is exchanged
before power can be manually applied to the electrical equipment inside the purged
enclosure.
NOTE: If you are using one of Purge Solutions Continuous Dilution

Purge Gas Inlet Kits to supply purge gas to an enclosure the
CYCLOPS Y or Z – Purge Indicator is monitoring refer to Purge
Solutions web site to use Dilution Time Software to calculate dilution
time for your size enclosure. The Dilution Software can only be used
if you are using a Purge Solutions Continuous Dilution Purge Gas
Inlet Kit, as the Dilution Time Software calculations are based on
empirical test performed with Purge Solutions Continuous Dilution
Purge Gas Inlet Kits and proprietary vents.
21
NOTE: The dilution time cycle can be reduced by increasing the

pressure of purge gas being supplied into the enclosure. Start at Step
9 and increase the pressure being read on the Continuous Dilution
Purge Gas Inlet Kit pressure regulator. Use the new pressure reading
to calculate a lower dilution time, repeating until an appropriate
dilution time is reached.
WARNING: The number of exchanged volumes may be higher in

some situations.
Step 13:
After a manual dilution time has been established, the manual dilution time and
Continuous Dilution Purge Gas Inlet Kit regulator gauge pressure reading should be
recorded for used during any future maintenance and / or service of the purge enclosure
being monitored by the CYCLOPS Y or Z – Purge Indicator.
NOTE: If purge pressure becomes less than 0.20 inches H2O (0.50
mbar), the CYCLOPS Y or Z – Purge Indicator does not disconnect
power to the electrical equipment within the enclosure it has been
monitoring, it will only alarm.
22
Manual Leakage Compensation Initial Startup

Procedure:
The following procedure should be performed when initially starting up a system
using a Purge Solutions Manual Leakage Compensation Purge Gas Inlet Kit and to
calculate the dilution time for any purged electrical equipment that uses the CYCLOPS
Y or Z – Purge Indicator to monitor the electrical equipment enclosure purge pressure.
WARNING: Do not open the electrical equipment enclosure in a

WARNING: Before initially starting the equipment, electrical power

wiring must be checked for correct size and routing.
NOTE: Refer to all ATEX, CEC, IECEx, NEC / NFPA certificates for any
Step 1:
Make sure that area surrounding the CYCLOPS Y or Z – Purge Indicator and the
known to be non-hazardous.
Step 2:
After assuring area surrounding the CYCLOPS Y or Z – purge Indicator and the
known to be non-hazardous, open electronics enclosure door.
Step 3:
After opening electronics enclosure door, install Manual Leakage Compensation
Purge Gas Inlet Kit per installation instructions located on page 20 of Option Users
Manual.
23
Step 4:
With electronics enclosure door still open, turn on purge protective gas supply to
electronics enclosure by turning the Manual Leakage Compensation Purge Gas Inlet Kit
shutoff valve to the ON position and verify that enclosure is being supplied with purge
gas.
Step 5:
After it has been verified that the enclosure is being supplied with purge gas,
turn off purge gas supply pressure to electronics enclosure at Manual Leakage
Compensation Purge Gas Inlet Kit pressure regulator.
Step 6:
With protective gas supply pressure to electronics enclosure turned off at
Manual Leakage Compensation Purge Gas Inlet Kit pressure regulator, assure that the
manual dilution valve on the Manual Leakage Compensation Purge Gas Inlet Kit
manifold block is in the OFF position.
Step 7:
After assuring that the manual dilution valve on the Manual Leakage
Compensation Purge Gas Inlet Kit manifold block is in the OFF position, make sure that
the leakage compensation valve is completely closed on the Manual Leakage
Compensation Purge Gas Inlet Kit manifold block.
Step 8:
After assuring that leakage compensation valve is completely closed on the
Manual Leakage Compensation Purge Gas Inlet Kit manifold block, close and latch
electronics enclosure door.
Step 9:
With electronics enclosure door closed and latched, apply power to electrical
equipment in enclosure, which should also apply power to the CYCLOPS Y or Z –
Purge Indicator.
WARNING: DO NOT TURN ON POWER TO ELECTRICAL
EQUIPMENT LOCATED IN ENCLOSURE CYCLOPS Y or Z – PURGE
INDICATOR WILL BE MONITORING PURGE PRESSURE, UNLESS
AREA HAS BEEN PROPERLY TESTED AND IS KNOWN NOT TO
CONTAIN EXPLOSIVE MATERIALS.
24
Step 10:
With power applied to the CYCLOPS Y or Z – Purge Indicator, turn on protective
gas supply pressure at Manual Leakage Compensation Purge Gas Inlet Kit pressure
regulator.
Step 11:
With protective gas supply pressure turned on at Manual Leakage
Compensation Purge Gas Inlet Kit pressure regulator and shutoff valve in the OFF
position, open leakage compensation valve on the Manual Leakage Compensation
Purge Gas Inlet Kit manifold block until the CYCLOPS Y or Z – Purge Indicator green
light comes on.
Step 12:
With the CYCLOPS Y or Z – Purge Indicator green light on, using jam nut, lock
leakage compensation valve in place on the Manual Leakage Compensation Purge Gas
Inlet Kit manifold block to maintain leakage compensation volume setting.
Step 13:
With the CYCLOPS Y or Z – Purge Indicator green light on and the leakage
compensation valve locked into place, record the pressure reading on the Manual
Leakage Compensation Purge Gas Inlet Kit pressure gauge. The recorded pressure
will be used to calculate the purge dilution time before power can be applied to
electronics within the purged enclosure. Only the pressure recorded when the Manual
Leakage Compensation Purge Gas Inlet Kit is in the OFF position should be used to
calculate the dilution time required before power can be connected to the electronics
with in the enclosure.
Step 14:
With leakage compensation purge protective gas being supplied to electronics
enclosure and CYCLOPS Y or Z – Purge Indicator green indicator light illuminated, start
the manual dilution time cycle by manually turning the dilution valve on the Manual
Leakage Compensation Purge Gas Inlet Kit shutoff valve to the ON position. The
manual dilution time delay must be long enough to ensure that at least five (5) times the
volume of free space in the electronics enclosure of purge protective gas is exchanged
before power can be manually applied to the electrical equipment inside the purged
enclosure.
some situations.
25
NOTE: If you are using one of Purge Solutions Manual Leakage

Compensation Purge Gas Inlet Kits to supply purge gas to enclosure
the CYCLOPS Y or Z – Purge Indicator will be monitoring refer to
Purge Solutions web site or Information CD to use Dilution Time
Software to calculate manual dilution time for your size enclosure.
The Dilution Software can only be used if you are using a Purge
Solutions Manual Leakage Compensation Purge Gas Inlet Kit, as the
Dilution Time Software calculations are based data from test
performed on Purge Solutions Manual Leakage Compensation Purge
Gas Inlet Kits and proprietary vents.
Step 15:
After the manual dilution time has elapsed, manually turn the Manual Leakage
Compensation Purge Gas Inlet Kit shutoff valve to the OFF position. Allowing only
enough purge gas volume into the now protected enclosure to maintain a pressure
above the required 0.20 inches H2O (0.50 mbar) through the leakage compensation
valve port.
Step 16:
After a manual dilution time has been established, the manual dilution time and
Manual Leakage Compensation Purge Gas Inlet Kit regulator gauge pressure reading
should be recorded for used during any future maintenance or service of the purge
enclosure being monitored by the CYCLOPS Y or Z – Purge Indicator.
NOTE: If purge pressure becomes less than 0.20 inches H2O (0.50
mbar), the CYCLOPS Y or Z – Purge Indicator does not shuts off
power to the electrical equipment it has been monitoring, it will only
alarm.
26
Continuous Dilution Maintenance or Service

Shutdown and Startup Procedure:
The following procedure should be performed when shutting down and re-starting
any purged electrical equipment that uses a Continuous Dilution Purge Gas Inlet Kit and
the CYCLOPS Y or Z – Purge Indicator to monitor the electronic equipment enclosure
purge pressure, which requires maintenance or service.
CAUTION: Do not open the electrical equipment enclosure in a


Indicator.

Step 1:
Properly disconnect power from all purged enclosure electronics that uses the
CYCLOPS Y or Z – Purge Indicator to monitor the electronics enclosure purge
pressure, which requires maintenance or servicing.
Step 2:
After power has been disconnected from the electronics within protective
enclosure, shut off purge gas supply at the Continuous Dilution Purge Gas Inlet Kit
shutoff valve. Not at the Continuous Dilution Purge Gas Inlet Kit pressure regulator.
The Continuous Dilution Purge Gas Inlet Kit pressure regulator setting should remain
the same to keep the purge gas CFM (LPM) the same as what was established during
the initial manual dilution time set up.
27
Step 3:
With power disconnected and purge gas supply properly shut off, the electronics
enclosure door may now be opened and maintenance or service can begin.

Step 4:
After maintenance and / or servicing have been completed, properly close and
latch electronics enclosure door.
Step 5:
After electronics enclosure door has been properly closed and latched, turn on
purge gas supply to electronics enclosure using the Continuous Dilution Purge Gas Inlet
Kit shutoff valve. Continuous Dilution Purge Gas Inlet Kit pressure regulator setting
should remain the same to keep the purge gas CFM (LPM) the same as what was
established during the initial manual dilution time set up.
Step 6:
With purge protective gas being supplied to the electronics enclosure, begin the
manual dilution time cycle. The manual dilution time cycle must be long enough to
ensure that at least five (5) times the volume of free space in the electronics enclosure
of purge protective gas is exchanged before power can be manually applied to the
electrical equipment in the purged enclosure.
some situations.
NOTE: The manual dilution time and Continuous Dilution Purge Gas
Inlet Kit regulator pressure should remain the same as what was
established during the Continuous Dilution Initial Startup Procedure.
Step 7:
After the manual time cycle has elapsed, power can then be apply to the
electrical equipment in the purged electronics enclosure.
28
Step 8:
After power has been applied to the electrical equipment in the purged
electronics enclosure, the CYCLOPS Y or Z – Purge Indicator green LED should be
illuminated, indicating the required 0.20 inches H2O (0.50 mbar) pressure is being
maintained within the now protected enclosure.
Step 9:
If power has been applied to the electrical equipment in the purged electronics
enclosure and the CYCLOPS Y or Z – Purge Indicator green LED is not illuminated,
check to see if the electronics enclosure door is properly closed and latched or a proper
Continuous Dilution Purge Gas Inlet Kit pressure regulator setting is being maintained.
NOTE: If green light does not remain on, check for the following
possible problems.
 Purge pressure is set too low at the pressure regulator.
 Enclosure door is open or allowing too much leakage.
 Continuous Dilution Purge Gas Inlet Kit shutoff valve has not
been put in the ON position.
29
Manual Leakage Compensation Maintenance or

Service Shutdown and Startup Procedure:
The following procedure should be performed when shutting down and re-starting
any purged electrical equipment that uses a Purge Solutions Manual Leakage
Compensation Purge Gas Inlet Kit and the CYCLOPS Y or Z – Purge Indicator to
monitor the electronics enclosure purge pressure, which requires maintenance or
service.
CAUTION: Do not open the electrical equipment enclosure in a


Indicator.

Step 1:
Properly disconnect power from all purged enclosure electronics that uses the
CYCLOPS Y or Z – Purge Indicator to monitor the electronics enclosure purge
pressure, which requires maintenance or servicing.
Step 2:
After power has been disconnected from the electronics within the protected
electronics enclosure, shut off purge gas supply at the Manual Leakage Compensation
Purge Gas Inlet Kit shutoff valve. Not at the Manual Leakage Compensation Purge Gas
Inlet Kit pressure regulator. The pressure regulator setting should remain the same to
keep the purge gas CFM (LPM) the same as what was established during the initial
manual dilution time set up.
30
Step 3:
With power disconnected and purge gas supply properly shut off, the electronics
enclosure door may now be opened and maintenance or service can begin.

Step 4:
After maintenance or servicing have been completed, properly close and latch
electronics enclosure door.
Step 5:
After electronics enclosure door has been properly closed and latched, turn on
purge gas supply to electronics enclosure using the Manual Leakage Compensation
Purge Gas Inlet Kit shutoff valve. Manual Leakage Compensation Purge Gas Inlet Kit
pressure regulator setting should remain the same to keep the purge gas CFM (LPM)
the same as what was established during the initial manual leakage compensation
dilution time set up.
Step 6:
With purge gas being supplied to the Manual Leakage Compensation Purge Gas
Inlet Kit, start the manual dilution time cycle by manually turning the Manual Leakage
Compensation Purge Gas Inlet Kit shutoff valve to the ON position. The manual
leakage compensation dilution time cycle must be long enough to ensure that at least
five (5) times the volume of free space in the enclosure of purge protective gas is
exchanged before power can be manually applied to the electrical equipment in the
purged enclosure.
some situations.
NOTE: The manual leakage compensation dilution time and Manual

Leakage Compensation Purge Gas Inlet Kit regulator pressure should
remain the same as what was established during the manual leakage
compensation initial startup procedure.
31
Step 7:
After the manual leakage compensation dilution time has elapsed, turn the
Manual Leakage Compensation Purge Gas Inlet Kit shutoff valve to the OFF position.
Allowing only enough purge gas volume, into the now protected enclosure, to maintain a
pressure above the required 0.20 inches H2O (0.50 mbar) from the leakage
compensation valve port.
Step 8:
After the manual leakage compensation time cycle has elapsed, power can then
be applied to the electrical equipment in the purged enclosure.
Step 9:
After power has been applied to the electrical equipment in the purged
enclosure, the CYCLOPS Y or Z – Purge Indicator green LED should be illuminated,
indicating the required 0.20 inches H2O (0.50 mbar) pressure is being maintained within
the now protected enclosure.
Step 10:
If power has been applied to the electrical equipment in the purged enclosure
and the CYCLOPS Y or Z – Purge Indicator green LED is not illuminated, check to see
if the electronics enclosure door is properly latched or a proper Manual Leakage
Compensation Purge Gas Inlet Kit pressure regulator setting is being maintained.
NOTE: If green light does not remain on, check for the following
possible problems.
 Purge pressure is set too low at the pressure regulator.
 Purge pressure is set too low at the leakage compensation
valve.
 Electronics enclosure door is open or allowing too much
leakage.
32
Section 6
Documents
Flow Diagram:
Page 33 – Illustration showing one position the CYCLOPS Y or Z – Purge
Indicator and Continuous Dilution Purge Gas Inlet Kit can be mounted on enclosure.
Mounting Hole Template:

