Manual Do Soprador Afs

VSB VALLOUREC & SUMITOMO TUBOS DO BRASIL LTDA
BLAST FURNACES 1 & 2

PLANT OF JECEABA
DATA BOOK
SINGLE STAGE
CENTRIFUGAL BLOWERS
TURBLEX INC.
A Reviso 21/08/2009 RDA RDA RDA
0 Emisso Inicial 20/07/2009 RDA RDA RDA
Rev. No.
Rev. No.
Descrio da Reviso
Description of Revision
Data
Date
Preparado
Prepared
Checado
Checked
Aprovado
Approved
Ttulo do Documento:
Title of Document / Designation:
Nmero PW:
PW Number:
Rev.
1375-02-0065
A
Documentos de Referncia:
Reference Documents:
DATA BOOK
SINGLE STAGE
CENTRIFUGAL BLOWERS
TURBLEX INC.
C-81/1375/OC/005
Nmero VSB:
VSB Number:
Rev. Nmero Subfornecedor:
Subsupplier Number:
Rev.
Nmero total de pginas
Number of pages

PRELIMINARY
OPERATION & MAINTENANCE MANUAL
FOR

VALLOUREC & SUMITOMO
TUBOS DO BRASIL LTDA
BRAZIL

SINGLE-STAGE
CENTRIFUGAL BLOWERS

July 30, 2009

VOLUME 1 OF 1
CONTAINS ITEMS A K

TURBLEX JOB #08104607T

1635 W. WALNUT
SPRINGFIELD, MO 65806
PHONE: 417-864-5599
FAX: 417-866-0235
www.turblex.com

1635 W. Walnut Street
Springfield, Missouri 65806-1643
Telephone (417) 864-5599
Facsimile (417) 866-0235
E-mail: turblex@turblex.com
Web Site: www.turblex.com

OPERATION & MAINTENANCE MANUAL
TABLE OF CONTENTS
Item Description
- Title/Cover Page
- Table of Contents
A General Information
a. Safety Precautions
b. Receiving & Handling
c. Recommended Lifting Diagram - 4 Point Lift
d. Storage Requirements
e. Vibration Isolator Installation Instructions
f. Instrument Installation Instructions
g. Allowable Load on Compressor Discharge Flange
h. Recommended Lubricants for Turblex/HV-Turbo Compressors
i. Suggested Preventative Maintenance Schedule
j. Sample Blower Data Log Sheet
k. Turblex/HV-Turbo Service & Spare Parts Capabilities
l. Service/Engineering Rate Schedule
m. Turblex Recommended Spare Parts
n. Troubleshooting Guide
B Compressor Information
a. Compressor Nameplate Data
b. Description of Turblex/HV-Turbo Compressor
c. VD Description of Operation
d. Surging & Recirculation
e. Performance Datasheet (PDS)
f . Speed Torque Curve
C Operation Description
a. Local Control Panel Operation Description
b. Local Control Panel Operator Interface/ Screens
c. Operating Restrictions
d. Instrument Setpoints
D Drawings
a. General Arrangement Drawing(s) and Installation Notes
b. Process & Instrumentation Diagram(s)
c. Local Control Panel Electrical Diagrams
E Coating System
F Performance/Functional/On-Site Testing
a. Compressor Performance Test Report
b. Motor Test Report
c. Functional/On-Site Testing
G Pre-Startup Inspection Checklist
H Turblex Equipment Warranty
I List of Components
J Appendix
a. Center of Gravity Calculations
b. Vibration Isolator Natural Frequency and Transmissibility
c. Instrument List
K Quality Manual

L:\Project_Engineering\Jobs\4607T\Engineering\Mechanical_Eng\O&M\Electronic_O&M\4607T Tblecnts Prelim O&M.doc.aj

Telephone (417) 864-5599
Facsimile (417) 866-0235

ITEM A
SAFETY PRECAUTIONS

1. ROTATING EQUIPMENT HAZARDS: Beware of the rotating equipment hazards around the blower and
motor area. Avoid wearing loose clothing and stay at least three (3) feet away from unit during normal
operation.

2. AUTOMATIC EQUIPMENT HAZARDS: Beware that the equipment can start AUTOMATICALLY. All site
tag-out/safety lockout procedures must be followed when working or standing on this equipment. The
coupling guard, which is painted safety yellow, must be in place at all times. Site tag-out/safety lockout
procedures must be followed if the coupling guard is removed for any reason.

3. NOISE HAZARDS: This equipment operates at noise levels of 80 dB(A) and above. All entrances to the
blower building must be posted with the appropriate OSHA warning signs. OSHA-approved ear protection
must be worn when working in the blower building while the equipment is in operation.

4. ELECTRICAL EQUIPMENT HAZARDS: Beware of the low and high voltage power requirements of the
control panels and the motors. All site tag-out/safety lockout procedures must be followed when working
in and around this equipment. The appropriate OSHA safety warnings should be posted where
necessary.

5. PRESSURIZED OIL HAZARDS: The lube oil system may consist of a pumping system, which supplies
oil to the blower bearings at pressures up to 120 psi. Use the proper site tag-out/safety lockout
procedures before performing maintenance operations.

6. MOVING AIR HAZARDS: Remove all loose objects and equipment from the vicinity of the blow-off outlet.
Use the proper site tag-out/safety lockout procedures before removing any piping from the inlet or
discharge of the compressor, including the changing of inlet air filters.

7. SAFETY EQUIPMENT: All site safety equipment rules and procedures must be followed when in this
area. This includes wearing proper protective goggles, ear muffs, shoes, clothing, etc.

8. EMERGENCY SHUTDOWN OF THE EQUIPMENT: Should an emergency occur, the equipment will
automatically shutdown or can be physically shutdown by pushing the red emergency stop (E-Stop) button
located on the front of the appropriate local control panel (LCP) door. CAUTION: Surging will occur when
the equipment is shutdown in emergency-stop situations. This is considered normal and will not damage
the equipment.

9. SPECIAL HV-TURBO BLOWER TOOLS: This equipment is provided with a special set of tools, which
are required to perform certain maintenance and repair operations. These tools are provided in a specially
marked toolbox, and should be maintained for their respective uses only. Failure to use the appropriate
tools for maintenance and repair operations may damage the equipment and/or injure service personnel.

Z:\Submittal_O&M\Master_Sub\Item_A_GenInfo\Source_Docs\Safety_Precautions.doc
Document Name: 4607T-Item A Rev A

Telephone (417) 864-5599
Facsimile (417) 866-0235

Z:\Submittal_O&M\Master_Sub\Item_A_GenInfo\Source_Docs\Receiving_&_Handling.doc
ITEM A

RECEIVING & HANDLING

Care is taken at the factory to ensure the compressor arrives at its destination in first class
condition. Inspect unit to make sure no damage has occurred during shipment. Make the
examination before removing from the truck. If damage or indication of rough handling is
evident, file a claim with the carrier at once, and notify Turblex.

Each compressor skid assembly is provided with lifting lugs at the four corners of the
base/skid for lifting the assembled machine. The equipment needed to handle the
compressor skid assembly should include a hoist and spreader bar arrangement of
sufficient strength to lift the compressor assembly safely. The spreader bar should have
lifting hooks positioned to equal the span of the lifting lugs. An experienced rigger should
be used to handle the equipment.

CAUTION
Uneven lifting must always be avoided. Slings of equal lengths must always be
used to avoid uneven lifting, when single point lifting is to be used.

CAUTION
Lifting lugs or eyebolts on the motor/compressor are designed for handling that
equipment only. They are not to be used to lift the compressor assembly.

WARNING
Failure to observe these precautions may result in damage to the equipment or
injury to personnel.

I T E M A

Telephone (417) 864-5599
Facsimile (417) 866-0235

STORAGE REQUIREMENTS

If the compressor is not to be installed and placed into service immediately, certain normal precautions must be taken
after it has been received to provide proper protection while the compressor is being stored. A unit is considered to be in
storage when:

1. It has been delivered to the jobsite and is awaiting installation
2. It has been installed, but operation is delayed pending completion of plant construction
3. There are long periods between operating cycles
4. The plant is shut-down

Storage requirements for up to six (6) months prior to start-up:

The compressor and all accessories, including any free standing control panel, valves, silencers, enclosure, instruments,
and spare parts must be stored indoors, under cover, in a clean, dry location. Since moisture can be very detrimental to
electrical and rotating equipment, the ambient temperature must be maintained above 50F (10C), with relative humidity
less than 90%, by providing either external or internal heating. If the motor is equipped with space heaters, they must be
energized at the voltage shown by the space heater nameplate attached to the motor. Incandescent light bulbs can be
placed within the motor or control panel to provide heat. However, if used, they must not be allowed to come in contact
with any parts of the motor or control panel because of the concentrated hot spot that could result. Avoid exposing
compressor and sensitive components to vibration.