Page 34 – A dimensioned drawing for creating a (1 to 1) scale drawing, helpful in
transferring the position of the necessary mounting holes. Use this after determining
the optimal location for the CYCLOPS Y or Z – Purge Indicator.
Wiring Diagram:
Page 35 - This drawing details the correct power and dry contact alarm-wiring
hookup.
Class I, Division 1 Intrinsically Safe Wiring

Diagram:
Page 36 - This drawing details the correct power hookup for all CYCLOPS Y –
Purge Indicators being installed in a Class I, Division 1 hazardous area.
33
34
35
36
37
Section 7
Options
Continuous Dilution Purge Gas Inlet Kit Introduction:
Continuous dilution is a method of maintaining pressure in an enclosure in which
after the enclosure has been pre-purged the protective gas is passed continuously
through the enclosure at a pressure above that of the specified minimum and
discharged to the outside atmosphere through an exhaust vent. The same volume of
purge gas is maintained during and after the dilution cycle.
Purge Solutions offers three sizes of continuous dilution models, the first size is
our Small Continuous Dilution Purge Gas Inlet Kit for enclosures with a volume up to 15
cubic feet (425 liters). Model number PSO-SCD-A is our small aluminum version and
model number PSO-SCD-S is our small stainless steel version. Purge gas supply inlet
to Small Continuous Dilution Purge Gas Inlet Kit regulator is 1/4-18 FNPT.
The second size we offer is our Medium Continuous Dilution Purge Gas Inlet Kit
for enclosures with volumes up to 75 cubic feet (2,125 liters). Model number PSO-
MCD-A is our medium aluminum version and model number PSO-MCD-S is our
medium stainless steel version. Purge gas supply inlet to Medium Continuous Dilution
Purge Gas Inlet Kit regulator is 1/2-14 FNPT.
The third size we offer is our Large Continuous Dilution Purge Gas Inlet Kit for
enclosures with volumes up to 200 cubic feet (5,663 liters). Model number PSO-LCD-A
is our large aluminum version and model number PSO-LCD-S is our large stainless
steel version. Purge gas supply inlet to Large Continuous Dilution Purge Gas Inlet Kit
regulator is 1/2-14 FNPT. All Continuous Dilution Purge Gas Inlet Kits include input
fittings, regulator, gauge, bracket and mounting hardware.
38
Manual Leakage Compensation Purge Gas Inlet Kit

Introduction:
Manual leakage compensation allows a higher volume of protective gas supply
to be manually selected to speed up dilution of potentially flammable materials to an
acceptable level, permitting a more-rapid application of initial power, or restoration of
power to protected electrical equipment, after service. When the dilution cycle has
elapsed, the large volume of purge gas can be manually turned off. A volume of purge
gas larger than the leak rate of the enclosure will be introduced into the now protected
enclosure to maintain at least 0.20 inches H2O (0.50 mbar).
Purge Solutions offers three sizes of leakage compensation models, the first
size is our Small Manual Leakage Compensation Purge Gas Inlet Kit for enclosures with
a volume up to 15 cubic feet (425 liters). Model number PSO-SMLC-A is our small
aluminum version and model number PSO-SMLC-S is our small stainless steel version.
Purge gas supply inlet to Small Manual Leakage Compensation Purge Gas Inlet Kit
regulator is 1/4-18 FNPT.
The second size we offer is our Medium Manual Leakage Compensation Purge
Gas Inlet Kit for enclosures with volumes up to 75 cubic feet (2,125 liters). Model
number PSO-MMLC-A is our medium aluminum version and model number PSO-
MMLC-S is our large stainless steel version. Purge gas supply inlet to Medium Manual
Leakage Compensation Purge Gas Inlet Kit regulator is 1/2-14 FNPT.
The third size we offer is our Large Manual Leakage Compensation Purge Gas
Inlet Kit for enclosures with volumes up to 200 cubic feet (5,663 liters). Model number
PSO-LMLC-A is our large aluminum version and model number PSO-LMLC-S is our
large stainless steel version. Purge gas supply inlet to Large Manual Leakage
Compensation Purge Gas Inlet Kit regulator is 1/2-14 FNPT. All Leakage
Compensation Purge Gas Inlet Kits include input fittings, regulator, gauge and manifold
block.
39
Back-Up Vent Introduction:

To protect the enclosure from over pressure; Purge Solutions offers three sizes
of back-up vents. The first size is our Small Back–Up Vent for enclosures with a volume
up to 15 cubic feet (425 liters). Model number PSO-SBUV-S is our small side mount
version and model number PSO-SBUV-T is our small top mount version.
The second size we offer is our Large Back-Up Vent for enclosures with
volumes up to 75 cubic feet (2,125 liters). Model number PSO-MBUV-S is our medium
side mount version and model number PSO-MBUV-T is our medium top mount version.
The third size we offer is our Large Back-Up Vent for enclosures with volumes
up to 200 cubic feet (5,663 liters). Model number PSO-LBUV-S is our large side mount
version and model number PSO-LBUV-T is our large top mount version. All Back-Up
Vents are constructed of 316 stainless steel and come with all mounting hardware.
40
Back-Up Purge Gas Kit: In the event the initial protective purge gas supply is
lost, this kit insures that a back up source of protective purge gas is automatically
applied to the protected enclosure. Purge Solutions model number PSO-BUPG-K has
inlets and outlet which are 3/8 – 18 FNPT.
NOTE: The Back-Up Purge Gas Kit requires a minimum air supply
pressure of 80 psig to function properly.
Protective Gas Loss Indicator Kit: An explosion-proof differential

pressure switch may be installed to provide an alarm contact output signal to indicate
the loss of primary purge gas supply. While a second can be installed to provide loss of
back-up purge gas. Model number is PSO-PGLI-K.
Differential Pressure Gauge Kit: Purge Solutions also offers an all

stainless steel Differential Pressure Gauge Kit, which can be mounted on the side, top
or bottom of an enclosure. Model number PSO-DPG-L is our left side mount version,
model number PSO-DPG-R is our right side mount version, model number PSO-DPG-T
is our top mount version and model number PSO-DPG-B is our bottom mount version.
Purge Gas Supply Blower: For applications were compressor gas is not
available or has oil, which can introduce hydrocarbons into the purge enclosure, Purge
Solutions offers a Purge Gas Supply Blower. The Purge Gas Supply Blower will be
mounted in a non-hazardous area, were the blower fan within the system, will move up
to 131 CFM (3,709 LPM) purge air through a 2 inch diameter (50.8 mm diameter) tube
to the enclosure located within the hazardous area. The Purge Gas Supply Blower is
constructed of 316 stainless steel and is available in 115VAC or 230VAC. The model
number for the 115VAC system is PSO-GSB-1 and the model number for the 230VAC
system is PSO-GSB-2.
NOTE: The Purge Gas Supply Blower is not certified for hazardous area
installation and use Purge Gas Supply Blower must be installed and
used within a non-hazardous area.
41
Section 8
Getting Help
Getting Help:
Answers to many questions concerning the CYCLOPS Y or Z – Purge
Indicator or any of our other products we offer can be found in this manual. If a
problem or question is encountered that is not covered in the documentation
provided, assistance is available Monday through Friday (except holidays), from 8
a.m. to 5 p.m. United States central time. To obtain assistance, please call Purge
Solutions at 832-368-7166.
For assistance during times other than normal business hours, consult our
World Wide Web Internet site at http://www.purgesolutions.com. This site
includes equipment information, news releases, and other information. E-mail can be
sent to info@purgesolutions.com.
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··UL & cUL listed pipe mount
based & light
··modules, indoor
··CSA certified for indoor use
SemiStat® MicroStat®v
··60 flashes per minute ··Available in five lens colors
··Flashing and Steady (amber, blue, clear, green & red)
Burn LED ··Quick and easy lens restacking
··Choice or tri-color or quad ··Type 4X enclosure
color models ··Surface or integrated 3/4” NPT
··Piezo sounder with pipe mount
volume control produces ··Crosshatch lens provides bright
60 dB @ 10ft. full-face illumination
··For indoor use only
··Surface Mount
Litestak
Lamp Overall Dim (In.) Federal Item Shpg.
Description Color Life (Hr.) Voltage Amps H Dia. Signal Model No. Wt.
Bases
Standard Base --- --- 120VAC --- 4 4.38 LSB-120 3T949 1.0
Surface-Mount --- --- 120VAC --- 0.25 4.38 LSBS 1N896 0.6
Light Modules
Incandescent Light Amber 7000 120VAC 0.13 3.25 4 LSL-120A 3T950 0.7
Incandescent Light Blue 7000 120VAC 0.13 3.25 4 LSL-120B 3T951 0.7
Incandescent Clear 7000 120VAC 0.13 3.25 4 LSL-120C 3T952 0.7
Incandescent Light Green 7000 120VAC 0.13 3.25 4 LSL-120G 3T953 0.7
Incandescent Light Red 7000 120VAC 0.13 3.25 4 LSL-120R 3T954 0.7
LED Amber 100,000 120VAC 0.04 3.25 4 LSLD-120A 3WU45 0.7
LED Blue 100,000 120VAC 0.04 3.25 4 LSLD-120B 3WU46 0.7
LED Clear 100,000 120VAC 0.04 3.25 4 LSLD-120C 3WU47 0.7
LED Green 100,000 120VAC 0.04 3.25 4 LSLD-120G 3WU48 0.7
LED Red 100,000 120VAC 0.04 3.25 4 LSLD-120R 3WU49 0.7
Horns
Horn Module --- --- 120VAC 0.04 3 1/4 4 LSH-120 4RM47 0.8
SemiStat
Lamp Overall Dim. (In.) Federal Item Shpg.

Type Life (Hr.) Voltage Amps H W D Signal Model No. Wt.
4-Light 100,000 24VAC/VDC 0.18 8.14 3.55 1.55 SCB-024QC 5LE18 1.0
3-Light 100,000 24VAC/VDC 0.18 8.14 3.55 1.55 SCB-024TC 5LE19 1.0
Warning Lights
When you approach an area that requires warning but the high ambient
noise level is a hindrance, look to Grainger for the complete line of Federal Signal warning lights.
Rotating
For areas where caution should be exercised, such as process control, start-up, overhead door
movement, or where action or movement requires attention, Grainger recommends a rotating light.
··40 watt incandescent lamp Flashing

A ··120VAC ··Available in 12VDC,
··Available in 2 dome colors B 24VDC & 36VDC
··UL, cUL Listed and ··Available in 2 dome colors
CSA Certified ··1/2” pipe mount or surface mount
··Type 4X ··UL Listed, CSA Certified
··1/2” pipe mount or surface mount ··Type 3R
Battery Powered
··200 watt sealed beam ··Uses two standard 6VDC
C ··120VAC D
··Available in 2 dome colors lantern batteries
··Available in 12VDC
··Pivoting lamp yoke ··Available in 2 dome colors
··Heavy duty die-cast housing ··300 hour, 5W
··UL, cUL Listed and CSA Certified
··1” pipe mount or surface mount incandescent lamp
··Type 3R weatherproof enclosure
Warning Lights Flashing Lights
Dimensions Federal
Lamp Flashes Federal
(In.) Flasher Flashes Signal Item Shpg.
Peak Life Per Signal Item Lots Shpg.
Key Color Voltage Amps Candela (Hr.) Minute H Dia. Model No. Qty Wt Key Type Per Min. Model No. Wt.
A Red 120VAC 0.36 2100 2000 60 6.26 5.13 121S-120R 4A961 3 2.1 D Incandescent 65 BPL26 1N744 2.4
A Amber 120VAC 0.36 2100 2000 60 6.26 5.13 121S-120A 4A962 3 2.1 M Strobe 60 BPL26ST 5WF83 3.8
C Red 120VAC 0.80 20,000 2000 60 11.38 9.12 371L-120R 1N747 3 11.8 Surface-Mount Strobe Lights
C Amber 120VAC 0.80 20,000 2000 60 11.38 9.12 371L-120A 1N748 3 11.8 A Clear Strobe 80 VALS-120C 1N741 0.3
Warning Light Mounting Kit LWMB2 5T588 4 2.9 A Red Strobe 80 VALS-120R 1N740 0.3
Electraflash Flashing
Dimensions (In.)
Federal
Key Color Voltage Amps Peak Candela Lamp Life (Hr.) Flashes Per Minute H Dia. Signal Model Item No. Shpg. Wt
B Red 12VDC 3.0 325 1000 70 5 5.5 141-012R 1N908 1.1
B Amber 12VDC 3.0 325 1000 70 5 5.5 141-012A 1N910 1.1
B Amber 24VDC 0.90 125 7000 70 5 5.5 141-024A 1N906 1.1
B Amber 36VDC 0.90 200 500 70 5 5.5 141-036A 1N904 1.1
Strobe
For areas requiring a warning potential dangers like toxic release, treacherous
walkways and moving robotic equipment, Grainger offers Federal Signal strobe warning lights.
··Uses two standard 6VDC ··Available in 12-24VDC, ··Available in 24VDC

E lantern batteries F 120VAC and 240VAC G
··Available in 12VDC ··Available in 2 lens colors and 120VAC
··Available in 3
··Available in 2 lens colors ··10,000 hour high-intensity
··Type 3R weatherproof strobe tube
dome colors
··Incandescent
enclosure ··1/2” pipe mount
··Magnetic mount ··UL, cUL Listed and CSA Certified lamp included
··Screw on lens
··Type 4X, IP66 enclosure ··Surface, Edison &
··Available in 24VDC,
120VAC and 240VAC ··Available in 12-24VDC, 1/2” pipe mount
··Available in 2 lens colors I ··UL, cUL Listed
H ··10,000 hour strobe tube
120VAC and 240VAC
··Available in 2 dome colors and CSA Certified
··1/2” pipe mount ··10,000 hour high-intensity ··Type 4X enclosure
··Dome guard optional strobe tube
··UL & cUL Listed CSA ··3/4” pipe mount
Certified, CSFM Approved ··UL, cUL Listed and CSA Certified
··Type 4X, IP66 enclosure ··Type 4X, IP66 enclosure
··Marine rated ··Marine rated
Explosion-Proof
Key Color Lamp Life (Hr.) Voltage Amps H D Federal Signal Model Item No. Shpg. Wt.
G Amber 10,000 120VAC 0.6 15.63 8.82 27XST-120ASC 1N751 18.1
G Red 10,000 120VAC 0.6 15.63 8.82 27XST-120RSC 1N750 17.9
Hazardous Location
D Red 10,000 120VAC 0.32 9.25 5.5 151XST-120R 1N754 4.5
D Amber 10,000 120VAC 0.32 9.25 5.5 151XST-120A 1N755 4.5
F Red 10,000 120VAC 0.32 7.5 5.5 225XST-120R 1N900 2.5
F Amber 10,000 120VAC 0.32 7.5 5.5 225XST-120A 1N902 2.5
··Available in 120VAC ··Available in 12VDC, 24VDC C ··Available in 120VAC

A ··Available in 2 lens colors B 120VAC & 240VAC ··Available in 2 dome colors
··40,000 hour strobe tube ··Available in 3 dome colors ··1/2” pipe mount or
··Flush or surface mount ··Low profile 2.6H x 2.3W x 5L surface mount
··UL Listed, CSA Certified ··Surface mount ··10,000 hour strobe tube
··Type 3R, IP44 enclosure ··UL Listed ··UL, cUL Listed and
··Type 4X, IP65 enclosure CSA Certified
··Type 4X, IP66 enclosure
D ··Available in 12-48VDC
··Available in 2 dome colors
E ··Available in 12VDC, F ··Available in 120VAC
··Low profile – only 24VDC & 120VAC ··Available in 2 dome colors
··Available in 2 dome colors ··Single or double
3-5/8” high
··Screw on dome ··4,000 hour strobe tube flash strobe
··Surface mount ··1/2” pipe mount or ··10,000 hour strobe tube
··UL, cUL Listed & CSA Certified surface mount ··1/2” pipe mount
··Type 4X enclosure ··UL Listed & CSA Certified ··UL, cUL Listed & CSA Certified
··Type 3R ··Type 3R, IP45 enclosure
Electraflash Strobe
Key Color Voltage Amps Peak Lamp Flashes Dim. (In.) Federal Item Shpg
Candela Life Per Signal No. Wt Streamline Low-Profile Mini Strobes
H Dia.
(Hr.) Minute Model
E Red 12VDC 0.18 100,000 4000 80 5 5.5 141ST-012R 3T943 1.1 Key Color Voltage L W H Fed Item Shpg.
Sig No. Wt.
E Amber 12VDC 0.18 100,000 4000 80 5 5.5 141ST-012A 3T944 1.1 Model
E Red 24VDC 0.08 100,000 4000 80 5 5.5 141ST-024R 3T945 1.1 B Green 120VAC 5 2.3 2.6 LP1- 4RM45 0.6
E Amber 24VDC 0.08 100,000 4000 80 5 5.5 141ST-024A 3T946 1.1 120G
E Red 120VAC 0.06 100,000 4000 80 5.25 5.5 141ST-120R 3T947 1.2 B Red 120VAC 5 2.3 2.6 LP1- 4RM46 0.6
E Amber 120VAC 0.06 100,000 4000 80 5.25 5.5 141ST-120A 3T948 1.2 120R
Strobe Warning Lights

Key Color Voltage Amps Peak Candela Lamp Life (Hr.) Flashes Per Minute Dimensions (In.) Fed Signal Model Item No. Lots Qty Shpg. Wt
H Dia.
C Red 120VAC 0.25 1,000,000 10,000 90 5.25 3.94 FB2PST-120R 4A963 3 2.12
C Amber 120VAC 0.25 1,000,000 10,000 90 5.25 3.94 FB2PST-120A 4A964 3 2.12
F Red 120VAC 0.60 1,000,000 10,000 80 8.5 5.7 131DST-120R 4A965 3 2.6
F Amber 120VAC 0.60 1,000,000 10,000 80 8.5 5.7 131DST-120A 4A966 3 2.6
Warning Light Mounting Kit LWMB2 5T588 4 2.9
Economical
Key Mounting Type Color Voltage Amps NEMA Rating Dimensions (In.) Federal Signal Item Shpg.
Model No. Wt.
H Dia
G A19 Screw-In Amber 120VAC 0.1 3R 6.06 3.18 LP3E-120A 5WF84 0.7
G A19 Screw-In Red 120VAC 0.1 3R 6.06 3.18 LP3E-120R 5WF85 0.7
G 1/2” Threaded w/Locknut Amber 12-48VDC 0.44-0.1 4X 5.81 3.18 LP3M-012-048A 5WF86 0.7
G 1/2” Threaded w/Locknut Green 12-48VDC 0.44-0.1 4X 5.81 3.18 LP3M-012-048G 5WF87 0.7
G 1/2” Threaded w/Locknut Red 12-48VDC 0.44-0.1 4X 5.81 3.18 LP3M-012-048R 5WF88 0.7
G 1/2” Threaded w/Locknut Amber 120VAC 0.1 4X 5.81 3.18 LP3M-120A 5WF89 0.7
G 1/2” Threaded w/Locknut Green 120VAC 0.1 4X 5.81 3.18 LP3M-120G 5WF90 0.7
G 1/2” Threaded w/Locknut Red 120VAC 0.1 4X 5.81 3.18 LP3M-120R 5WF91 0.7
G 1/2” Threaded w/Locknut Amber 120VAC 0.1 4X 5.75 3.18 LP3P-120A 5WF92 0.7
G 1/2” Threaded w/Locknut Red 120VAC 0.1 4X 5.75 3.18 LP3P-120R 5WF93 0.7
G Flat Surface Amber 12-48VDC 0.44-0.1 4X 5.69 3.18 LP3T-012--048A 5WF94 0.8
G Flat Surface Red 12-48VDC 0.44-0.1 4X 5.69 3.18 LP3T-012--048R 5WF95 0.7
D Flat Surface Amber 12-48VDC 0.44-0.1 4X 3.63 5 LP6-012-048A 5WF96 0.8
D Flat Surface Red 12-48VDC 0.44-0.1 4X 3.63 5 LP6-012-048R 5WF97 0.8
Audible Signals
When you enter a corrosive atmosphere area with high noise levels, extreme temperatures, dust and
humidity, Grainger offers a wide array of Federal Signal audible signals.
A Vibratone®Horn E Weatherproof Back Box
Low current horn used for producing For weatherproof outdoor surface
coded blast or sustained tones for mounting of No. 4A967 horn, No.
paging, and for start and dismissal 1N742 siren, No. 4A960 and No.
signaling indoors or outdoors (with 5T589 bells, and No. 5LE20 speaker
No. 4A969 weatherproof box). Gray amplifier. Cast-aluminum gasketed
powder coat finish with mounting weatherproof box complete with
screws included. UL listed; CSA mounting lugs and threaded conduit
Certified; FM approved. openings, 1/2” and 3/4”.
B Electronic Siren F Flush-Mount Trim
Produces one of four different high Gasketed trim ring is used to mount
decibel tone outputs: wail, yelp, No. 4A967 Vibratone Horn. Made
horn or temporal whoop. Rugged, of 18-gauge R10 aluminum with
highimpact plastic construction. neoprene gaskets between mounting
Resistant to ultraviolet light and is surface and plate and between plate
rated NEMA 3R when mounted on and horn.
No. 4A969 weatherproof box. Unit
o
can be pointed anywhere within 360
half sphere of area. UL listed indoor/
outdoor; cUL listed.
C Resonating Horn G Telephone Extension Ringers

Electric horn produces sound by Designed to draw attention to a
means of a diaphragm, which ringing phone in high noise areas.
resonates a column of air. Features Activated by a ringing signal of
corrosion resistant, cast- an analog phone (between
aluminum housing with 40-150VAC @16-60
brass projector. Gray Hz). Feature die-cast
powder coat finish. Duty aluminum housing and
cycle of five minutes on, five minutes gray powder coat paint.
off. UL listed indoor/outdoor, CSA Requires duplex jack, not included
certified. (order No. 6C080). UL listed for
indoor use. FCC approved.
D Vibratone® Bells H SelecTone® Signal
Vibrating bells signal general alarm, Self-amplified, solid-state signal

start and dismissal, and danger device with gain control Requires
warnings. Mount on standard outlet one tone module No. 1N894 listed
box. Outdoor applications use No. below (order separately). Used for
4FA969 weatherproof box. Gray coded paging, general alarm, start
powder coat finish. UL listed, CSA and dismissal, evacuation, and other
certified, and FM approved. specific warnings. Gray powder coat
finish. UL listed indoor/outdoor. CSA
approved.
Audible Signals
I SelecTone® Speaker Amplifier L Siren
Produces crisp, clear tones, digital Electronic Siren capable of producing
voice messages, and live public three different high decibel tones from
address. Internal gain control allows the same unit. Designed for stand-
output adjustment. Solid-state alone, high-output in any application
circuitry. NEMA 3R enclosure. Suitable where multiple tones are needed but
for outdoor use when installed with No. 4A969 weatherproof voice paging is not required.
box. Flush or surface mount. UL listed, cUL Listed, CSA certified
and CSFM approved.
M SelecTone® Speaker/Amplifier
J Electric Horn Loudspeaker has built-in volume

control. Use with Universal Tone
Vibrating stainless steel diaphragm Module No. 1N894 to produce one
produces 100dB at 10 feet. of 32 different tones. 86dB to 110dB
Copper-free, corrosion-resistant, at 10 feet.
cast aluminum enclosure is tapped
for 3/4” mounting feature internal
volume control. NEC Class 1, Div. 1, Groups C & D; Class II,
Div. 1 Groups E, F, & G; Class III. UL listed, cUL listed and CSA
certified. N Universal Tone Module
For exclusive use with No. 4A968,

K Die-Cast Zinc Horn
No. 3WU52, and No. 3WU53
audible signals. Micro-controller
Zinc housing with polyurethane based tone generator is capable of
finish; surface or flush-mount. For producing any one of 32 different
coded or sustained tones. NEC Class tones, including; Wail, Yelp, Hi Lo,
1, Div. 2, Groups A, B, C & D; Class Bell, Yeow, Horn, Beep, Stutter, Slow Whoop, Gradual Horn,
II, Div. 2, Groups F & G; Class III. Temporal Slow Whoop, Westminster Chime, Evac, Air Horn,
Chime, 6 Eurotones and more.
Audible Signaling Devices

Key Type of Signal Required Power Amps Overall Dim. (In.) Federal Signal Model Item No. Lots Qty. Shipg Wt.
H W D
A Horn, 100 dB @ 10 ft 120VAC, 60 Hz 0.18 4 4 2.5 350-120-30 4A967 4 1.9
B Siren, 111 dB @ 10ft 24VDC, 120/240VAC 0.60 12 14.5 9 SST-MV 1N742 3 6.0
C Horn, 105 dB @ 10 ft 120VAC, 60 Hz 0.75 8 8 19.75 55-120-1 1N745 3 6.4
D 4” Bell, 98 dB @ 10 ft 120VAC, 60 Hz 0.08 4.3 4.3 2.25 504-120 4A960 4 1.5
D 6” Bell, 100 dB @ 10 ft 120VAC, 60 Hz 0.08 6 6 2.63 506-120 5T589 4 2.5
E Weatherproof Box -- -- 4.53 4.53 2.44 WB 4A969 4 1.2
F Trim Plate -- -- 5.56 0.25 --- TR 5LE17 4 0.3
G 4” Bell, 98 dB @ 10 ft 120VAC 0.08 4.20 4.81 5.11 TELB 3LY37 4 3.2
G Horn, 100 dB @ 10 ft 120VAC 0.18 4.81 4.81 5.11 TELH 3LY38 4 3.9
H 110 dB @ 10 ft 120VAC, 60 Hz 0.27 8 12.25 8.25 300GC-120 4A968 2 6.0
I 88 dB @ 10 ft 120VAC, 60 Hz 0.04 4.5 4.5 3.44 50GC-120BG 5LE20 3 2.1
N Tone Module -- -- --- --- --- UTM 1N894 4 0.3
Hazardous Location Audible and Explosion-Proof Signaling Devices

Key Voltage Amps Dimensions (In.) Federal Signal Model Item No. Shpg. Wt.
H W/Dia. D
M 24VDC 0.55 12.3 8 8.25 300GCX-024 3WU52 5.1
M 120VAC 0.27 12.3 8 8.25 300GCX-120 3WU53 6.2
K 120VAC 0.18 5.33 5.33 3.66 350WBX-120 3WU54 3.5
J 120VAC 0.2 7.63 6.5 6.5 31X-120-3 1N749 8.1
L 24VDC, 120 & 240VAC 210 mA 17 13.1 16.3 SSTX-MV 3WU51 22.5
Fire Alarm Initiating (Input) Devices
Grainger offers signaling systems that are designed to ensure safety, sound alarms, increase productivity,
or provide a means of communication. Federal Signal initiating devices are the cost–effective method of
activating audible and visual signals.
Fire Alarm Pull Stations Initiating
Can be used as either break-glass or non-break-glass Description Coverage Federal Signal Stock Shpg.
(Sq. Ft.)* Model No. Wt.
type. Stations mount on 4” square single gang electrical
boxes. Die-cast body is painted red. Single-Action Fire Alarm Station --- FSF103 4BY45 3.8
Dual-Action Fire Alarm Station --- FSF102 4BY44 1.4
Combination Heat Detector - 200 2500 FSF101SB 4BY43 0.6
Heat Detectors Combination Heat Detector - 135 2500 FSF100 4BY42 0.5
··Surface mount Ionization Type Smoke Detector 900 FSF110SB 4BY51 0.7
··FM approved Photoelectric Type Smoke Detector 900 FSF109 4BY50 0.9
··UL listed Duct Smoke Detector --- FSF107 4BY48 4.4
Smoke Sampling Tube --- FSF108 4BY49 2.4
(*) Coverage at 30-ft. spacing, except Nos. 4BY43 and 4BY42 are 50-ft. spacing
Combination - 135o
Ionization Type
Detector activates either at a fixed temperature of 135oF
Responds quickly to fast-burning, low-smoke fires by sensing air-
or at a 15oF per minute rate-of-rise in temperature.
born combustion particles.
Combination - 200o
Photoelectric Type
Detector activates at a fixed temperature of 200oF
Detects dark or thick smoke and responds quickly to slow-smolder-
or at a 15oF per minute rate-of-rise in temperature.
ing, high-smoke fires.
Duct
Activates when combustion particles exceed 2.3% per feet in air
Smoke Detectors moving at 100
··LEDs on units give visual to 4000 feet per minute. Includes housing and detector; use with
indication of alarm activation sampling tube no. 4BY49.
··Include test switch Smoke Sampling Tube
··UL listed 5-foot tube for use with detector No. 4BY48 can be trimmed for
shorter duct distances.
Fire Alarm Signaling (Output) Devices