Additional storage requirements after first six (6) months prior to start-up:

Compressors and motors having sleeve journal bearings are shipped without oil in the reservoirs. In storage, the
reservoirs must be properly filled with the manufacturers recommended lubricant. Grease lubricated motors are
generally shipped with the bearings lubricated and ready for operation.

To prevent the bearings from flattening and the shaft journals from pitting, rotate the compressor and motor shafts one-
half turn (180) every two (2) to three (3) weeks. If the unit is supplied with an electric oil pump, run electric oil pump for
30 minutes to thoroughly lubricate the bearings prior to rotating the shafts.

To prevent the control vanes from sticking, cycle the vanes open and close at least two (2) cycles every two (2) to three
(3) weeks.

Provide temporary power to the local control panel in order to run the electric oil pump, if supplied, and cycle the control
vanes. If the control panel is not pre-wired to the compressor skid assembly, provide temporary connections between
motor starters located in the control panel and the terminals in the junction box at the skid assembly. If the control panel
is provided with umbilical cords for quick and easy connections to the skid assembly, plug the umbilical cords into the
connectors at the skid assembly.

Recommended storage procedures after start-up:

If the compressor is to remain idle for more than 60 days, follow the above pre-start-up storage requirements. In addition,
place the compressor control in the service mode and cycle the valves open and close at least two (2) cycles every two
(2) to three (3) weeks. The local control panel is to remain energized while the compressor is idle.

NOTE: For more details on motor storage requirements, refer to motor manufacturers instructions in the Operation and
Maintenance Manual.
WARNING
Warranty will be voided if storage instructions are not followed.

Z:\Submittal_O&M\Master_Sub\Item_A_GenInfo\Source_Docs\Storage_Reqmts.doc
ITEM A

Telephone (417) 864-5599
Facsimile (417) 866-0235

ITEM A

VIBRATION ISOLATOR INSTALLATION INSTRUCTIONS FOR XLW TYPE

FOR USE WITH MODELS KA22 KA66 COMPRESSORS

Proper baseplate leveling is critical and must be achieved in strict accordance with the
following instructions prior to start-up.

Transverse level is to be set over the width of the baseplate by placing a
machinist level on skid beams.

Longitudinal level is to be set over the length of the baseplate by placing a
machinist level on the motor shaft.

The vibration isolators are supplied assembled with a 6x12x thick mounting
plate and related fasteners.

INSTALLATION STEPS

1. Lower the compressor into position on the concrete floor while positioning the
isolators using the holes in the skid and fasteners provided. The top plates of the
isolators should rest on their respective housings prior to adjustment. Check for
isolators where the top plates do not touch the housings and measure the distances.
This indicates that these isolators are resting on low spots on the floor. If the
isolator top plates are resting on the housings, and a level bubble confirms that the
baseplate is not level, then the isolators are resting on the high spots on the floor.
Check the skid to be sure that it is resting level.
2. If the distance between the top plates and the housing is more than 1/16, shims
may be inserted between the top plates and the compressor base to shorten these
distances to within 1/16. If shims are used, they must be at least the same size as
the top plate of the isolators. If the distance is greater than , this indicates that
the concrete in these areas is excessively low (below ) and must be filled in with
epoxy and allowed to harden. Alternatively, the high spots under the isolators
where the top plate is resting on the housingcan be ground down to narrow the
gap between the top plate and the housings of the isolators located in the low spots.
3. Once all isolator top plates are either resting on the housings or within 1/16 of the
housing, and the compressor base is level, scribe a mark around the 3/4' isolator
mounting plates.
4. Remove the skid to isolator attachment fasteners, lift the compressor away from the
area, and remove the isolators from their mounting position.

ITEM A

VIBRATION ISOLATOR INSTALLATION INSTRUCTIONS FOR XLW TYPE

FOR USE WITH MODELS KA22 KA66 COMPRESSORS

2
5. The area is now ready for the vibration isolators to be glued to the floor. Follow the
directions on the Loctite Depend Adhesive package supplied and apply the adhesive
to the scribed area on the floor. Use enough adhesive to completely cover the
isolator scribed area. Apply the activator to both the concrete and the bottom of the
isolator mounting plates.
6. Within 15 minutes after the activator is applied, set the isolators into place on the
scribed areas taking care to be sure the mounting plates register properly with the
glue. Set the skid on top of the isolators taking care to align the isolator and skid
mounting holes and attach the skid to the isolators with the fasteners provided.
Allow a drying time of 4 hours minimum for the adhesive to reach approximate full
strength before leveling the compressor.
7. Adjust the isolators so that the top plates are a minimum of or a maximum of
off the housings. Start at one isolator by turning its adjusting nut clockwise four (4)
times, then move to the next isolator and turn its adjusting nut four (4) times.
Continue this procedure until the top plates of each of the isolators are to off
their respective housings. Check the skid to be sure it is level. The skid may now
be leveled by making small adjustments of individual isolators at the high and low
points.
8. After the equipment is level, visually check each isolator to make sure spring coils
are not closed solid and there is sufficient clearance between the top plate and
housing.

Z:\Submittal_O&M\Master_Sub\Item_A_GenInfo\Source_Docs\Vibo_Install_XLW_Type.doc
INSTALLATION STEPS FOR XLW VIBRATION ISOLATOR
XLW VIBRATION ISOLATOR
STEP 1a
ISOLATOR
1/2-13 BOLT
1/2- LOCK WASHER
1/2- WASHER
STEP 1b
NO GAP
1. NORMAL IF SKID IS LEVEL
2. INDICATES ISOLATOR IS RESTING ON A HIGH SPOT IF SKID
IS NOT LEVEL
STEP 1c
GAP
MEASURE
1. INDICATES ISOLATOR IS RESTING ON A LOW SPOT
STEP 2a
ISOLATOR SHIM
1. IF GAP IS MORE THAN 1/16 INCH BUT LESS THAN 1/4 INCH
ADD SHIMS
STEP 2b
GAP
1. IF GAP IS MORE THAN 1/4 INCH FILL AREA WITH EPOXY
TO LEVEL
STEP 2c
NO GAP
1. HIGH SPOTS CAN BE REMOVED TO CLOSE THE GAP OF
ISOLATORS LOCATED IN LOW SPOTS
x x x x x x x
STEP 2d
GAP
1. GAP ON ALL ISOLATORS SHOULD BE FROM 0 - 1/16 INCH
STEP 3
STEP 4a
REMOVE FASTENERS
ITEM A
STEP 4b
STEP 4c
STEP 5a
STEP 5b
STEP 5c
STEP 5d
STEP 6a
12
6
3 9
12
6
3 9
STEP 6b
6
3 9
3 9
12
12
6
STEP 7a
CHECK GAP
TURN ADJUSTING NUT CW 4 TURNS PER ISOLATOR
AND REPEAT UNTIL 1/4 TO 1/2 INCH GAP IS ACHIEVED
ADJUSTING NUT
ITEM A
STEP 7b
ADJUSTING NUT
CW RAISES SKID
CCW LOWERS SKID
1. CHECK TRAVERSE AND LONGITUDINAL LEVEL OF SKID
2. ADJUST LEVEL AS REQUIRED
STEP 8
SPRING COIL TO
COIL CLEARANCE
1. SPRING COILS SHOULD NOT CONTACT EACH OTHER
2. ADJUST GAP AS REQUIRED TO OPEN COIL CLEARANCE
ITEM A

Telephone (417) 864-5599
Facsimile (417) 866-0235

INSTALLATION INSTRUCTIONS FOR FIELD MOUNTED
INSTRUMENTS 1.

Install Tubing between High-Side of Differential Pressure
Transmitter and pitot tube at discharge cone.
Recommended tube size is 5/16 stainless steel.
PITOT Tube with process connections,
one on each side. Install tubing from
differential pressure transmitter here. If
supplied, install discharge pressure gauge on
opposite side.
Differential Pressure
Transmitter with
process connections.
Process connections. One on each
side. If supplied, install discharge
temperature gauge or transmitter here or
on opposite side.
Reinstall oil temperature
gauge when shipped
loose.
Reinstall oil pressure
gauge when shipped
loose.
ITEM A

Telephone (417) 864-5599
Facsimile (417) 866-0235

INSTALLATION INSTRUCTIONS FOR FIELD MOUNTED
INSTRUMENTS 2.