Fire Alarm Bell Fire Alarm Horns and Strobes
6” vibrating motor bell is red and includes mounting plate. Indoor units provide combination of synchro-
Fire Alarm Horn nized audible and visual signals. Horn pattern
High energy horn can be operated in continuous or tem- can be set to continuous or temporal (On-Off)
poral (on-off) mode. model. Includes trim plate.
Fire Alarm Chime Synchronization Module
Indoor-mount chime has adjustable volume Synchronizes strobes or horn/strobes in fire
Fire Alarm Strobes alarm systems up to 3 amps per circuit.
Indoor strobes flash once per second. Includes trim plate. Meets UL 1971 standards.
Signaling (Output) Devices

Description Dimensions (In.) Alarm Current (Amps) Operating Voltage (VDC) Flash (Candela) Peak Output (dBA at 10 Ft.) Fed Signal Model Stock No. Shpg. Wt.
H W L
Fire Alarm Bell 7 3 7 0.012 24 --- 87 FSF106-024R 4BY41 1.4
Fire Alarm Horn 4 3 4 0.030 24 --- 85 FSF104-024R 4BY47 0.6
Fire Alarm Chime 6 3 6 0.040 24 --- 85 FSF105-024R 4BY46 0.5
Fire Alarm Strobe 6 3 6 0.016 24 75/110 --- FSF205ST-024R 4BY61 0.7
Fire Alarm Strobe 6 3 6 0.073 24 15/75 --- FSF204ST-024R 4BY54 0.7
Fire Alarm Horn/Strobe 6 3 6 0.089 24 15/75 88 FSF200ST-024R 4BY53 0.7
Fire Alarm Horn/Strobe 6 3 6 0.149 24 110 87 FSF201ST-024R 4BY60 0.7
Sychronization Module 6 3 6 0.009 24 --- --- FSF206 4BY62 0.6
Vehicular Warning Lights
Let Grainger get your vehicle ready for safety. Federal Signal’s attention-getting warning signals can attach to
vehicles such as fork lifts, dump trucks, waste disposal vehicles and tow trucks.
··80,000 candelas per flash

A ··Meets SAE J845 Class 1 requirements B Strobe
··Large parabolic reflector ··65 flashes per minute
··55 watt halogen bulb ··Hard wired
··Dome and base are impact-resistant ··Provides quad flash 9 joules
··polycarbonate ··Conforms to SAE J1318
··Magnetic Mount with 10 ft. cord with ··Class 2 requirements
··cigarette lighter plug or hard wire
··55 watt halogen lamp produces D Parabolic

··68,000 candelas ··95 flashes per minute
C ··95 or 175 flashes per minute ··55 watt halogen lamps produce
··Dome and base are ··80,000 candelas
··impact-resistant polycarbonate ··Magnetic mount with 10 ft. cord
··Swivel and magnetic mount with ··with cigarette lighter plug
··10 ft. cord with cigarette lighter plug ··Conforms to SAE J845
··Conforms to SAE J845 ··Class 1 requirements
E ··1,000 hour lamp life Pulsator
··Meets SAE J1318 Class 2 requirements Key Color Voltage Amps Flashes Dim. Federal Item Shpg
··Helical halogen strobe tube Per (In.) Signal No. Wt.
··Dome and base are Min.

H Dia
Model
··impact-resistant polycarbonate Magnetic Mount

C Amber 12-48VDC 0.9-0.25 80 4 6.5 211682-02 2YE24 1.6
Hard Wire
Sentry C Amber 12-48VDC 0.9-0.25 80 4 6.5 211823-02 2YE23 1.6
Key Color Voltage Amps Lamp Flashes Dim. (In.) Fed Item Shpg. C Amber 12-48VDC 1.4 120 6 6.5 211832 3WU43 1.9
Life Per Signal No. Wt.
H Dia.
(Hrs.) Min. Model
Magnet Mount Rotating Light
A Amber 12VDC 4.3 1000 95 6.5 6.4 448142 3WU44 2.8
Key Dome Voltage Amps Dimensions Federal Item Shpg
Highlighter Mini Lightbars Color Signal No. Wt.
L W R
Model
B Strobe Amber 12- --- 15 9 5 453201- 2YE25 5
24VDC 02 E Amber 12VDC 4.3 5.1 3.8 4.8 FB3SM-A 4RM42 2.1
D Parabolic Amber 12VDC 8.6 15.8 7 5.3 HLCM-A 3LY39 8.1 E Blue 12VDC 4.3 5.1 3.8 4.8 FB3SM-B 4RM43 2
Back Up Alarms
Designed for use in a wide variety of vehicles that operate in populated areas – both indoor and outdoor.
A ··Produces two distinct tones –

puls and constant-on
B ··97dB at 4’
··60 pulses per minute
··Impact resistant housing ··Conforms to SAE J994 Sound
··Designed for multi-volt operation ··Level Type C
··Conforms with SAE and ··Type 4X enclosure
··OSHA requirements
··Universal Mounting bracket Vehicle Back-Up Alarms
Key Voltage Amps Decibels Fed Signal Item Shpg.
C ··Adjusts sound output automatically
(dB) Model No. Wt
A 9 to 48VDC 0.04 97 EPBA 2YE26 0.6
··80 pulses per minute
··Operates on 12-48VDC power B 12-48VDC 0.2 97 at 4Ft 252-012-048 1N898 0.7
··UL listed
··Type 4X enclosure C 12-48VDC 0.25 82 - 107 at4Ft 253-012-048 4RM40 1.6
Enclosure Rating Reference Guide
Nema Ratings IP Ratings

National Electrical Manufacturers Association Ingress Protection
Type Indicates: Prefix First # — Solids

1 General Purpose, Indoor — To prevent accidental contact of personnel with the IP 0 — No Protection
enclosed equipment in areas where unusual service conditions do not exist. IP 1 — Over 50mm
Provide protection against falling dirt. IP 2 — Over 12mm
2 Drip-Proof, Indoor — Similar to Type 1, but also protects against falling non-cor- IP 3 — Over 2.5mm
rosive liquids and falling dirt. Drainage provisions provided. IP 4 — Over 1.0mm
3 Dust-Tight, Rain-Tight, Sleet-Resistant, Outdoor — Protected against wind- IP 5 — Dust, limited ingress from
blown dust and water. all directions
3R Rainproof, Sleet-Resistant, Outdoor — Protected against rain.
IP 6 — Total protection against dust
3S Dust-Tight, Rain-Tight and Sleet-Proof, Outdoor — Protected against windblown Prefix Second # — Water
dust and water, remains operable when covered by external ice or sleet. (Not pro- IP 0 — No Protection
tected against internal icing.) IP 1 — Dripping
4 Water-Tight and Dust-Tight, Indoor and Outdoor — Protected against wind- IP 2 — Dripping when tilted up to 15ϒ
blown dust and rain, splashing water, seepage water, falling or hose-directed IP 3 — Spraying when tilted up to 60ϒ
water, and severe external condensation. Mountings are external to cavity. IP 4 — Splashing
4X Water-Tight, Dust-Tight, Indoor and Outdoor — Same as Type 4 but also corro- IP 5 — Low pressure jets
sion-resistant. Passes 200-hr. salt spray (fog) test. IP 6 — Strong jets
How To Choose An Audible Signal

Purpose When choosing a signal for an application, remember the acronym PAC. If
Ambient Noise you determine a signal’s PURPOSE, the AMBIENT NOISE of the environment
and the area of COVERAGE that is needed, you will be able to fit the right
Coverage device to your application.
Purpose Determine whether the signal will be used for the monitoring of a process or for emergency
notification (fire, chlorine leak, natural disasters). Study operational uses such as start/stop work, coded paging
and voice messages. Also, the type of duty cycle (i.e.: time device is on vs. time off) will determine what device is
best suited for a given application.
Ambient Ambient noise levels and the frequency (low or high) are critical in determining the type of device
Noise to be recommended. Most facilities will have already recorded this information for OSHA compliance.
Coverage How big of an area is to be covered? Coverage requirements dictate the type(s) and number of devices that will be
needed. A plot plan of the plant or a blueprint of the building can be very helpful in determining area of coverage,
and help analyze what obstructions might be a factor in complete plant coverage.
Measuring Sound
The following chart demonstrates the role distance plays in the “loudness” of an audible signal. Most of our
devices are measured at a distance of 10 feet (on axis); Outdoor Warning Sirens are measured at 100 ft. (on
X
axis). This gives us a common point for comparison.
To understand the range of these devices, use a 6dB loss per distance doubled for the regular devices and a
400'
107dB
10dB loss per distance doubled for outdoor sirens.
200'
117dB
For example, a regular device produces 6dB less at a distance of 20' than at 10'. An outdoor
OUTDOOR 100'
127dB warning device is 10dB less at 200' than at 100'.
Glossary
Alarm: A signal for attracting attention to an event. NEMA: National Electrical Manufacturers Association. NEMA
provides a forum for the standardization of electrical equipment.
Ambient Noise Level: The level of acoustic noise existing at
See the Federal Signal product catalog or website for a complete
a given location, such as in a room, in a compartment, or at a
listing of NEMA ratings.
place outside.
Nema Type 1: Intended for use primarily to provide a degree of
Amplifier: An electronic component that boosts the voltage or
protection against limited amounts of falling dirt.
power level of a signal.
Nema Type 3R: Intended for outdoor use primarily to provide
Beacon: A device used to produce a visible indication of an event.
a degree of protection against rain, sleet, and damage from
Candela (cd): The standard unit for luminous intensity. external ice formation.
Crosshatch Lens: The pattern of the plastic material of the lens Nema Type 4X: Intended for indoor or outdoor use primarily to
that results in a brilliant illumination of the signal. provide a degree of protection against corrosion, windblown dust
and rain, splashing water, hose-directed water, and damage from
Decibel (dB): A unit used to convey the intensity of sound.
ice formation
Dip Switch: Stands for Dual Inline Package switch, one of a set
Parabolic Reflector: A reflective device formed in a dish
of small (sometimes very small) toggle switches on a circuit board
(concave) shape which helps produce a parallel light towards
that are used for configuring the device.
its focused direction.
Dome: The top component of a visual signal—manufactured in
Polycarbonate: An engineering plastic used to build housings;
various colors to create different color signals.
noted for its impact-, weather-, and heat-resistant qualities.
Gain Control: A device that adjusts the gain of an amplifier by
Powder Coat Finish: A mixture of finely ground particles of
altering the amount of negative feedback in the amplifying
pigment and resin which is then sprayed onto a surface and cured
system.
with a heat process. Powder coat finishes are attractive, high
Note: Not the same as volume control.
quality, and are resistant to chipping, scratching, UV damage
Halogen Bulb: A bulb filled with halogen gas, a substance that and rust.
causes the particles of tungsten to be redeposited onto the
SAE: Society of Automotive Engineers, an organization that
tungsten filament. This process extends the lamp’s life and also
develops the standards to help advance mobility engineering.
makes the light whiter and brighter.
SAE Standard J845: The standard for optical warning devices for
FM Approved: FM stands for Factory Mutual, a third party
emergency vehicles (single color, 360 degree lights).
approval and certification company that performs rigorous testing
to specifications to ensure products meet or exceed their claims. SAE Standard J994: The standard for vehicle electric back-up
alarm devices.
Housing: A protective cover designed to contain or support a light
or horn. Often constructed of polycarbonate or die-cast aluminum. SAE Standard J1318: The standard for gaseous discharge
warning lamp for authorized emergency, maintenance and
IP: Is an international classification system to classify the Ingress
service vehicles.
Protection of an enclosure against solids and liquids as prescribed
in the International Standard IEC 60529. For additional information Tone Output: The sound that comes out of an electronic siren.
on the IP classification system, see the Federal Signal product Federal Signal products have various tones such as wail, yelp,
catalog or website whoop, voice tones and more.
Incandescent Lamp: A light source that uses electricity to heat Rotating Light: A continuous beam of light that rotates inside
up a filament until until it gets so hot that it glows bright. the housing.
Lamp: A complete light source unit, usually consisting of a light Status Indicator: A signal used to indicate the status of an event,
generating element (arc tube or filament), support hardware, such as the startup of machinery.
enclosing envelope and base.
Strobe Light: A device that emits a bright flashes of light at a
LED: Stands for Light Emitting Diode. A diode designed to give timed rate. Strobe lights use xenon-gas tubes and are typically
off light when current flows through it. brighter than flashing lights.
LED Lamp: The bulb or tube portion of an electric lighting device. Tone: Refers to the sound that emits from a horn. Federal Signal
has products with various tone styles such as wail, yelp,
Low-Profile: A signal that is short in physical size. A low profile
signal might be used in a location with limited or small space. UL: Underwriters Laboratories Inc., an organization that tests
products for public safety.
Lumen: A unit of measurement quantifying the amount of light
emitted from a light source. cUL: The Canadian approval given by Underwriters Laboratory
that meet the safety standards for Canada.
NEC: National Electrical Code, developed and published by the
National Fire Protection Association.
RH Series Relays & Sockets
RH Series Compact Power Relays

Switches & Pilot Lights
SPDT through 4PDT, 10A contacts

Compact power type relays
The RH series are miniature power relays with a large capacity. The RH relays feature
10A contact capacity as large as the RR series but in a miniature package. The compact
size saves space.
Display Lights
Part Number Selection

Part Number
Blade PCB Coil Voltage Code
Contact Model
Terminal Terminal (Standard Stock in bold)
Basic RH1B-U RH1V2-U
SPDT With Indicator RH1B-UL —
AC6V, AC12V, AC24V, AC110V, AC120V,
With Check Button RH1B-UC — AC220V, AC240V DC6V, DC12V, DC24V,
DC48V, DC110V
With Indicator and Check Button RH1B-ULC —
Relays & Sockets
Top Bracket Mounting RH1B-UT —

With Diode (DC coil only) RH1B-UD RH1V2-UD DC6V, DC12V, DC24V, DC48V, DC110V
With Indicator and Diode (DC coil only) RH1B-ULD — DC12V, DC24V, DC48V, DC110V
DPDT
With Indicator RH2B-UL RH2V2-UL
AC6V, AC12V, AC24V, AC110-120V,
With Check Button RH2B-UC — AC220-240V
DC6V, DC12V, DC24V, DC48V, DC100-110V
With Diode (DC coil only) RH2B-UD RH2V2-UD
DC6V, DC12V, DC24V, DC48V, DC100-110V
With Indicator and Diode (DC coil only) RH2B-ULD —
Timers

3PDT
With Check Button RH3B-UC — AC220V, AC240V DC6V, DC12V, DC24V,
DC48V, DC110V
With Diode (DC coil only) RH3B-D* RH3V2-D*
DC6V, DC12V, DC24V, DC48V, DC110V
With Indicator and Diode (DC coil only) RH3B-LD* —
Terminal Blocks

4PDT
With Check Button RH4B-UC — AC220V, AC240V DC6V, DC12V, DC24V, DC48V,
DC110V
With Diode (DC coil only) RH4B-UD RH4V2-UD
DC6V, DC12V, DC24V, DC48V, DC110V
With Indicator and Diode (DC coil only) RH4B-LD* —
1. *Carries no UL recognition mark.