Install tubing between low-side
of Differential Pressure
Transmitter and Inlet
Filter/Silencer shroud.
Recommended tube size is
5/16stainless steel.
ITEM A
Inlet Filter Differential Pressure
Gauge/Switch. If supplied, install
conduits and wires to Local Control
Panel (LCP).
Inlet
Filter/Silencer
Differential
Pressure
Transmitter
Inlet Filter/Silencer shroud with
process connection. Install
tubing from differential pressure
transmitter here.

Telephone (417) 864-5599
Facsimile (417) 866-0235

INSTALLATION INSTRUCTIONS FOR FIELD MOUNTED DEVICES

Discharge Valve
Blow-Off Silencer
Discharge Cone
Discharge Check Valve
See Note 1
A pipe spool piece (minimum one pipe diameter)
must be installed between the check valve and
the discharge valve to allow clearance for the
valve plates to open
Note 1: Please note, regardless of the discharge orientation of the blower, Turblex
recommends the discharge check valve be installed in the horizontal position. The
discharge check valve is to be installed as close to the discharge cone as possible. If it is
not installed in the horizontal position, please notify Turblex. The hinge post must be in
the vertical position.
Vibration Isolators
Local Control Panel
Blow-Off Valve
Discharge Expansion
Joint
ITEM A

Telephone (417) 864-5599
Facsimile (417) 866-0235

Z:\Submittal_O&M\Master_Sub\Item_A_GenInfo\Source_Docs\Allowable_Load_on_Comp_Dischrg_Flange_Eng.doc
ITEM A

ALLOWABLE LOAD ON THE COMPRESSOR DISCHARGE FLANGE

The discharge air dynamic forces are absorbed by the static restraint of the base assembly. Likewise, the
dynamic forces in the discharge piping must be restrained by independent mounting and support of the
discharge piping.

The allowable misalignment forces, which can be applied to the compressor discharge flange through the
deflection of the expansion joint, are listed in the table below.

See Figure 1.

Fax = Forces in the discharge pipe direction.
Flat = Forces perpendicular to Fax.
M = Moment in any direction.

TYPE

FAX
LB.

FLAT
LB.

M
IN. LB.

KA2

KA5

KA10

KA22

KA44

KA66

KA80

KA100

247

607

899

1236

1708

2248

3035

3934

74

180

270

360

495

675

900

1124

575

1991

3098

5310

7965

13275

17700

30976
Flat
Fax
M

Telephone (417) 864-5599
Facsimile (417) 866-0235

L:\Project_Engineering\Submittal_O&M\Master_Submittal\Item_A_GenInfo\Source_Docs\Recomm_Lubricants_GA_GB_GC_GL_Gearbox.doc
ITEM A
RECOMMENDED LUBRICANTS
FOR TURBLEX/HV-TURBO COMPRESSORS WITH JOURNAL BEARINGS

FOR USE WITH GA, GB, GC, & GL SERIES GEARBOXES
EXCEPT KA100-GL500 COMPRESSOR

COMPANY

TRADE NAME
VISCOSITY
GRADE
cSt @
40C
cSt @
100C
BP BP Bartran HV 46 46 46.50 8.22
Castrol Dual Range HV 46 46.50 7.90
Chevron Rando HDZ ISO 46 46 46.00 8.60
CITGO A/W Hydraulic Oil 46 46 46.50 6.80
76 Lubricants by
Conoco Philips
76 UnaxAW 46 46 46.5 7.00
Dryden Paradene 46AW 46 45.89 6.72
Exxon Nuto H 46 46 46.00 6.70
Mobil DTE 25 46 44.20 6.65
Petro-Canada Hydrex AW46 46 45.70 6.70
Primrose Syn-0-Gen 46 46 58.50 10.10
Royal Purple Syndraulic 46 46 46.00 7.10
Schaeffers Mfg 112 HTC ISO 46 46 48.50 7.10
Shell Tellus Premium 46 46 46.00 6.80
Valvoline
Premium Anti-wear
Hydraulic Oil
46 46.20 6.70
Lubrication
Engineers Int.
LE 6110 Monolec
Hydraulic Oil
46 48.80 6.84
Lubriplate Lubriplate HO-46 46 42.00 7.00
Ultramar Canada
Inc
Hydraulik AW 46 46 45.70 6.70

Oil Temperature Limits In Oil Reservoir:

Normal: 120F-130F/50C-55C
Maximum: 160F/71.1C
Minimum: 50F/10C

NOTE: If the above recommended lubricant is not available, please provide alternate oil specification
data sheet and MSDS to Turblex for approval. If improper lubricant is used, any damage that
could be caused by this will not be covered under Turblex warranty.

OIL VOLUME PER BLOWER____________ GALLONS.

275
(1041 Liters)

Telephone (417) 864-5599
Facsimile (417) 866-0235

ITEM A

SUGGESTED PREVENTATIVE MAINTENANCE SCHEDULE

ROUTINE INSPECTIONS (by Plant Personnel)

Inspect for cleanliness and general condition of compressor assembly unit
Inspect and replace inlet filter(s) as required
Inspect and clean/change oil filter(s) as required (if applicable)
Check lube oil level and sample/change oil as required
Test safety switches
Verify all 4-20 mA current loops are operating properly
Verify surge detection unit operates properly (See Item I 1370)

ANNUAL INSPECTIONS (by Plant Personnel)

Repeat routine inspections, plus - - -
Inspect inlet silencer for cleanliness and general condition
Verify discharge check valve operates properly to prevent back flows
Inspect control arm(s) of variable control vanes for slippage
Inspect and tighten all mechanical and electrical connections
Check coupling alignment and tightening torques of all bolts

18,000 HOURS -CLASS I INSPECTION (air-end only)

First inspection, after 18,000 hours of service (or sooner if site conditions dictate); thereafter, based on
conditions and appearance of operating mechanisms. Estimated service time: 2-4 days, per unit,
assuming one (1) local helper and crane facilities. A Class I Inspection includes the following:

Repeat routine and annual inspection, plus - - -
Dismantle compressor air-end
Inspect and clean variable vane system
Check variable vane geometry
Check axial movement on high and low-speed shafts
Dismantle gearbox (GK series gearbox only)
Replace fast shaft ball bearings (GK series gearbox only)
Check unit alignment before re-start as required

36,000 HOURS -CLASS II INSPECTION (air-end and gearbox)

Only GC and GK series gearboxes require Class II inspections after approximately 36,000 hours of service.
Other gearboxes may require Class II inspections only based on conditions and appearance of
operating mechanism during Class I inspection.

Estimated service time: 2-7 days, per unit, assuming one (1) local helper and crane facilities. A Class II
Inspection includes the following:

Repeat Class I Inspection, plus - - -
Dismantle gearbox
Inspect gearwheels, bearings & seals and check clearances
Replace roller/ball bearings (GC series gearbox only)
Replace slow shaft ball bearings (GK series gearbox only)
Replace flexible seals (O-rings)
Inspect electric motor, oil pump, oil cooler, coupling, valves, etc.

2
Z:\Submittal_O&M\Master_Sub\Item_A_GenInfo\Source_Docs\Sugg_Prev_Maint_Sch.doc

DRIVE MOTOR (by Plant Personnel)

Keep motor clean and ventilation openings clear of dust, dirt, or other debris. Lubricate bearings every 3
months. Follow instructions found in the Components section of this manual (Item I).

DRIVE COUPLING (by Plant Personnel)

N10 Coupling (used on all compressor models except KA2-GK2/B3): Check alignment and outer blades of
disc-pack for fatigue cracks every 12 months. Check tightening torques of all drive bolts. Follow
instructions found in the Components section of this manual (Item I).
T10 Coupling (used on KA2-GK2/B3): Inspect seal ring and gasket every 12 months. Re-lube coupling
based on recommendation of lubricant manufacturer. Check tightening torques of all drive bolts and
fasteners. Follow instructions found in the Components section of this manual (Item I).

AUXILIARY OIL PUMP MOTOR (If applicable, by Plant Personnel)

Keep motor clean and ventilation openings clear of dust, dirt, or other debris. Lubricate bearings every 3
years. Follow instructions found in the Components section of this manual (Item I).

MAIN OIL PUMP MOTOR (If applicable, by Plant Personnel)

Keep motor clean and ventilation openings clear of dust, dirt, or other debris. Lubricate bearings every year.
Follow instructions found in the Components section of this manual (Item I).

LUBE OIL FILTER (If applicable, by Plant Personnel)

Check filter indicator frequently to determine when the element needs servicing. Follow instructions found
in the Components section of this manual (Item I).

CHANGE OF LUBE OIL (by Plant Personnel)

The lube oil should be changed after the first 500 hours of operation. For GA, GB, GC and GL series
gearboxes, subsequent oil samples should be evaluated by an oil analysis service every three (3)
months, with change of lube oil to take place according to the recommendation of the oil analysis
service. For GK series gearbox, subsequent oil change is to take place every 6,000 hours of
operation.

SOLENOID VALVE AND BUTTERFLY VALVE (If applicable, by Plant Personnel)

While unit is off-line, operate the valve once a month to insure proper opening and closing.

To schedule a Turblex Field Service Technician for assistance, please contact the Turblex Service Department
(Tel: 417-864-5599; Fax: 417-866-0235) approximately two weeks prior to shut-down. Rates would be per
the most current published Turblex Service Rate Schedule. Estimates are available upon request.

BLOWER DATA LOG SHEET - COMPRESSOR DATE:
0800 1200 1600 2000 2400 0400
HOUR METER
VARIABLE DIFFUSER POSITION (SCALE)
INLET GUIDE VANE POSITION (SCALE)
INLET TEMPERATURE
DISCHARGE TEMPERATURE
OIL PRESSURE
OIL TEMPERATURE
NOTE: This chart or facsimile should be filled out on each shift.
U:\Sub-O&M\Blower Data Log Sht.xls
ITEM A
1
(SAMPLE)
TIME
INSTRUMENTS

Telephone (417) 864-5599
Facsimile (417) 866-0235

Z:\Submittal_O&M\Master_Sub\Item_A_GenInfo\Source_Docs\Svc_Spare_Parts_Capabilities.doc
ITEM A

TURBLEX/HV-TURBO SERVICE & SPARE PARTS CAPABILITIES

Turblex in Springfield, Missouri, has field service engineers/technicians capable of reacting within 24 hours to
emergency service needs.

Spare and replacement parts commonly used for bearing replacement, O-rings, and gaskets, are maintained
as stock components, and are available for overnight shipment from Springfield, Missouri.

HV-Turbo in Helsingor, Denmark, maintains a staff of service engineers and technicians on 24-hour
emergency notice from the Helsingor plant.

A complete stock of standard repair and replacement parts, for all machine sizes, are maintained in
Springfield, Missouri.

Telephone (417) 864-5599
Facsimile (417) 866-0235

ITEM A
2009 INSTALLATION & COMMISSIONING ENGINEERING RATE SCHEDULE
USD
DESCRIPTION HOUR/DAY/MILE
Factory Representatives normal working hours (Monday through Friday) $150.00/hr
1st through 4th working hours in excess of normal
working hours and working on Saturday 225.00/hr
Additional overtime hours and working on Sunday
and national holidays $300.00/hr
Engineering Personnel normal working hours (Monday through Friday) $200.00/hr
1st through 4th working hours in excess of normal working
hours and working on Saturday $300.00/hr

Additional overtime hours and working on Sunday
and national holidays $400.00/hr

Traveling hours $150.00/hr
Helper working/traveling hours $75.00/hr
Airfare Cost, plus 15%
Per diem (domestic), including: lodging, car rental, telephone, fax, meals, gas $290.00/day
International per diem, including: lodging, car rental, telephone, fax, meals, gas, Cost, plus 15%
Helper per diem (less car rental) $205.00/day
Traveling expenses by Company car/truck per mile $0.65/mi
Charge for waiting time on Saturdays, Sundays and holidays: $250.00/day
Replacement parts/supplies (i.e., special sealants, etc.), if necessary: as per Invoice
Delivery of replacement parts (domestic), if any. Prepaid/Added to the invoice
Delivery of replacement parts (international), if any. Collect

TRAVEL TIME
All travel time from home base of operation to jobsite and return shall be charged in accordance with the above defined
workday rates. Daily travel time to and from lodging will not be included and billed as part of the workday.

STAND-BY TIME
All time the Factory Representative is on stand-by or is available to work Monday through Friday, but is unable to due to
reasons other than his own sickness or injury, shall be charged in accordance with the normal workday rates.

TRANSPORTATION AND LIVING EXPENSES
All transportation and living expenses during the service period from the time the Factory Representative leaves his base
of operation until the time he returns shall be charged as defined above.

RESPONSIBILITY
The Factory Representative shall interpret the Company's drawings and data for the equipment and advise/assist the
Customer regarding the sequence of steps and procedures for installation, start-up, dismantling, repairing and assembly of
the equipment as the case may be.

The Customer shall supply, at their own expense, all labor, material, replacement parts, special tools (other than
Company-supplied tools and instruments required for unique procedures and/or collection of operating data), equipment
cranes, rigging tools, outside balancing/machining and facilities required to perform the physical work on the equipment.

L:\Turb\SERVICE\Forms\TURBLEX\Svc Rate 2009.doc

Telephone (417) 864-5599
Facsimile (417) 866-0235

ITEM A

TURBLEX RECOMMENDED SPARE PARTS

1 Set Compressor Bearings

1 Set Compressor Seals/O-Rings

1 Each Variable Diffuser Actuator

1 Each Mechanical Oil Pump

1 Each Complete Auxiliary Oil Pump Assembly including Motor, Coupling
and Pump

1 Set Oil Filter Elements/Filter

1 Set STE- Compressor Special Tools

DRIVE MOTOR

1 Set Bearing - Opposite Drive End (ODE)

1 Set Bearing - Drive End (DE)

INLET AIR FILTER HOUSING

1 Set Coarse Primary Filters/Unit

1 Set Fine Secondary Filters/Unit

NOTE: FOR ACTUAL SPARE PARTS, REFER TO COMPONENTS LIST UNDER TAB I.

Z:\Submittal_O&M\Master_Sub\Item_A_GenInfo\Source_Docs\Recomm_Spare_Parts.doc
OBSERVED PROBLEM PROBABLE CAUSE CHECK FOR OPERATOR RESPONSE
1. Blower fails to start. 1a. 1a. 1a.
1b. Blow-off valve not fully open. 1b. Check blow-off valve status at LCP. 1b.
1c. 1c. Verify switch position. 1c. Set the switch to NORMAL position.
1d. NORMAL/TEST switch in TEST position. 1d. Verify switch position. 1d. Set the switch to NORMAL position.
1e. Alarms not cleared. 1e. Check for alarms at LCP. 1e. Reset the alarm condition.
1f. No power. 1f. 1f. Replace fuse and/or close breaker.
1g. 1g. Verify time of last starts. 1g. Wait.
1h. Discharge valve not closed. 1h. 1h.