2. PCB terminal relays are designed to mount directly to a circuit board without any socket. Ordering Information
Circuit Breakers
When ordering, specify the Part No. and coil voltage code:
(example) RH3B-U AC120V
Part No. Coil Voltage Code
726 www.idec.com
Relays & Sockets RH Series
Sockets (for Blade Terminal Models)

Relays Standard DIN Rail Mount 1 Finger-safe DIN Rail Mount 1 Through Panel Mount PCB Mount

RH1B SH1B-05 SH1B-O5C SH1B-51 SH1B-62
RH2B SH2B-05 SH2B-05C SH2B-51 SH2B-62
1. DIN Rail mount
RH3B SH3B-05 SH3B-05C SH3B-51 SH3B-62 socket comes with
RH4B SH4B-05 SH4B-05C SH4B-51 SH4B-62 two horseshoe
clips. Do not use
unless you plan to
insert pullover wire
spring. Replacement
horseshoe clip part
number is Y778-011.
Hold Down Springs & Clips
Display Lights
For DIN For Through Panel &
Appearance Description Relay Min Order Qty
Mount Socket PCB Mount Socket
RH1B SY2S-02F1 2 2. Must use horseshoe clip
when mounting in DIN
Pullover Wire RH2B SY4S-02F1 2
SY4S-51F1 10 mount socket. Replacement
Spring RH3B SH3B-05F1 2 horseshoe clip part number is
Y778-011.
RH4B SH4B-02F1 2 3. Two required per relay.
Leaf Spring
Relays & Sockets

RH1B, RH2B, RH3B, RH4B SFA-202 3 SFA-302 3
(side latch)
20
Leaf Spring
RH1B, RH2B, RH3B, RH4B SFA-101 3 SFA-301 3
(top latch)
AC Coil Ratings
Rated Current (mA) ±15% at 20°C Coil Resistance (Ω) Operation Characteristics
Voltage AC 50Hz AC 60Hz ±10% at 20°C (against rated values at 20ºC)
(V)
Max. Continuous Pickup Dropout
SPDT DPDT 3PDT 4PDT SPDT DPDT 3PDT 4PDT SPDT DPDT 3PDT 4PDT
Applied Voltage Voltage Voltage
Timers
6 170 240 330 387 150 200 280 330 330 9.4 6.4 5.4
12 86 121 165 196 75 100 140 165 165 39.3 25.3 21.2
24 42 60.5 81 98 37 50 70 83 83 153 103 84.5
110 9.6 — 18.1 21.6 8.4 — 15.5 18.2 18.2 — 2,200 1,800
9.4- 80% 30%
110-120 — — — — 8.0-9.2 — — — — — — 110%
10.8 maximum minimum
120 8.6 — 16.4 19.5 7.5 — 14.2 16.5 16.5 — 10,800 7,360
Terminal Blocks
220 4.7 — 8.8 10.7 4.1 — 7.7 9.1 9.1 — 10,800 7,360
220-240 — 4.7-5.4 — — — 4.0-4.6 — — 18,820 — —
240 4.9 — 8.2 9.8 4.3 — 7.1 8.3 8.3 — 12,100 9,120
DC Coil Ratings
Coil Resistance (Ω) Operation Characteristics
Rated Current (mA) ±15% at 20°C
Voltage ±10% at 20°C (against rated values at 20ºC)
(V) Max. Continuous Pickup Dropout
SPDT DPDT 3PDT 4PDT SPDT DPDT 3PDT 4PDT
Applied Voltage Voltage Voltage
Circuit Breakers
6 128 150 240 250 47 40 25 24

Standard coil voltages
12 64 75 120 125 188 160 100 96
are in BOLD.
24 32 36.9 60 62 750 650 400 388 80% 10%
110%
48 18 18.5 30 31 2,660 2,600 1,600 1,550 maximum minimum
100-110 — 8.2-9.0 — — — 12,250 — —
110 8 — 12.8 15 13,800 — 8,600 7,340
USA: 800-262-IDEC Canada: 888-317-IDEC 727

Contact Ratings UL Ratings

Maximum Contact Capacity Resistive General Use Horse Power Rating
Allowable Contact Power Rated Load Voltage RH1 RH1 RH1

Continuous RH3 RH4 RH3 RH4 RH3 RH4
Model RH2 RH2 RH2
Current Resistive Inductive Voltage Res. Ind.
Load Load (V) Load Load 240V AC 10A 7.5A 7.5A 7A 6.5A 5A 1/3 HP 1/3 HP —
110 AC 10A 7A 120V AC — 10A 10A — 7.5A 7.5A 1/6 HP 1/6 HP —
1540VA 990VA
SPDT 10A 220 AC 7A 4.5A 30V DC 10A 10A — 7A — — — — —
300W 210W
30 DC 10A 7A 28V DC — — 10A — — — — — —
110 AC 10A 7.5A
DPDT CSA Ratings
1650VA 1100VA
3PDT 10A 220 AC 7.5A 5A
300W 225W Horse
4PDT
30 DC 10A 7.5A Resistive General Use Power
Note: Inductive load for the rated load — cos ø = 0.3, L/R = 7 ms Voltage Rating
Display Lights
RH1 RH2 RH3 RH4 RH1 RH2 RH3 RH4 RH1, 2, 3
TÜV Ratings 240V AC 10A 10A — 7.5A 7A 7A 7A 5A 1/3 HP
Voltage RH1 RH2 RH3 RH4 120V AC 10A 10A 10A 10A 7.5A 7.5A — 7.5A 1/6 HP
240V AC 10A 10A 7.5A 7.5A 30V DC 10A 10A 10A 10A 7A 7.5A — — —
30V DC 10A 10A 10A 10A
AC: cos ø = 1.0, DC: L/R = 0 ms

Relays & Sockets
Socket Specifications
Sockets Terminal Electrical Rating Wire Size Torque
(Coil) M3 screws 5.5 - 9 in•lbs
SH1B-05 250V, 10A Maximum up to 2–#12AWG
DIN Rail (contact) M3.5 screws with captive wire clamp 9 - 11.5 in•lbs
Mount SH2B-05
Sockets SH3B-05 M3.5 screws with captive wire clamp 300V, 10A Maximum up to 2–#12AWG 9 - 11.5 in•lbs
SH4B-05
(coil) M3 screws 5.5 - 9 in•lbs
SH1B-05C 250V, 10A Maximum up to 2–#12AWG
Finger-safe (contact) M3.5 screws with captive wire clamp, fingersafe 9 - 11.5 in•lbs
DIN Rail SH2B-05C
Mount
Timers
SH3B-05C M3.5 screws with captive wire clamp, fingersafe 300V, 10A Maximum up to 2–#12AWG 9 - 11.5 in•lbs
SH4B-05C
Through SH1B-51
Panel SH2B-51
Solder 300V, 10A — —
Mount SH3B-51
Socket SH4B-51
SH1B-62 PCB mount 250V, 10A — —
PCB Mount SH2B-62
Socket SH3B-62 PCB mount 300V, 10A — —
Terminal Blocks
SH4B-62
Accessories
Description Appearance Use with Part No. Remarks
IDEC offers a low-profile DIN rail (BNDN1000). The BNDN1000 is de-
Aluminum
signed to accommodate DIN mount sockets. Made of durable extruded
DIN Rail All DIN rail sockets BNDN1000
aluminum, the BNDN1000 measures 0.413 (10.5mm) in height and 1.37
(1 meter length)
(35mm) in width (DIN standard). Standard length is 39” (1,000mm).
Circuit Breakers
DIN Rail End

DIN rail BNL5 9.1 mm wide.
Stop
Replacement
DIN mount sockets and hold For use on DIN rail mount socket when using pullover wire hold down
Hold-Down Y778-011
down springs. spring. 2 pieces included with each socket.
Spring Anchor
728 www.idec.com
Specifications
Contact Material Silver cadmium oxide

Contact Resistance 1 50mΩ maximum
Minimum Applicable Load 24V DC, 30 mA; 5V DC, 100 mA (reference value)
SPDT
20ms maximum
DPDT
Operate Time 2
3PDT
25ms maximum
4PDT
SPDT
20ms maximum
DPDT
Release Time 2
3PDT
25ms maximum
Display Lights
4PDT
SPDT AC: 1.1VA (50Hz), 1VA (60Hz) DC: 0.8W
Power Consumption DPDT AC: 1.4VA (50Hz), 1.2VA (60Hz) DC: 0.9W
(approx.) 3PDT AC: 2VA (50Hz), 1.7VA (60Hz) DC: 1.5W
4PDT AC: 2.5VA (50Hz), 2VA (60Hz) DC: 1.5W
Insulation Resistance 100MΩ minimum (500V DC megger)
Between live and dead parts: 2,000V AC, 1 minute
SPDT Between contact and coil: 2,000V AC, 1 minute
Relays & Sockets

Between contacts of the same pole: 1,000V AC, 1 minute
Dielectric Strength 3
Between live and dead parts: 2,000V AC, 1 minute
DPDT
Between contact and coil: 2,000V AC, 1 minute
3PDT Between contacts of different poles: 2,000V AC, 1 minute
4PDT Between contacts of the same pole: 1,000V AC, 1 minute
Electrical: 1,800 operations/hour maximum
Operating Frequency
Mechanical: 18,000 operations/hour maximum
Damage limits: 10 to 55Hz, amplitude 0.5 mm
Vibration Resistance
Operating extremes: 10 to 55Hz, amplitude 0.5 mm
Damage limits: 1,000m/s2 (100G)
Shock Resistance Operating extremes: 200m/s2 (20G - SPDT, DPDT)
100m/s2 (10G - 3PDT, 4PDT)
Timers
Mechanical Life 50,000,000 operations minimum
DPDT 500,000 operations minimum (120V AC, 10A)
Electrical Life SPDT

3PDT 200,000 operations minimum (120V AC, 10A)
4PDT
SPDT –25 to +50°C (no freezing)
Operating DPDT
Temperature 4 3PDT –25 to +40°C (no freezing)
4PDT
Terminal Blocks
Operating Humidity 45 to 85% RH (no condensation)
Weight (approx.) SPDT: 24g, DPDT: 37g, 3PDT: 50g, 4PDT: 74g
Note: Above values are initial values.

1. Measured using 5V DC, 1A voltage drop method
2. Measured at the rated voltage (at 20°C), excluding contact bouncing
Release time of relays with diode: 40 ms maximum
3. Relays with indicator or diode: 1000V AC, 1 minute
4. For use under different temperature conditions, refer to Continuous Load Current vs. Operating Temperature Curve. The operating
temperature range of relays with indicator or diode is –25 to +40°C.
Circuit Breakers

Characteristics (Reference Data)

Electrical Life Curves

AC Load DC Load
1000 1000
(RH1) 120V AC resistive (RH1)

500 500
Life (× 10,000 operations)

30V DC resistive
100 100
50 50
100V DC resistive
Display Lights
30V DC inductive
20 20
240V AC inductive 240V AC resistive
120V AC inductive 100V DC inductive
10 10
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
Load Current (A) Load Current (A)
(RH2) 1000 (RH2) 1000

120V AC resistive
30V DC resistive
500 500

Relays & Sockets
100 100
50 50 100V DC resistive 30V DC

inductive
240V AC inductive 240V AC resistive
20 20
10 10
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
(RH3/RH4) 1000 (RH3/RH4) 1000
120V AC resistive
30V DC resistive
500 500
Timers

30V DC inductive
100 100
50 50
20 240V AC inductive 20 100V DC resistive

240V AC resistive 100V DC inductive
120V AC inductive
Terminal Blocks
10 10
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
Maximum Switching Capacity

(RH1) (RH2/RH3/RH4)
10.0 10.0
AC resistive AC resistive
5.0 5.0 AC inductive

AC inductive
Load Current (A)
Load Current (A)
DC resistive
Circuit Breakers
DC resistive
1.0 1.0
DC inductive
0.5 DC inductive 0.5
0.1 0.1
1 5 10 50 100 200 300 1 5 10 50 100 200 300
Load Voltage (V) Load Voltage (V)
730 www.idec.com
Continuous Load Current vs. Operating Temperature Curve (Basic Type, With Check Button, and Top Bracket Mounting Type)

(RH1) Note: The rated voltage is (RH2) Note: The rated voltage is (RH3/RH4) Note: The rated voltage is
applied to the coil. applied to the coil. applied to the coil.
100 100 100
90 90 90
Operating Temperature (oC)