2. 2a. High discharge pressure. 2a. 2a. Lower discharge pressure; verify flow.
2b. IGV not at proper position. 2b. 2b.
2c. IGV arm slipped on shaft 2c. IGV lever arm slipped on shaft. 2c. Verify match marks on IGV shaft.
Recalibrate 4-20 mA.
2d. VD not at proper position. 2d. 2d.
2e. VD arm slipped on shaft. 2e. VD lever arm slipped on shaft. 2e. Verify match marks on VD shaft.
3. 3a. Obstruction in piping or diffusers. 3a. Closed valves. 3a. Open valves to maximize flow.
3b. Plugged diffusers. 3b.
3c. Wrong tank level. 3c. Verify correct tank level.
3d. Stuck check valve. 3d. 3d.
3e. Discharge valve not fully open. 3e. 3e. Visually verify valve position.
Reset limit switch.
3f. Check power to valve operator. 3f.
3g. 3g. Remove any debris.
1
High discharge
pressure.
Check for obstruction in valve, or operator's
gears.
Blower volume
discharge low.
Verify discharge pressure is within normal
range.
Visually evaluate diffuser pattern; attempt
to spot plugged diffusers.
Verify pressure upstream and downstream of
check valve.
Repair check valve if differential pressure
data shows valve is faulty.
Verify IGV position on compressor scale
relative to readout on LCP.
Verify electronics. Set to SERVICE mode
and verify operation of IGV throughout
range. Recalibrate 4-20 mA.
Verify VD position on compressor scale
and verify operation of VD throughout
GENERAL TROUBLESHOOTING GUIDE ITEM A
Set the SERVICE/NORMAL/TEST selector
switch to SERVICE, and open the blow-off
valve. Verify limit switches by using
handwheel if necessary.
NORMAL/SERVICE/TEST switch in
SERVICE position
Check at the breaker for blown fuse or breaker
not engaged.
Inlet guide vane open, possible failure of
interlock.
Check inlet guide vane open/closed status at
LCP.
Set the SERVICE/NORMAL/TEST mode to
SERVICE, and close the inlet guide vane.
Restart blocking; attempting more than two
(2) starts per hour.
Set the SERVICE/NORMAL selector switch
to SERVICE and close the discharge valve.
Verify valve operation and limit switch
settings if closed LED does not illuminate
on LCP.
Discharge valve closed LED not illuminated.
Check control panel indicators to see if
"Discharge Valve Open" indicator is lit.
Tighten any loose connections. Verify
leads are connected properly.
4. Blower surge. 4a. High discharge pressure. 4a. 4a. Check items under Section 3.
4b. High inlet temperature. 4b. Verify inlet temperature is over 130
o
F. 4b.
4c. Plugged inlet air filter. 4c. 4c.
4d. 4d. Visually inspect connections. 4d.
4e. Water in compressor volute. 4e. Verify operation of blow-off/discharge valve. 4e.
5. 5a. Inlet temperature over 130
o
F. 5a. Verify with another thermometer. 5a. Run Compressor in the 60-80% range.
5b. Inlet probe too close to volute. 5b. Verify inlet probe is not too close to volute. 5b. Relocate inlet probe.
5c. Surge. 5c. Check points listed under Section 4. 5c. Check points listed under Section 4.
6. 6a. High inlet temperature. 6a. Verify transmitter/sensor with thermometer. 6a. Replace the transmitter/sensor if faulty.
6b. Operating off design. 6b. Verify IGV/VD position. 6b.
6c. Discharge temperature over 275
o
F. 6c. Verify with thermometer. 6c.
7. Motor overload. 7a. 7a. 7a. Reduce VD position.
7b. Motor/blower malfunctions. 7b. Blower can be rotated easily. 7b.
7c. Low input voltage. 7c. Verify 4160V input voltage. 7c. Correct under voltage situation.
8. 8a. Auxiliary oil pump overload tripped. 8a. Verify touchpad warning light. 8a. Reset overload at MCC.
8b. Auxiliary oil pump circuit breaker/fuses. 8b. Verify MCC. 8b.
8c. Low oil level. 8c. View sight glass/level dipstick. 8c.
8d. Auxiliary oil pump failure. 8d. Verify oil pump malfunction. 8d.
9. 9a. Main oil pump loss of suction. 9a. Low pressure at main oil pump discharge. 9a. Prime main oil pump.
9b. Lube oil piping failure. 9b. Inspect piping. 9b. Repair piping. Refill oil reservoir.
9c. Low oil level. 9c. Verify oil level. 9c. Refill oil reservoir.
9d. Main oil pump failure. 9d. Verify oil pump internals. Check valves
operation.
9d.
2
Lockout blower at MCC. Remove coupling
guard. Blower and motor should rotate
with approximately 200 ft/lb of torque
applied to shaft.
Low oil pressure
during start/stop
sequence.
Reset circuit breaker, replace fuses, and
verify operating current.
Repair low oil level switches and add oil.
Low oil pressure
during operation.
Lockout compresor and auxiliary oil pump.
Verify oil pump internals.
Operate blower in the 60-80% range if
possible.
Operate blower in the 60-80% range if
possible.
High inlet temperature; VD's at full open;
discharge pressure high.
Verify inlet temperature, discharge pressure,
and VD position.
Operate in SERVICE mode. Verify
rotation. Rebuild oil pump.
Pressure connections loose to surge
switch.
Tighten connections on blower and surge
switch.
High discharge air
temperature.
Remove plug at bottom of volute and drain.
High inlet air
temperature.
Verify high discharge pressure check points
listed under Section 3.
Replace air filter elements. Verify
differential pressure meter operation.
Verify differential pressure across air filter.
Visually inspect air filter.
Operate blower in the 60-80% range. If
surging continues, discharge pressure
should be reduced.
10. 10a. Oil cooler fan not operating. 10a. Loss of power, motor overloads tripped. 10a. Reset.
10b. Faulty temperature modulation. 10b. Temperature modulating valve closed. 10b. Repair valve.
10c. Little or no water flow to cooler. 10c. 10c.
11. 11a. Low ambient temperaure. 11a. Verify auxiliary oil pump is operating. 11a.
11b. 11b. 11b. Repair valve.
11c. Cold oil. 11c. Verify Oil Temperature. 11c.
12. Oil filter bypass. 12a. Dirty oil filter. 12a. 12a. Replace filter cartridge.
13. 13a. High oil temperature. 13a. 13a. Check oil cooler.
13b. 13b. 13b. Reduce VD/IGV setting.
13c. Temperature monitor problems. 13c. Verify temperature monitor operation. 13c.
13d. Bearing problems. 13d. Abnormal log data. 13d.
14. 14a. Low oil temperature. 14a. 14a. Verify modulating valve operation.
14b. Coupling out of alignment. 14b. Verify coupling alignment. 14b.
14c. Fault with vibration monitor. 14c. 14c. Notify TURBLEX.
14d. Mechanical damage within the gearbox. 14d. Review logs for trends. 14d. Notify TURBLEX.
14e. Impeller imbalance. 14e. Verify log for trends. 14e. Notify TURBLEX.
15. 15a. Low motor lube oil level. 15a. Verify motor lube oil level. 15a. Add motor lube oil.
15b. Contaminated motor bearing lube oil. 15b. Verify color and level of oil. 15b. Replace motor lube oil.
15c. Wrong lubricant. 15c. Verify compatible lubricant. 15c. Replace motor lubricants per
manufacturing recommendations.
15d. Motor/blower out of alignment. 15d. Misalignment. 15d.
Lockout drive motor and verify coupling
alignment.
15e. Failed motor bearing. 15e. Review operation logs and grease
bearings.
15e.
Contact authorized motor service shop.
3
Verify RTD reading, temperature monitor
operating, lights green.
Temperature modulating valve stuck open.
Verify temperature modulating valve
operation.
High differential pressure across oil filter via
indicator on oil filter.
Switch to SERVICE mode and operate
auxiliary oil pump to raise temperature to at
least 100
o
F and verify oil pressure.
Stop machine and let cool. Start-up and
record log data every 15 minutes until
machine reaches stable temperature.
Notify TURBLEX.
Verify oil temperature is between 110
o
F-
120
o
F.
Lockout motor and verify coupling
alignment.
Blower/motor/
proximity vibration
high and abnormal
noise.
Blower bearing high
temperature.
Verify that the oil temperature is between
110
o
F-120
o
F.
Verify monitor operation by initiating self-test.
High motor bearing
temperature.
High inlet temperature and high discharge
pressure.
Verify inlet temperature, discharge pressure,
and motor current amps.
Low oil temperature.
Check water pressure, valve operation and
position.
Switch to SERVICE mode and start
auxiliary oil pump if it has not automatically
started.
Low water pressure, faulty
solenoid/temperature modulating valve, closed
block valves.
High oil temperature.
16. 16a. 16a. 16a. Reduce VD/IGV setting.
16b. High motor current. 16b. Verify motor loading. 16b. Review observed problem at motor
overload.
16c. Undervoltage/overvoltage. 16c. Verify 4160V input voltage on each phase. 16c. Correct voltage problem.
16d. Connection resistance. 16d. Verify high voltage connections. 16d. Correct motor connection problem.
16e. Internal motor damage. 16e. Review logs for evidence. 16e. Retain authorized motor repair shop.
16f. High motor winding temperature. 16f. Verify motor winding temperature. 16f. Review motor winding problems.
16g. Faulty RTD. 16g. Verify RTD functionality. 16g. Use spare RTD motor.
16h. Faulty transmitter. 16h. Verify transmitter functionality. 16h. Contact Turblex for new transmitter.
16i. Motor winding ventilation 16i. Verify free of debris. 16i. Contact authorized motor service shop.
17. 17a. 17a. 17a.
17b. Blow-off does not open. 17b. 17b. Visually verify valve position.
Reset limit switch.
17c. Discharge does not open. 17c. 17c. Visually verify valve position.
Reset limit switch.
4
High motor winding
temperature.
High pressure, high inlet temperature, and
VD/IGV at maximum.
Verify inlet and ambient temperatures,
discharge pressure, and VD/IGV position.
Stopping; Sequence
fail on shut-down (not
shut-down in two (2)
minutes
and verify operation of VD throughout
Check control panel indicators to see if "Blow-
Off Valve Open" indicator is lit.
Check control panel indicators to see if
"Discharge Valve Closed" indicator is lit.
VD doesn't close. Verify VD position on compressor scale
Document Name: 4607T-Item B Rev B

Telephone (417) 864-5599
Facsimile (417) 866-0235

ITEM B

DESCRIPTION OF TURBLEX / STE COMPRESSOR

The Turblex/STE compressor is of the single-stage, radial type driven by an electric motor through a speed
increasing gear. The compressor is furnished as a complete unit with variable control guide vanes, integral
speed increasing gear, drive motor, lubrication system, and various other accessories specified by the
customer. All parts of the compressor are designed to minimize noise and vibration, and will be suitable for the
service intended.