80

80 80
DC Coil
70 70 DC Coil 70
60 60 60
50 AC Coil 50 50 AC/DC Coil

40 AC Coil 40
40
30 30 30
20 20 20
10 10 10
0 0 0
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
Load Current (A) Load Current (A) Load Current (A)
Display Lights
Internal Connection (View from Bottom)
Basic Type
SPDT DPDT 3PDT 4PDT With Check Button
Front
1 1 4 1 2 4 1 2 3 4 Pushbutton
5 5 8 5 6 8 5 6 7 8
9 9 12 9 10 12 9 10 11 12
13( – ) ( + )14
Contacts can be operated by pressing the
13 14 13 ( – )
Relays & Sockets

(–) (+) ( + )14 13( – ) ( + )14 check button.
With Indicator (-L type)

SPDT 3PDT 4PDT DPDT
1 1 2 4 1 2 3 4 1 4
5 5 6 8 5 6 7 8 5 8
Below 9 9 10 12
Below 9 12
9 10 11 12
100V 13 14 24V When the relay is energized,
(–) (+) 13 ( – ) ( + )14 ( + )14
AC/DC 13( – ) ( + )14
AC/DC 13( – ) the indicator goes on.
• Relay coils less than 100V
DC do not contain a protec-
tion diode (except DPDT).
• Relay coils below 100V
Timers
1 1 2 4 1 2 3 4 1 4 use LED indicator, coils
5
100V 5 6 8 5 6 7 8 24V 5 8
above 100V use neon lamp
9 9 10 12 9 12
AC/DC 9 10 11 12 AC/DC indicator.
13 14 13( – ) ( + )14
and over (–) (+) 13( – ) ( + )14 and over
13( – ) ( + )14
With Diode (-D type)

SPDT DPDT 3PDT 4PDT
Terminal Blocks
Contains a diode to absorb the back emf
1 1 4 1 2 4 1 2 3 4 generated when the coil is de-energized. The
5 5 8 5 6 8 5 6 7 8 release time is slightly longer. Available for DC
9 9 12 9 10 12 9 10 11 12 coil only.
13 14 13( – ) ( + )14 13 ( – ) ( + )14 13( – ) ( + )14 • Diode Characteristics
(–) (+)
Reverse withstand voltage: 1,000V
Forward current: 1A
Circuit Breakers

With Indicator LED & Diode (-LD type)

SPDT 3PDT 4PDT DPDT
1
1 2 4 1 2 3 4 1 4
5
5 6 8 5 6 7 8 5 8
9 Below
Below 9 10 12 9 10 11 12 9 12
13 14 24V
100V DC (–) (+) 13( – ) ( + )14 13( – ) ( + )14 13( – ) ( + )14
AC/DC
Contains an LED indicator and

a surge absorber, and has the
same height as the basic type.
1
1 2 4 1 2 3 4 1 4
5
5 6 8 5 6 7 8 5 8
9 24V
100V DC 9 10 12 9 10 11 12 9 12
14( + ) AC/DC
and over 13 ( – )
Display Lights
13( – ) ( + )14 13( – ) ( + )14

and over
13 14
(–) (+)
Dimensions (mm)
RH1B-U/RH1B-UL/RH1B-UD/RH1B-ULD RH2B-U/RH2B-UL/RH2B-UD/RH2B-ULD RH3B-U/RH3B-UL/RH3B-D/RH3B-LD

Total length from panel surface including relay socket Total length from panel surface including relay socket Total length from panel surface including relay socket
SH1B-05: 61.5 (63.5) max., SH1B-51: 39.6 (41.6) max. SH2B-05: 61.5 (63.5) max., SH2B-51: 39.6 (41.6) max. SH3B-05: 61.5 (63.5) max., SH3B-51: 39.6 (41.6) max.
Relays & Sockets
Dimensions in the ( ) Dimensions in the ( ) Dimensions in the ( )

include a hold-down spring. include a hold-down spring. include a hold-down spring.
4.7
ø2.6 hole
4.7
ø2.6 hole
ø2.6 hole
4.7
1
5 1 4
27.5
9 5 8
0.5
27.5
0.5
9 12
13 14
13 14 1 2 4
5 6 8
27.5
5.4 14
0.5
9 10 11
35.6 max. 6.4 35.6 max. 6.4 21 13 14
35.6 max. 6.4 31

Timers
RH4B-U/RH4B-UL/RH4B-UD/RH4B-LD RH1B-UT RH2B-UT

Total length from panel surface including relay socket
4.7
SH4B-05: 61.5 (63.5) max., SH4B-51: 39.6 (41.6) max.
10
Dimensions in the ( )
include a hold-down spring.
ø2.6 hole ø2.6 hole
0.5
4.7
4.7
0.5
4.7
1
5 1 4
5.9
5.9
5 8
43.2
27.5
43.2
27.5
38
38
9
9 12
13 14
13 14
ø2.6 hole
7.25
6.6
4.7
Terminal Blocks
3.5 2 5.4 3.5 2

14.5 35.6 max. 6.4
1 2 3 4 21.5 35.6 max. 6.4
5 6 7 8
27.5
0.5
9 10 11 12
13 14
35.6 max. 6.4 41
RH3B-UT RH4B-UT
10 10
10
4.7
Circuit Breakers
10
10
3.5
4.7
ø2.6 hole 2 3.5

0.5
4.7
0.5
ø2.6 hole
4.7
1 2 4
5.9
1 2 3 4
43.2
5 6 8
38
28
5.9
5 6 7 8
28
38
44
9 10 12
9 10 11 12
13 14
13 14
7.25
7.25
21.5 2 35.6 max. 6.4 28

31.5 35.6 max. 6.4 42 max. 41.5
732 www.idec.com
Dimensions con’t (mm)

RH1V2-U/RH1V2-UD RH2V2-U/RH2V2-UL/RH2V2-UD
8-ø2.4 holes
0.5
4.7
3-ø2.4 holes
2-ø2 holes
7.25
0.5
1.5
4.7
2
0.5
2
7.15
0.5
1
13.15
5
7.8
27.5
12.5
9 1 4
0.5
27.5
5 8
6.6
13 14
9 12
5
13 14
35.6 max. 4.6 14 10
2
35.6 max. 4.6 21
4.4 14.2
RH3V2-U/RH3V2-UL/RH3V2-D RH4V2-U/RH4V2-UL/RH4V2-UD
Display Lights
30
11-ø2.4 holes 10 10
4.7
14-ø2.4 holes 10
4.7
2
13.15
13.15
1 2 4
7.8
7.8
27.5
5 6 8 1 2 3 4
5 6 7 8
0.5
27.5
9 10 11
0.5
13 14 9 10 11 12
13 14
7.25
7.25
0.5 31
0.5 41
35.6 max. 4.6
35.6 max. 4.6
Relays & Sockets

Standard DIN Rail Mount Sockets
SH1B-05 SH2B-05
17 31.5 22 31.5
8 18 DIN Rail Terminal Arrangement DIN Rail
M3.5 Terminal 8 M3.5 Terminal 18
(BNDN) (BNDN) Terminal Arrangement
Screw 2-ø4.2 Mounting Holes Screw
5 2-ø4.2 Mounting Holes 8 5
(or M4 Tapped Holes)
4.2
1
4.2
4 1
67
47
16
67
47
26
M3 Terminal 5.5 min. 4.8 min. 14 13 4.4 max. 5.5 min. 14 13

Screw 9 12 9
4.4 max. 4 max.
(Top View) (Top View)
16 14.5 26 14.5 7.9 max.
ø3.6 min. ø3.2 min.
2.5
Timers
2.5
20 25 30 25 ø3.6 min.
7.9 max. 5.9 max.
(For terminals 1, 5, and 9) (For terminals 13 and 14)
SH3B-05 SH4B-05
31.5 42 31.5
32
8 18 DIN Rail 8 18 DIN Rail
M3.5 Terminal Terminal Arrangement M3.5 Terminal Terminal Arrangement
(BNDN) (BNDN)
Screw Screw
2-ø4.2 Mounting Holes 2-ø4.2 Mounting Holes
8 6 5 8 7 6 5
4.2
4.2
(or M4 Tapped Holes) 4 2 1 4 3 2 1
Terminal Blocks
67
47
67
47
36 46
4.4 max. 5.5 min. 14 13 4.4 max. 5.5 min. 14 13

12 10 9 12 11 10 9
(Top View) (Top View)

36 14.5 46 14.5
7.9 max. 7.9 max.
2.5
40 25 ø3.6 min.
2.5
50 25 ø3.6 min.
Circuit Breakers


Finger-safe DIN Rail Mount Sockets

SH1B-05C SH2B-05C
22 36
17 36 M3.5 Terminal
M3.5 Terminal 7 25 DIN Rail
7 25 Screw (BNDN) Terminal Arrangement
Screw DIN Rail Terminal Arrangement
(BNDN)
5
ø5 2-ø4.2 Mounting Holes 8 5
ø5 (or M4 Tapped Holes) 4 1
2-ø4.2 Mounting Holes
4.2
1
4.2
49
69
48
69
26
16
14 13
M3 Terminal
14 13 12 9
Screw
9
Ring terminals 18.7 Ring terminals (Top View)
26
(Top View) cannot be used.
1.7
16 18.7
cannot be used. 30 29.5
1.7
20 29.5
Display Lights
SH3B-05C SH4B-05C
32 42 36
M3.5 Terminal 36
7 Screw DIN Rail 7 25
25 Terminal Arrangement
(BNDN) DIN Rail
(BNDN) Terminal Arrangement
8 6 5
ø5 2-ø4.2 Mounting Holes
4 2 1 8 7 6 5
(or M4 Tapped Holes) ø5 2-ø4.2 Mounting Holes
4.2
(or M4 Tapped Holes) 4 3 2 1
4.2
49
69
49
69
36
46
14 13
12 10 9 14 13
12 11 10 9
Ring terminals (Top View)
Relays & Sockets
36 18.7 Ring terminals (Top View)

cannot be used.
1.7
40 29.5 46 18.7 cannot be used.

1.7
50 29.5
Through Panel Mount Socket

SH1B-51 SH2B-51
+0.5
Panel Thickness: [18 (N–1) + 12.4] +0.5
0 Panel Thickness: [27 (N–1) + 21.4] 0
1 to 2 Terminal Arrangement 1 to 2
Terminal Arrangement
1 1 4
+0.2
25.6 +0.2
0
0
5 5 8
25.4
25.4
25.6
31
31
9 9 12
13 14 13 14
0.3
0.3
(Bottom View) 27 3 (Bottom View) N: No. of sockets mounted

18 3 N: No. of sockets mounted
5.4 min.∗
5.4 min.∗
Timers
11
11
18.7
18.7
∗ 10.4 min. when using hold-down springs
3.5 ∗ 10.4 min. when using hold-down springs 3.5
2.4 21.2
12.2
SH3B-51 SH4B-51
Panel Thickness: [36 (N–1) + 30.4] +0.5
0 Panel Thickness: [45 (N–1) + 39.4] +0.5
0
1 to 2 1 to 2
Terminal Arrangement Terminal Arrangement
+0.2
1 2 3 4
+0.2
1 2 4
0
0
Terminal Blocks
5 6 8 5 6 7 8
25.6
25.4
25.6
25.4
31
31
9 10 12 9 10 11 12
13 14 13 14
0.3
N: No. of sockets mounted

0.3
36 3 N: No. of sockets mounted 45 3 (Bottom View)

(Bottom View)
5.4 min.∗
5.4 min.∗
11 11
18.7
18.7
∗ 10.4 min. when using hold-down springs
3.5 ∗ 10.4 min. when using hold-down springs 3.5
30.2 39.2
Circuit Breakers
734 www.idec.com

PCB Mount Sockets
SH1B-62 SH2B-62
Terminal Arrangement 3-ø2.4 holes 6.8 Terminal Arrangement 2.85 21.5 min.
18 min.
6.95
1 1 4 15.5
4.4
5.65
5 8
25.4
5 10
4.7
25.4
29
4.7
31
9 9 12
13 14 13 14
11.85
0.3
0.3
21.2 3 (Bottom View)
29 min.∗ 12.5
18 3 (Bottom View)
5.95
11
11
31 min.
6.6
2-ø2 holes 15
15 8-ø2.4 holes
2
1.5 (Tolerance p0.1) 2

36 min. when using ∗ 34 min. when using (Tolerance ±0.1)
12.2 hold-down springs hold-down springs
Display Lights
SH3B-62 SH4B-62
Terminal Arrangement 36 min. Terminal Arrangement 6.85 45 min.
7.35 21.3 1 2 3 4 31.3
1 2 4
6.65
5 6 7 8
25.4
5 6 8 10 10 10 10 10
4.7
25.4
31
4.7
31
9 10 12 9 10 11 12
13 14 13 14
0.3
0.3
45 3
6.65
12.5
3 (Bottom View)
12.5
36 (Bottom View)
11
11
6.6
31 min.∗
31 min.∗
6.6
15
15
11-ø2.4 holes 14-ø2.4 holes
2
2 ∗ 36 min. when using
39.2 (Tolerance ±0.1)
∗ 36 min. when using (Tolerance ±0.1) hold-down springs
30.2
hold-down springs
Relays & Sockets

Timers
Terminal Blocks
Circuit Breakers

Operating Instructions Relays & Sockets
Operating Instructions
Driving Circuit for Relays Protection for Relay Contacts

1. To ensure correct relay operation, apply rated voltage to the relay coil. 1. The contact ratings show maximum values. Make sure that these values are
not exceeded. When an inrush current flows through the load, the contact
2. Input voltage for the DC coil: may become welded. If this is the case, connect a contact protection circuit,
A complete DC voltage is best for the coil power to make sure of stable relay such as a current limiting resistor.
operation. When using a power supply containing a ripple voltage, suppress
the ripple factor within 5%. When power is supplied through a rectification 2. Contact protection circuit:
circuit, the relay operating characteristics, such as pickup voltage and dropout When switching an inductive load, arcing causes carbides to form on the
voltage, depend on the ripple factor. Connect a smoothing capacitor for better contacts, resulting in increased contact resistance. In consideration of contact
operating characteristics as shown below. reliability, contact life, and noise suppression, use of a surge absorbing circuit
Pulsation
is recommended. Note that the release time of the load becomes slightly
longer. Check the operation using the actual load. Incorrect use of a contact
Display Lights
Smoothing
protection circuit will adversely affect switching characteristics. Four typical
Emin Emax Emean DC
Capacitor examples of contact protection circuits are shown in the following table:
+
R Relay Emax – Emin
– × 100%
Ripple Factor (%)
Emean This protection circuit can be used when the load
Emax = Maximum of pulsating current impedance is smaller than the RC impedance in an
Emin = Minimum of pulsating current
Emean = DC mean value
AC load power circuit.
Power
C R
Ind. Load
• R: Resistor of approximately the same resistance
3. Leakage current while relay is off: value as the load
• C:0.1 to 1 μF
RC
When driving an element at the same time as the relay operation, special
consideration is needed for the circuit design. As shown in the incorrect This protection circuit can be used for both AC and
Relays & Sockets
circuit below, leakage current (Io) flows through the relay coil while the relay C
DC load power circuits.
is off. Leakage current causes coil release failure or adversely affects the Power
R Ind. Load R: Resistor of approximately the same resistance
vibration resistance and shock resistance. Design a circuit as shown in the value as the load
C: 0.1 to 1 μF
correct example.
This protection circuit can be used for DC load power
Incorrect Correct + circuits. Use a diode with the following ratings.
Diode
R TE R Power D Ind. Load Reverse withstand voltage: Power voltage of the

– load circuit x 10
Io
Forward current: More than the load current
This protection circuit can be used for both AC and
4. Surge suppression for transistor driving circuits: DC load power circuits.
Varistor
For a best result, when using a power voltage of 24

Varistor
When the relay coil is turned off, a high-voltage pulse is generated, causing a Power Ind. Load
to 48V AC/DC, connect a varistor across the load.
transistor to deteriorate and sometimes to break. Be sure to connect a diode When using a power voltage of 100 to 240V AC/DC,
Timers
to suppress the back electromotive force. Then, the coil release time becomes connect a varistor across the contacts.
slightly longer. To shorten the coil release time, connect a Zener diode
between the collector and emitter of the transistor. Select a Zener diode with 3. Do not use a contact protection circuit as shown below:
a Zener voltage slightly higher than the power voltage.
This protection circuit is very effective in arc suppression when
Back emf
suppressing diode opening the contacts. But, the capacitor is charged while the
+
C
Load contacts are opened. When the contacts are closed, the capacitor
Power
–
R Relay is discharged through the contacts, increasing the possibility of
contact welding.
Terminal Blocks

C
Load opening the contacts. But, when the contacts are closed, a current
Power
flows to charge the capacitor, causing contact welding.
Generally, switching a DC inductive load is more difficult than switching a DC

resistive load. Using an appropriate arc suppressor, however, will improve the
switching characteristics of a DC inductive load.
Soldering
Circuit Breakers
1. When soldering the relay terminals, use a soldering iron of 30 to 60W, and
quickly complete soldering (within approximately 3 seconds).
2. Use a non-corrosive rosin flux.
774 www.idec.com
Relays & Sockets Operating Instructions
Operating Instructions con’t

Other Precautions
1. General notice: 2. UL and CSA ratings may differ from product rated values determined by IDEC.
To maintain the initial characteristics, do not drop or shock the relay.
3. Do not use relays in the vicinity of strong magnetic field, as this may affect
The relay cover cannot be removed from the base during normal operation. To relay operation.
maintain the initial characteristics, do not remove the relay cover.
Use the relay in environments free from condensation, dust, sulfur dioxide
(SO2), and hydrogen sulfide (H2S).
Make sure that the coil voltage does not exceed applicable coil voltage range.
Display Lights
Safety Precautions
• Turn off the power to the relay before starting installation, removal, wiring, Precautions for the RU Relays
maintenance, and inspection of the relays. Failure to turn power off may
cause electrical shock or fire hazard. • Before operating the latching lever of the RU relay, turn off the power to
the RU relay. After checking the circuit, return the latching lever to the
• Observe specifications and rated values, otherwise electrical shock or fire original position.
hazard may be caused.
Relays & Sockets

• Do not use the latching lever as a switch. The durability of the latching lever
• Use wires of the proper size to meet voltage and current requirements. Tight- is a minimum of 100 operations.
en the terminal screws on the relay socket to the proper tightening torque.
• When using DC loads on 4PDT relays, apply a positive voltage to terminals of
• Surge absorbing elements on AC relays with RC or DC relays with diode are neighboring poles and a negative voltage to the other terminals of neighbor-
provided to absorb the back electromotive force generated by the coil. When ing poles to prevent the possibility of short circuits.
the relay is subject to an excessive external surge voltage, the surge absorb-
ing element may be damaged. Add another surge absorbing provision to the • DC relays with a diode have a polarity in the coil terminals. Apply the DC volt-
relay to prevent damage. age to the correct terminals.
Timers
Terminal Blocks
Circuit Breakers

RR Series Relays & Sockets
RR Series Power Relays

SPDT through 4PDT, 10A contacts

Midget power type relays
• Available in pin and blade terminal styles.
• Options include an indicator, check button for test operations and side flange.
• DIN rail, surface and panel mount sockets are available for a wide a variety of
mounting applications.
Part Number Selection

Display Lights
Part Number
Coil Voltage Code
Contact Model Pin Terminal Blade Terminal*
(Standard Stock Items in Bold)
SPDT Basic RR1BA-U
With Indicator RR1BA-UL
With Check Button — RR1BA-UC
With Indicator and Check Button RR1BA-ULC
Side Flange Model RR1BA-US
Relays & Sockets
DPDT Basic RR2P-U RR2BA-U

With Indicator RR2P-UL RR2BA-UL
With Check Button RR2P-UC RR2BA-UC AC220V, AC240V,
With Indicator and Check Button RR2P-ULC RR2BA-ULC DC6V, DC12V, DC24V, DC48V, DC110V
Side Flange Model — RR2BA-US
3PDT Basic RR3PA-U RR3B-U

With Indicator RR3PA-UL RR3B-UL
With Check Button RR3PA-UC RR3B-UC
With Indicator and Check Button RR3PA-ULC RR3B-ULC
Timers
Side Flange Model — RR3B-US
*Blade type not TUV tested or CE marked.

Ordering Information
When ordering, specify the Part No. and coil voltage code:
(example) RR3B-U AC120V
Part No. Coil Voltage Code
Sockets
Terminal Blocks
Relays Standard DIN Rail Mount Finger-safe DIN Rail Mount Through Panel Mount
SR2P-05
RR2P SR2P-05C SR2P-51
SR2P-06
SR3P-05
RR3PA SR3P-05C SR3P-51
SR3P-06
RR1BA
RR2BA SR3B-05 — SR3B-51
RR3B
Circuit Breakers
All DIN rail mount sockets shown above can be

mounted using DIN rail BNDN1000.
748 www.idec.com
Relays & Sockets RR Series
Hold Down Springs & Clips

For DIN For Through Panel &

Appearance Description Relay Min Order Qty
Mount Socket PCB Mount Socket
RR2P SR2B-02F1
SR3P-01F1
Pullover Wire RR3PA SR3B-02F1
10 pcs
Spring
RR1BA, RR2BA,
SR3B-02F1 SR3B-02F1
RR3B
Leaf Spring
RR2P, RR3PA SFA-203 – 20 pcs
(side latch)
Accessories
Description Appearance Use with Part No. Remarks
Display Lights
IDEC offers a low-profile DIN rail (BNDN1000). The BNDN1000 is de-
Aluminum
signed to accommodate DIN mount sockets. Made of durable extruded
DIN Rail All DIN rail sockets BNDN1000
aluminum, the BNDN1000 measures 0.413 (10.5mm) in height and 1.37
(1 meter length)
(35mm) in width (DIN standard). Standard length is 39” (1,000mm).
DIN Rail End

DIN rail BNL5 9.1 mm wide.
Stop
Horseshoe clip for sockets

Y778-011
SR3B-05, SR2P-06, SR3P-06
Relays & Sockets

Replacement
For use on DIN rail mount socket when using pullover wire hold down
Hold-Down
spring. 2 pieces included with each socket.
Spring Anchor Chair clip for sockets
Y703-102
SR2P-05(C), SR3P-05(C)
Specifications
Contact Material Silver
Contact Resistance 1
30 mΩ maximum
Minimum Applicable Load 1V DC, 10 mA
Operate Time 2
25 ms maximum
Release Time 2
25 ms maximum
Timers
AC: 3 VA (50 Hz), 2.5 VA (60 Hz)
Power Consumption (approx.)
DC: 1.5W
Insulation Resistance 100 MΩ minimum (500V DC megger)
Between live and dead parts: 1500V AC, 1 minute
Between contact and coil: 1500V AC, 1 minute
Pin Terminal
Between contacts of different poles: 1500V AC, 1 minute
Dielectric Between contacts of the same pole: 1000V AC, 1 minute
Terminal Blocks
Strength Between live and dead parts: 2000V AC, 1 minute 1. Measured using 5V DC, 1A voltage drop method
Between contact and coil: 2000V AC, 1 minute 2. Measured at the rated voltage (at 20°C), excluding
Blade Terminal contact bouncing
Between contacts of different poles: 2000V AC, 1 minute 3. For use under different temperature conditions, refer
to Continuous Load Current vs. Operating Temperature
Between contacts of the same pole: 1000V AC, 1 minute Curve.
Electrical: 1800 operations/h maximum
Operating Frequency
Mechanical: 18,000 operations/h maximum
Damage limits: 10 to 55 Hz, amplitude 0.5 mm
Vibration Resistance
Operating extremes: 10 to 55 Hz, amplitude 0.5 mm
Damage limits: 1000 m/s2 (100g)
Circuit Breakers
Shock Resistance
Operating extremes: 100 m/s2 (10G)
Mechanical Life 10,000,000 operations
Electrical Life 200,000 operations (220V AC, 5A)
Operating Temperature 3 –25 to +40°C (no freezing)
Operating Humidity 5 to 85% RH (no condensation)
Weight (approx.) (Basic type) RR2P: 90g, RR3PA: 96g, RR1BA/RR2BA/RR3B: 82g

Coil Ratings
Rated Current (mA) ±15% (at 20°C) Operating Characteristics (values at 20°C)
Coil Resistance (Ω)

Rated Voltage (V) Maximum Continuous
50 Hz 60 Hz ±10% (at 20°C) Pickup Voltage Dropout Voltage
Applied Voltage
6 490 420 4.9
12 245 210 18
AC 24 121 105 79
110% 80% maximum 30% minimum
(50/60 Hz) 110 27 23 1,680
120 24 20.5 2,100
240 12.1 10.5 8,330
6 240 25
Display Lights
12 120 100
DC 24 60 400 110% 80% maximum 10% minimum
48 30 1,600
110 13 8,460
Contact Ratings UL Ratings

Maximum Contact Capacity Voltage Resistive General use Horse Power Rating
Allowable Contact Power Rated Load 240V AC 10A 7A 1/3 HP
Relays & Sockets
Continuous
Current Resistive Inductive 120V AC 10A 7.5A 1/4 HP
Voltage (V) Res. Load Ind. Load
Load Load 30V DC 10A 7A —
110 AC 10A 7.5A
1650VA AC 1100VA AC CSA Ratings
10A 220 AC 7.5A 5A
300W DC 150W DC
30 DC 10A 5A Voltage Resistive General use
240V AC 10A 7A
Note: Inductive load for the rated load — cos ø = 0.3, L/R = 7 ms
120V AC 10A 7.5A
100V DC — 0.5A
TÜV Ratings 30V DC 10A 7.5A
Voltage
Timers
240V AC 10A
AC: cos ø = 1.0, DC: L/R = 0 ms
30V DC 10A
Socket Specifications
Relays Terminal Electrical Rating Wire Size Torque
SR2P-05 M3 screw with captive wire clamp 300V, 10A 2-12 AWG 9 - 11.5in•lbs
Terminal Blocks
SR2P-05C M3 screw with captive wire clamp, fingersafe 300V, 10A 2-12 AWG 9 - 11.5in•lbs
DIN Rail
Sockets
SR3P-05C M3 screw with captive wire clamp, fingersafe 300V, 10A 2-12 AWG 9 - 11.5in•lbs
SR3B-05 M3 screw with captive wire clamp 300V, 15A (10A)* (*CSA rating) 2-12 AWG 9 - 11.5in•lbs
SR2P-51 Solder 300V, 10A — —
Through
Panel Mount SR3P-51 Solder 300V, 10A — —
Sockets
Circuit Breakers
SR3B-51 Solder 300V, 10A — —
750 www.idec.com
Characteristics (Reference Data)

Electrical Life Curves
AC Load DC Load
1000 1000
500 500

30V DC
resistive
100 100
110V AC resistive
100V DC resistive
50 50
220V AC resistive
20 20
220V AC inductive
30V DC inductive
10 10
Display Lights
0.1 0.5 1 5 10 0.01 0.05 0.1 0.5 1 5 10
Continuous Load Current vs. Operating Temperature Curve

Maximum Switching Capacity (Basic Type, With Check Button, and Side Flange Type)
10.0
AC 100
resistive
5.0 90
AC
Operating Temperature (°C)

inductive 80
Load Current (A)
DC resistive
70
DC Coil
60
1.0
Relays & Sockets

50
DC inductive AC Coil
0.5 40
30
20
10
1 5 10 30 50 100 200 300 0

1 2 3 4 5 6 7 8 9 10
Load Voltage (V) Load Current (A)
Internal Connection (View from Bottom)

Basic Type
RR2P-U RR3PA-U RR1BA-U RR2BA-U RR3B-U With Check Button
4 5 6
2 1 3 1 2 3 Front
Timers
5 7
Pushbutton
4 8 5 4 6 4 5 6
3 6
3 9 7 7 9 7 8 9 Contacts can be operated by pressing the

2 7
(–) (+) 2 10
check button.
A B A B A B
(–) (+)
1 8 (–) (+) (–) (+) (–) (+)
1 11
With Indicator (-UL type)

RR2P RR3PA RR1BA RR2BA RR3B
Terminal Blocks
4 5 6 2 1 3 1 2 3
5 7
5 4 6 4 5 6
3 6 4 8
Coil 7 7 9 7 8 9
3 9
Below 2 7
A B A B A B
100V (–) (+) 2 10 When the relay is energized,
(–) (+) (–) (+) (–) (+) (–) (+)
AC/DC 1 8 1 11
the indicator goes on.
• The LED protection diode is
not contained in relay coils
∗ ∗ ∗ ∗ ∗
below 100V DC.
• Coils below 100V use
4 5 6 2 1 3 1 2 3
5 7 LED indicator while coils
Circuit Breakers
5 4 6 4 5 6 above 100V use neon lamp

Coil 3 6 4 8
indicator.
100V 3 9
7 7 9 7 8 9
AC/DC 2 7
(–) (+) 2 10 A B A B A B
and over (–) (+) (–) (+) (–) (+) (–) (+)
1 8 1 11

Dimensions (mm)
RR2P-U/RR2P-UL RR3PA-U/RR3PA-UL
Total length from panel surface including relay socket Total length from panel surface including relay socket
SR2P-05: 84.5 (87.5) max., SR2P-511: 63 (68) max. SR3P-05: 84.5 (87.5) max., SR3P-511: 63 (68) max.
6
5 7
4 5 4 8
35.6
35.6
3 6
2 7 3 9
1 8
2 10
1 11
9.9 9.9
28.6 35.6
55.5 max. 13 55.5 max. 13
Dimensions in the ( ) Dimensions in the ( )
include a hold-down spring. include a hold-down spring.
RR1BA-U/RR2BA-UL/RR2BA-U
Display Lights
RR2BA-UL/RR3B-U/RR3B-UL RR1BA-US/RR2BA-US/RR3B-US
63.5
4.7
7.3 3.0 × ø2.0 oblong hole
2-ø4.5 Mounting Holes
11.1
16.0
4.2
11.1
3.0 × ø2.0 oblong hole
63.5
Total length from panel surface including relay socket
4.7
SR3B-05: 73 (76) max., SR3B-51: 56 (60) max. 16.1
47.5 max.
73.5
0.5
Relays & Sockets
1 2 3
4 5 6
36
7 8 9
0.5
1 2 3
4 5 6
A B
36
7 8 9
36 A B
47.5 max. 7.3
Dimensions in the ( ) 36
include a hold-down spring.