Compressor Performance

The compressor is designed in accordance with the customer's specifications for inlet capacity, discharge
pressure, inlet temperature and pressure, and relative humidity.

Compressor Case Housing

The casing, rear plate, and flanges are made of close-grained cast iron ASTM A278, Class 30B, have a
maximum design temperature of 400 F and a maximum design pressure of 50 psig. The compressor inlet is a
slip ring design that connects to either an inlet silencer or inlet duct by a flexible band. The discharge flange is
faced and drilled to ANSI 16.1, 125 pounds. All joints in the casing and rear plate are machined for close fit.
The casing is vertically split and designed so that the impeller can be removed from the inlet side without
removal of the casing. Lifting eyes capable of supporting the casing and a drain plug at the lowest point of the
casing are provided.

Impeller

The impeller is of radial flow type with open and backward leaning blades that are machined from a forged
hiduminium aluminum alloy material, ASTM B247 AA2618 (Al Cu2 Mg1.5 Fe1 Ni1, Rolls Royce Aircraft Alloy
No. 58). The impeller is attached to the shaft by a shrink-fit and locknut arrangement, and is statically and
dynamically balanced. The axial gap between the impeller and the casing is adjustable by means of shims.

Variable Control Guide Vanes

KA S Compressor: A single guide van machine with adjustable discharge variable diffuser vanes (VD) for
capacity control. The vanes are multi-leaf, pivoted, and attached to permanently lubricated sleeve bearings.
The VD assembly is mounted integral with the compressor. The assembly includes a lever/scale arrangement
for local indication of vane position, an electric actuator with a built-in position feedback for remote indication of
vane position, and two adjustable max/min position limit switches.

Integral Gearbox

The gear housing is made of high-grade cast iron that is sufficiently rigid to maintain the shaft positions under
maximum loads. The gear housing assemblies are machined to close tolerances for bearing fits, gear
alignment, and oil tightness. All gears are manufactured according to AGMA 6025-C90, to minimum AGMA
quality number of no less than 12, as specified in AGMA 2000/A88. The gear is rated for continuous duty with
a minimum service factor of at least 1.8 at ambient temperatures within the customer's operating conditions in
accordance with AGMA 421.06. All exposed machined surfaces are coated with a corrosion-resistant
compound before shipment.

GL Series Gearbox: The speed increasing gear is a one-stage increase, helical, parallel shaft type. The gear
housing is vertically split.

ITEM B

DESCRIPTION OF TURBLEX/HV-TURBO COMPRESSOR
(REFER TO NAMEPLATE DATA SHEET FOR COMPRESSOR MODEL SUPPLIED)

Shafts and Seals

The shafts are made of high quality alloy steel, accurately machined, case hardened, and ground to size. The
shaft seals are non-contact, multi-point labyrinth type with small clearances and sufficient touch points to
minimize air leakage out of or into the casing while the compressor is running in the specified operating range
or during shutdown. The seals are operated dry and are suitable for any variations in pressure conditions that
may occur during start-up, normal operation, and shutdown.

Bearings

GL Series Gearbox: The drive shaft radial bearings are cylindrical journal bronze bearings. The drive shaft
thrust bearings are multiple segment, double-acting bronze bearings designed for thrust in both directions. The
pinion shaft radial bearings are multiple segment babbitted bronze bearings designed to suppress
hydrodynamic instabilities and provide sufficient damping to limit motor vibrations. The pinion shaft thrust
bearings are multiple segment, tapered land bronze bearings designed for thrust in both directions. The radial
and thrust bearings are pressure lubricated and designed for fully hydrodynamic lubrication with sufficient oil
film thickness under all operating conditions.

Lubrication System

A complete lube oil system is provided with each compressor unit. The system is capable of supplying clean
oil at suitable pressure and temperature to lubricate the compressor gears and bearings. All components of
the lubrication system typically are installed and/or integral with the compressor unit baseplate. The
components are arranged to permit ease of accessibility for operation, maintenance, inspection, and cleaning.

GL Series Gearbox: The lube oil system consists of a reservoir in the compressor unit baseplate, a gearbox
driven main oil pump, an electric motor driven auxiliary oil pump, an oil cooler, a thermostatic control valve, an
oil filter, and miscellaneous appurtenances. The thermostatic control valve will maintain constant oil
temperature.

Oil Pumps

The oil pumps are positive displacement type. Typically, one main and one auxiliary pump are provided,
except for the GK series gearbox. The motors for electrically driven pumps are TEFC type; the horsepower is
rated for the application and usually requires 460 VAC.

Oil Cooler

A customer specified oil cooler is provided to remove excess heat from the lube oil circuit. The two primary
types of oil coolers used by Turblex are the shell and tube water/oil cooler, and the fin and tube air/oil cooler.

Oil Reservoir

The oil reservoir is integral to the compressor baseplate. The interior of each oil reservoir is de-scaled and rust
proofed by the application of a permanent coating of the manufacturers standard. The equipment attached to
the top of the reservoir will be mounted by means of pads to ensure that no tapped holes will extend into the
reservoir. All covered openings are gasketed. Reservoirs will be baffled to minimize air entrainment and to
isolate foam. The reservoir is equipped with a suitably sized vent and breather. The oil
reservoir will have a minimum working capacity of three minutes retention time based upon the mechanical oil
pump flow.

ITEM B

DESCRIPTION OF TURBLEX/HV-TURBO COMPRESSOR
(REFER TO NAMEPLATE DATA SHEET FOR COMPRESSOR MODEL SUPPLIED)

Oil Filter

GL Series Gearbox: The oil filter is a full flow, replaceable cartridge type, capable of removing particles 9
microns in diameter with 98.7% efficiency. The clean oil filter pressure drop shall not exceed 5 psi at the
design temperature and flow. A duplex (two bowl) or simplex (single bowl) filter is supplied in accordance with
the customers specification. The filter element collapse pressure is twice the bypass pressure. The minimum
bypass pressure is 35 psid. A visual indicator is provided to indicate filter condition and filter replacement.
.
Coupling

GL Series Gearbox: The motor-to-compressor coupling is a forged steel, flexible, spacer type with a design
safety factor of at least 1.5 under all operating conditions. The coupling spacer is of sufficient length to permit
the dismantling of the compressor without removing the compressor housing or the electric motor.

Baseplates

The compressor unit is furnished with a baseplate of adequate size to support the compressor, motor,
lubricating system, and accessories. The baseplate is constructed of fabricated steel and is provided with four
lifting lugs. The baseplate is sufficiently rigid to permit lifting the unit, with all equipment mounted, by the four
lifting lugs using a four point lift, without distorting or damaging the baseplate or components mounted to the
baseplate.

Z:\Submittal_O&M\Master_Sub\Item_B_CompressorInfo\Source_Docs\Descrip_of_Tublx_Compressor.doc

Telephone (417) 864-5599
Facsimile (417) 866-0235

ITEM B

VARIABLE DIFFUSERS
DESCRIPTION OF OPERATION

Single-stage HV-Turbo Type S compressors have the unique capability of turndown from 100 to
45% of capacity utilizing variable diffusers (VD) in concert.

This device, used independently, effectively controls capacity, however, maximum efficiencies are
achieved through utilization of integrated automatic controls applied to machines equipped with
variable diffusers (VD).

Variable Diffusers - Variable diffusers are a series of aerodynamic vanes around the discharge of
the impeller that essentially act as an extension of the impeller blades. The variable diffusers alter
the radial component of the velocity of the air exiting the impeller. Thus, rather than throttling, like
the inlet guide vanes, the variable diffusers actually alter the flow direction of the air exiting the
impeller. As a result, compressor efficiency is not significantly affected as the capacity is reduced.

The diffuser vanes further, streamline the flow of air in the compressor internals and volute and
reduce losses due to turbulence. More of the velocity energy of the air is then available at the
blower outlet. The direction of rotation, shape and spacing of the vanes are such that the capacity
of the machine can be varied from 100% to approximately 45% with virtually no decrease of
efficiency.


Telephone (417) 864-5599
Facsimile (417) 866-0235

ITEM B

SURGING AND RECIRCULATION

Surging is one of the most discussed and most feared foibles of centrifugal and other non-positive
displacement compressors.