SR2P-05 SR2P-06
Timers
36 DIN Rail 40
8 M3.5 Terminal 35 8 DIN Rail
(BNDN) Terminal Arrangement 25.5
Screw (BNDN) Terminal Arrangement
2-ø4.2 Mounting Holes 5 4 M3.5 Terminal
2-ø4.2 Mounting Holes 6 5 4 3
(or M4 Tapped Holes) 6 3 Screw
ø25
52
33
ø25
60
29 7 2
33
8 1
4.4 max. 5 min.
ø4.2 hole (Top View) 4.9 max. 5 min. 7 8 1 2
16.5 ø4.2 hole
(Top View)
3
29 20 33 18
7.9 max.
1
28.5 22 7.9 max.

ø3.6 min.
ø3.6 min.
Terminal Blocks
SR3P-05 SR3P-06
42 59
DIN Rail DIN Rail
8 M3.5 Terminal 35 8 M3.5 Terminal 28.5
(BNDN) (BNDN)
Screw Terminal Arrangement Screw Terminal Arrangement
2-ø4.2 Mounting Hole 7 6 5
2-ø4.2 Mounting Holes 8 7 6 5 4
(or M4 Tapped Holes) 4
8 (or M4 Tapped Holes)
ø27
52
33
ø27
60
34 9 3 33
10 11 1 2
4.4 max. 5 min. ø4.2 hole
ø4.2 hole (Top View) 4.9 max. 5 min.
9 10 11 1 2 3
34 16.5
18 (Top View)
20 33
3
7.9 max.
1
28.5 22 7.9 max.

ø3.6 min.
Circuit Breakers
ø3.6 min.
752 www.idec.com

SR3B-05
36
8
31.5 DIN Rail Terminal Arrangement
M3.5 Terminal (BNDN)
Screw 6 5 4
2-ø4.2 Mounting Holes 3 2 1
4.2
37
76
56
B A
4.4 max. 5.5 min. 9 8 7
(Top View)
7.9 max.
37 14.5 ø3.6 min.
2
43 25
Display Lights
Finger-safe DIN Rail Mount Sockets
SR2P-05C SR3P-05C
36 42
36.5 DIN Rail 36.5
7 7 DIN Rail
(BNDN)
Terminal Arrangement (BNDN)
2-ø4.2 Mounting Holes Terminal Arrangement
ø5
5
5 4
ø
(or M4 Tapped Holes) 7 6 5
6 3 2-ø4.2 Mounting Holes
(or M4 Tapped Holes) 8 4
58
29
58
ø4.2 hole 7 2
ø4.2 hole 34 9 3
8 1
10 11 1 2
(Top View)
Ring type crimping (Top View)
Relays & Sockets

21.5 terminals cannot be used.
29
2.2
30 34 21.5 Ring type crimping

2.2
30 terminals cannot be used.
Through Panel Mount Socket

SR2P-51 SR3P-51
Surfarface
2-ø3.5 Mounting Holes Surfarface 2-ø3.5 Mounting Holes

4.2 4.2
Panel
Panel
(or M3 Tapped Holes) (or M3 Tapped Holes)

6
6
Terminal Arrangement Terminal Arrangement
4 5 5 6 7
0
ø29
4 8
0
ø29
3 6
38
38
50
38
ø3
38
50
ø3
3 9
2 7
2 10
1 8 1 11
Timers
(Bottom View) (Bottom View)
34 2.5 10 11 34 2.5 10 11
2.5 2.5
SR3B-51
35.5∗ 2-ø4.2 Mounting Holes
38 7.5 11 max. Terminal Arrangement (M4 Tapped Holes)
6.75 22
11.5 min.
1 2 3
0.3
32.5
4 5 6
51.5
32
35
43
43
7 8 9
A B
Terminal Blocks
22 3 6.5
(Bottom View)
(Tolerance ±0.3)
3.5 ∗ When two or more sockets are

35 mounted side by side:
L = 38 (N – 1) + 35.5
N: No. of sockets mounted
Circuit Breakers

Operating Instructions Relays & Sockets
Operating Instructions
Driving Circuit for Relays Protection for Relay Contacts

1. To ensure correct relay operation, apply rated voltage to the relay coil. 1. The contact ratings show maximum values. Make sure that these values are
not exceeded. When an inrush current flows through the load, the contact
2. Input voltage for the DC coil: may become welded. If this is the case, connect a contact protection circuit,
A complete DC voltage is best for the coil power to make sure of stable relay such as a current limiting resistor.
operation. When using a power supply containing a ripple voltage, suppress
the ripple factor within 5%. When power is supplied through a rectification 2. Contact protection circuit:
circuit, the relay operating characteristics, such as pickup voltage and dropout When switching an inductive load, arcing causes carbides to form on the
voltage, depend on the ripple factor. Connect a smoothing capacitor for better contacts, resulting in increased contact resistance. In consideration of contact
operating characteristics as shown below. reliability, contact life, and noise suppression, use of a surge absorbing circuit
Pulsation
is recommended. Note that the release time of the load becomes slightly
longer. Check the operation using the actual load. Incorrect use of a contact
Display Lights
Smoothing
protection circuit will adversely affect switching characteristics. Four typical
Emin Emax Emean DC
Capacitor examples of contact protection circuits are shown in the following table:
+
R Relay Emax – Emin
– × 100%
Ripple Factor (%)
Emean This protection circuit can be used when the load
Emax = Maximum of pulsating current impedance is smaller than the RC impedance in an
Emin = Minimum of pulsating current
Emean = DC mean value
AC load power circuit.
Power
C R
Ind. Load
• R: Resistor of approximately the same resistance
3. Leakage current while relay is off: value as the load
• C:0.1 to 1 μF
RC
When driving an element at the same time as the relay operation, special
consideration is needed for the circuit design. As shown in the incorrect This protection circuit can be used for both AC and
Relays & Sockets
circuit below, leakage current (Io) flows through the relay coil while the relay C
DC load power circuits.
is off. Leakage current causes coil release failure or adversely affects the Power
R Ind. Load R: Resistor of approximately the same resistance
vibration resistance and shock resistance. Design a circuit as shown in the value as the load
C: 0.1 to 1 μF
correct example.
This protection circuit can be used for DC load power
Incorrect Correct + circuits. Use a diode with the following ratings.
Diode
R TE R Power D Ind. Load Reverse withstand voltage: Power voltage of the

– load circuit x 10
Io
Forward current: More than the load current
This protection circuit can be used for both AC and
4. Surge suppression for transistor driving circuits: DC load power circuits.
Varistor
For a best result, when using a power voltage of 24

Varistor
When the relay coil is turned off, a high-voltage pulse is generated, causing a Power Ind. Load
to 48V AC/DC, connect a varistor across the load.
transistor to deteriorate and sometimes to break. Be sure to connect a diode When using a power voltage of 100 to 240V AC/DC,
Timers
to suppress the back electromotive force. Then, the coil release time becomes connect a varistor across the contacts.
slightly longer. To shorten the coil release time, connect a Zener diode
between the collector and emitter of the transistor. Select a Zener diode with 3. Do not use a contact protection circuit as shown below:
a Zener voltage slightly higher than the power voltage.
Back emf
suppressing diode opening the contacts. But, the capacitor is charged while the
+
C
Load contacts are opened. When the contacts are closed, the capacitor
Power
–
R Relay is discharged through the contacts, increasing the possibility of
contact welding.
Terminal Blocks

C
Load opening the contacts. But, when the contacts are closed, a current
Power
flows to charge the capacitor, causing contact welding.
Generally, switching a DC inductive load is more difficult than switching a DC

resistive load. Using an appropriate arc suppressor, however, will improve the
switching characteristics of a DC inductive load.
Soldering
Circuit Breakers
1. When soldering the relay terminals, use a soldering iron of 30 to 60W, and
quickly complete soldering (within approximately 3 seconds).
2. Use a non-corrosive rosin flux.
774 www.idec.com
Relays & Sockets Operating Instructions
Operating Instructions con’t

Other Precautions
1. General notice: 2. UL and CSA ratings may differ from product rated values determined by IDEC.
To maintain the initial characteristics, do not drop or shock the relay.
3. Do not use relays in the vicinity of strong magnetic field, as this may affect
The relay cover cannot be removed from the base during normal operation. To relay operation.
maintain the initial characteristics, do not remove the relay cover.
Use the relay in environments free from condensation, dust, sulfur dioxide
(SO2), and hydrogen sulfide (H2S).
Make sure that the coil voltage does not exceed applicable coil voltage range.
Display Lights
Safety Precautions
• Turn off the power to the relay before starting installation, removal, wiring, Precautions for the RU Relays
maintenance, and inspection of the relays. Failure to turn power off may
cause electrical shock or fire hazard. • Before operating the latching lever of the RU relay, turn off the power to
the RU relay. After checking the circuit, return the latching lever to the
• Observe specifications and rated values, otherwise electrical shock or fire original position.
hazard may be caused.
Relays & Sockets

• Do not use the latching lever as a switch. The durability of the latching lever
• Use wires of the proper size to meet voltage and current requirements. Tight- is a minimum of 100 operations.
en the terminal screws on the relay socket to the proper tightening torque.
• When using DC loads on 4PDT relays, apply a positive voltage to terminals of
• Surge absorbing elements on AC relays with RC or DC relays with diode are neighboring poles and a negative voltage to the other terminals of neighbor-
provided to absorb the back electromotive force generated by the coil. When ing poles to prevent the possibility of short circuits.
the relay is subject to an excessive external surge voltage, the surge absorb-
ing element may be damaged. Add another surge absorbing provision to the • DC relays with a diode have a polarity in the coil terminals. Apply the DC volt-
relay to prevent damage. age to the correct terminals.
Timers
Terminal Blocks
Circuit Breakers

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2010-08-31

Assembly and operation instructions

Read the instructions prior to performing any task!

Installation and operating instructions (translation of the original)

© NEUMAN & ESSER GmbH & Co. KG 2010

These instructions enable you to use reciprocating compressor

NEA USA 291007 / Ser. No. 108399

3 Construction and function ................................................35

NEA USA 291007 / Ser. No. 108399

3.3 Assembly description.................................................39

4 Transportation, packaging and storage ...........................56

5 Installation and initial commissioning .............................66

7 Long-term removal from service ......................................71

NEA USA 291007 / Ser. No. 108399

8.4.8.2 Replacing the discharge valves ..105

10 Disassembly and disposal ..............................................137

11 Spare parts ......................................................................138

12 Technical data .................................................................139

NEA USA 291007 / Ser. No. 108399

12.10 Cylinder plate .......................................................... 155

13 Index ................................................................................ 157

NEA USA 291007 / Ser. No. 108399

1 Drive unit 3 Compressor section

NEA USA 291007 / Ser. No. 108399

1.1 Warranty terms

1.2 Customer Service

NEA USA 291007 / Ser. No. 108399

2.1 Explanation of symbols

DANGER This combination of symbol and signal word indicates an immedi-

WARNING This combination of symbol and signal word indicates a possibly-

CAUTION This combination of symbol and signal word indicates a possibly-

NOTICE This combination of symbol and signal word indicates a possibly-

Tips and recommendations

Additional markings To emphasise operating instructions, results, lists, references and

NEA USA 291007 / Ser. No. 108399

Listing without fixed sequence

[Buttons] Operating elements (e.g. buttons, switches),

"Display" Screen elements (e.g. buttons, program-

NEA USA 291007 / Ser. No. 108399

2.2 Proper use

The reciprocating compressor 108399, type 1+1TVL190 is used

Proper use also includes adherence to all the stipulations in these

WARNING Hazard due to improper use.

NEA USA 291007 / Ser. No. 108399

2.3 Basic hazards

2.3.1 General hazards in the workplace

2.3.2 Hazards due to electrical energies

NEA USA 291007 / Ser. No. 108399

There is an immediate risk of fatal electric shock if live components

2.3.3 Mechanical hazards

Sharp edges and pointed corners

CAUTION Danger of injury posed by sharp edges and pointed corners!

2.3.4 Hazards due to hydraulic energies

NEA USA 291007 / Ser. No. 108399

CAUTION Danger of injury from oil mist!

2.3.5 Hazards due to pressurised gases

2.3.6 Hazards due to high or low temperatures

WARNING Danger of injury from hot surfaces!

NEA USA 291007 / Ser. No. 108399

WARNING Risk of injuries from cold surfaces!

2.3.7 Fire hazards

Fire prevention and protection

NEA USA 291007 / Ser. No. 108399