Surging and recirculation occur when the adiabatic head generated by the compressor is less than
is needed to maintain a uniform, forward flow of air through the impeller. If the air flow rate reduces
below a certain level, the directions of the air flow inside the impeller are so different from the
angles of the impeller blades, that air flow breaks down completely.

When this occurs, compressed air from downstream of the compressor expands through the
impeller in surges, giving rise to the characteristic surging noise.

Other effects of surging are to produce rapid changes in the mechanical load on the rotating
impeller and drive components, and to produce momentary pressurizing in the compressor inlet.

Siemens Turbomachinery Equipment (STE) uses the pressure rise in the inlet to initiate a surge
alarm and to stop the compressor before serious mechanical damage occurs.

Recirculation will occur before full scale surging and results in discrete streams of hot air from the
compressor outlet channeling into the inlet through low flow surfaces of the impeller. This results in
a rapid temperature rise in the inlet of the compressor.

Unless it is checked, continued recirculation can result in thermal damage to the compressor
internals. A temperature sensor in the inlet is used by STE to shut down the compressor if the
temperature in the inlet rises above 130
o
F.

Surging and recirculation result from either a decrease in the adiabatic head being generated by the
impeller or an increase in the system pressure ratio to levels above the design pressure ratio.

Pressure Ratio = Absolute outlet pressure = P
2

Absolute inlet pressure P
1

Factors which can upset the pressure ratio are increases in system pressure downstream of the
compressor or decreases in system pressure at the inlet to the compressor.

Either can be caused by excessive fouling or throttling.

A reduction in the adiabatic head being generated by the compressor can result from:

increased inlet air temperature
increased relative humidity of the inlet air
reduced operating speed of the compressor

It is important then to design compressors for the worst conditions of pressure ratio, inlet air
temperature, relative humidity and flow which they will be expected to endure in service.

2
Item B

Because surging and recirculation occur primarily due to a reduction in flow rate, even compressors
such as the STE Types S and SV, which control air flow without throttling, are limited in their
turndown capacity. For STE that is usually at 45% of design flow. For other types of compressors,
which rely on throttling for flow control, the turn-down limit could be as high as 65% of design flow
and such a limited turn-down gives rise to other, more serious problems in process control where
more than one compressor is in service.

Z:\Submittal_O&M\Master_O&M\Item_B_CompressorInfo\Source_Docs\Surge.doc

Item B
Indgangsakselomdrejningstal (o/m) AntriebswelleDrehzahl (upm) Driveshaftspeed (rpm)
O
p
s
t
a
r
t
s
m
o
m
e
n
t

(
N
m
)

A
n
l
a
u
f
m
o
m
e
n
t

(
N
m
)

T
o
r
q
u
e
(
N
m
)
0 500 1000 1500 2000 2500 3000 3500
0
500
1000
1500
2000
2500
3000
3500
4000
4500
>10 rad/s^2
HVTURBO Verdichter
Anlaufmomentkurve
KA66 S GL400
Dato:010808:09:18:41
HVTURBO compressor
Speedtorque curve
KA66 S GL400
Dato:010808:09:18:41
HVTURBO kompressor
Opstartsmomentkurve
KA66 S GL400
Dato:010808:09:18:41
Pbaro= 0.8980 (Bar) Tmin=281.15 (K) Qmin = 31589. (m3/h)
I=wk2= 34.3 (kg*m2)
GD2 = 137.2 (kg*m2) Sign:__________
I
t
e
m

B

Telephone (417) 864-5599
Facsimile (417) 866-0235

ITEM C
LOCAL CONTROL PANEL (LCP)
OPERATION DESCRIPTION
FOR COMPRESSORS WITH GL SERIES
GEARBOX AND SINGLE VANE CONTROL

The following is the basic concept for controlling the Turblex/HV-Turbo compressor with variable diffusers.
1 - Compressor In Stand-by/Read For Start Conditions
Before a compressor may be started, the following stand-by conditions must be established:
- VD [Variable Diffusers] closed (in minimum)
- BOV [Blow-Off Valve] opened
- DV [Discharge Valve] closed
- No alarms
- Reservoir oil temperature above 50F
If the above conditions are not met, start is inhibited at the LCP (Local Control Panel).
2 - Start Sequence
The start sequence may be initiated by pushing the "Blower Start" button on the Operator Interface, or by a
start/stop signal from a MCP (Master Control Panel) or plant control system, where applicable.
- The auxiliary oil pump starts a 2-minute pre-lubrication cycle; the oil pressure at the inlet to the
gearbox must be established (higher than 15 psig) within 1 minute of the start sequence. If the oil
pressure setpoint is not achieved in 1 minute, the start sequence is terminated on a Low-Low Oil
Pressure Alarm (Sequence Failure).
- At the end of the 2-minute pre-lubrication cycle, the LCP gives a Start/Stop (dry contact) signal to the
Main Motor Starter to energize the drive motor.
- The LCP receives a feed back signal (dry contact) from the Main Motor Starter (normally no later than
20 seconds after the start signal has been given); this confirms that the drive motor is running. If the
start verification is not received in 20 seconds, the start sequence is terminated on a No Motor
Feedback Alarm (Sequence Failure).
- After the motor feed back signal is received, the DV starts to open and a 5-minute BOV "guardian"
timer starts.
- The oil pressure at the mechanical oil pump must be established (higher than 29 psig) within 20
seconds after the motor feed back is received. If the oil pressure setpoint is not achieved in 20
seconds, the start sequence is terminated on a Low Oil Pressure Alarm (Sequence Failure). If the oil
pressure setpoint is achieved in 20 seconds, the auxiliary oil pump will run for another 10 seconds
before going off-line.
- After the auxiliary oil pump has gone off-line, and the DV is opened, the BOV begins to close slowly
via a pulsed motion (closing time normally between 30-120 seconds).
Example: Travel time = 30 seconds
2 seconds "on", 5 seconds "off"
105 seconds closing time
- If the BOV is not closed when the 5-minute BOV guardian timer expires, the start sequence is
terminated on a Start Taking Too Long Alarm (Sequence Failure).
- After the BOV is closed the VD is ready for operational control.

Document Name: 4607T_LCP_Oper_Descrp_Rev 0
ITEM C

2
2 - Start Sequence Continued
- The start sequence is finished.
During the start sequence, the surge monitor is bypassed until the auxiliary oil pump has gone off-line.
3 - Remote/Local Operation
- When the LCP is set in the Local mode, the VD is positioned manually by open/close controls on the
operator interface. Press VD open to increase flow and VD close to decrease flow.
- When the LCP is set in the Remote mode, control of the VD is based on an increase or decrease
capacity signal sent from a MCP or plant control system, where applicable.
4 - Stop Sequence
Normal Stop:
The stop sequence may be initiated by pushing the "Blower Stop" button on the Operator Interface, or by
dropping the start/stop signal from a MCP or plant control system, where applicable.
- The VD moves to the minimum position and a 120-second stop timer starts.
- When the VD is at the minimum position, the BOV opens fast (nominal 15 seconds).
- When the BOV is opened, the DV closes.
- When the DV (motorized) is closed, or the 120-second timer expires, the start/run signal will drop to
the Main Motor Starter to stop the drive motor.
- After the motor feedback signal is lost, the auxiliary oil pump starts the 5-minute post-lube cycle.
- 5 minutes after the motor feedback signal is lost, the auxiliary oil pump stops.
- The stop sequence is finished.
"Soft" Stop:
See 5, below, for conditions that initiate a soft stop.
- The VD moves to the minimum position, the BOV opens fast, and an 8-second stop timer starts.
- When the BOV is opened or the 8-second timer has run out, the start/run signal will drop to the Main
Motor Starter to stop the drive motor.
- After the motor feedback signal is lost, the auxiliary oil pump starts the 5-minute post-lube cycle, and
the DV closes.
- 5 minutes after the motor feedback signal is lost, the auxiliary oil pump will stop.
Emergency Stop:
See 5, below, for conditions that initiate an emergency stop.
- The start/run signal will drop to the Main Motor Starter to stop the drive motor, the BOV opens fast,
the DV closes, and the VD moves to the minimum position.
- After the Main Motor Starter feedback signal is lost. The auxiliary oil pump starts the 5-minute post-
lube cycle.
- 5 minutes after the motor feedback signal is lost, the auxiliary oil pump stops.

ITEM C

3
4 - Stop Sequence Continued
All of the above stop sequences place the blower in "stand-by" position with the correct positioning of all
components for re-start.
During any stop sequence, the surge control unit and vibration alarms will be bypassed.
5 - Alarms and Shut-Downs (Trips)
There are two ways to stop the blower under abnormal conditions:
A. A "Soft" stop is initiated when any of the following trip conditions occur:
"High Oil Temperature"
"High Inlet Air Temperature"
"Surge"
"High Drive Motor Amps"
"High Blower Bearing Temperature"
"High Motor Bearing Temperature"
High Motor Winding Temperature
Some mild surging may occur during a soft stop.
B. An "Emergency" is initiated when the "Emergency-Stop" button is pushed or when any of the following
trip conditions occur:
"Low Oil Pressure"
"PLC Failure"
No Motor Feedback at Start
Lost Motor Feedback During Normal Run
Start Sequence Taking Too Long
Motor not Stopped in 2 Minutes of Stop Sequence
"High Blower Casing Vibration"
Some surging will occur during an emergency stop.
If any of the above alarm/trip conditions occurs, a common alarm signal will be available to a MCP or plant
control system, where applicable. If the OIT (Operator Interface) fails, Turblex recommends stopping the
machine; do not continue operation. If the PLC fails, the unit will drop all the output/input signals and the unit
will shut-down.
All the alarms must be re-set or acknowledged one alarm at a time. Furthermore, the alarms will disappear
after the reason for the alarm is corrected.
6 - Drive Motor High Amp Warning/Alarm Operation
- If the drive motor begins pulling 98% of its rated amperage during normal operation, the LCP will
automatically prevent the VD position from being increased further.
- If the drive motor begins pulling 102% of its rated amperage during normal operation, the LCP will
automatically decrease the VD position to decrease the motor amperage below its alarm setpoint.
- If the drive motor amperage continues to increase to 105% of its rated amperage, and a 45 second
timer starts,the LCP will then initiate a "soft stop sequence.
7 Restart Blocking
If the blower is started and stopped more than two (2) times in less than an hour from the first start, the LCP
will inhibit the next start attempt on a Restart Blocking Alarm until that hour has ended.
8 Zero Speed Switch (Optional, included if specified)
When the blower is stopped, the zero speed switch is activated. Upon detection of rotation, the auxiliary oil
pump will start to keep the bearings lubricated. The auxiliary oil pump will run for another 2 minutes after the
Zero Speed Alarm is cleared.

ITEM C

4
9 - Mechanical & Auxiliary Oil Pump Operation
Upon initiation of compressor start, the auxiliary oil pump is started along with a 60-second timer to allow the
oil pressure to rise above the PSLL setpoint. If the oil pressure is not greater than the PSLL setpoint within 60
seconds, the start sequence is terminated on a Low-Low Oil Pressure Alarm.
Upon start of the drive motor, a 30-second guardian timer is initiated to allow the mechanical oil pump to build
oil pressure above the PSL setpoint. If the oil pressure is not greater than the PSL setpoint within 20 seconds,
the start sequence is terminated on a Low Oil Pressure Alarm.
At a time between 20 and 30 seconds after the drive motor is started and the oil pressure is greater than the
PSL setpoint, the auxiliary oil pump shall go off-line. Once oil pressure above the PSL setpoint has been
achieved, the drop of oil pressure below PSL and/or PSLL will initiate the start of the auxiliary oil pump and an
emergency stop.
When the compressor is stopped, the oil temperature is continuously monitored. If the oil temperature falls
below the Low Oil Temperature Alarm setpoint (60F), the auxiliary oil pump will start to provide a heat source
to the oil and will remain energized for 2 minutes after the oil temperature has reached above the Low Oil
Temperature Alarm setpoint. If the oil temperature falls below the Low-Low Oil Temperature Alarm setpoint
(50F), the LCP will inhibit compressor start until the temperature rises above the Low-Low Oil Temperature
Alarm setpoint.
10 Service-Normal-Test Switch Operation
There is a software switch displayed on the Operator Interface called the "Service-Normal-Test" switch. With
this switch in the "Test" position, the dry contact signal for start to the Main Motor Starter is bypassed, and a
simulated feedback signal from the Main Motor Starter is created so a start-up procedure can be simulated
without running the drive motor.
When the Service-Normal-Test switch is in the Service position, the following components can be manually
"exercised" or turned on and off from the Operator Interface:
a. Manual start/stop of electric oil pump
b. Manual open/close of BOV
c. Manual open/close of VD
d. Manual open/close of oil cooler solenoid valve (water cooler)
During normal operation, the Service-Normal-Test switch shall be placed in the normal position. While the
compressor is running, the VD control can be switched from local to remote (LCP Control or MCP Control), or
conversely.
11 Automatic Vane Exercise
Every 12 hours that the blower is setting idle (not running), the processor will automatically exercise the VD
from their full closed position to their full open position, and return them to their closed position. This helps
prevent unnecessary maintenance due to the unit sitting idle for long periods of time. The LCP will also
automatically recalibrate the VDs if out of calibration.
12 Automatic Calibration of VD
There is a software button displayed on the Operator Interface called the R/I Automatic Calibration. Push
this button to automatically calibrate the VD scales in the PLC to the mechanical scales on the blower. This
button is disabled when the blower is in start sequence or on-line.

Z:\Submittal_O&M\Master_Sub\Item_C_OperationDesc\Source_Docs\LCP_Oper_Descrp_GL_GB_V.doc

Telephone (417) 864-5599
Facsimile (417) 866-0235

Turblex 4607T Local Control Panel (LCP) Interface / Screens:

Please note: LCP operator interface / screens will be available in the Final Turblex Operation and Maintenance
Manual.
ITEM C

Telephone (417) 864-5599
Facsimile (417) 866-0235

ITEM C

OPERATING RESTRICTIONS
(REFER TO NAMEPLATE DATA SHEET FOR GEARBOX MODEL SUPPLIED)

1. Blower cannot be started under load.
2. Blower cannot start or stop if another blower is starting/stopping.
3. Maximum lubricating oil temperature is 160F for GA, GB, GC, and GL series gearboxes, 230
o
F for
GK series gearboxes.
4. Minimum lubricating oil temperature is 50F for GA, GB, GC, and GL series gearboxes.
5. Maximum inlet air temperature is 130F.
6. Proper oil level in the oil reservoir or oil sump must be maintained.
7. Minimum lubricating oil pressure downstream of the oil filters is 15 psig (not applicable to GK2/B3
gearbox).
8. Minimum lubricating oil pressure at the mechanical pump discharge is 20 psig (applies to GB and GL
series gearboxes, only).
9. Power must be left on to LCP when the blower is not operating, except for maintenance.
10. Blower safety shutdowns must not be bypassed.
11. Program in PLC must not be changed without written permission from Turblex.
12. Blower rotation is unidirectional depending on the gearbox model:

13. Motor starting capability at the motor starter or motor control center (MCC) must be deleted or
disabled. Start must be initiated from the local control panel (LCP).
14. The discharge check valve is to be installed as close to the discharge cone as possible. Turblex
recommends the discharge check valve be installed in the horizontal position. If it is not installed in
the horizontal position, please notify Turblex. The hinge post must be in the vertical position. A pipe
spool (minimum one pipe diameter) must be installed between the check valve and the discharge
valve to allow clearance for the valve plates to open. Please refer to Item A for Installation
Instructions for Field Mounted Components.

NOTE: If safety shutdowns are bypassed and/or PLC program is changed without written permission from
Turblex, the Warranty will be VOIDED.

Z:\Submittal_O&M\Master_Sub\Item_C_OperationDesc\Source_Docs\Operating Restrictions CCW -1.doc
COUNTER-CLOCKWISE
ROTATION
(looking at the blower input
shaft)

GA200, GA250, GB225,
GK200, GL210, GL225, GL285,
GL315, GL400 and GL500

REV DATE:
INSTRUMENT SETPOINTS (PAGE 1)
DESCRIPTION ACTION US SETPOINT SI SETPOINT OIT DESCRIPTION NOTATION GA GB GC GK GL OTHERS
INLET GUIDE VANE POSITION INLET GUIDE VANE POSITION 1 N.N SCALE SCALE INLET GUIDE VANE POSITION IGV
VARIABLE DIFFUSER VANE POSITION VARIABLE DIFFUSER VANE POSITION 1 N.N SCALE SCALE VARIABLE DIFFUSER VANE POSITION VD
BLOWER DIFFERENTIAL PRESSURE TRANSMITTER BLOWER DIFFERENTIAL PRESSURE TRANSMITTER 2 N.NN PSID kPa D BLOWER DIFFERENTIAL PRESSURE
LUBE OIL SYSTEM
DESCRIPTION ACTION US SETPOINT SI SETPOINT OIT DESCRIPTION
OIL PRESSURE RELIEF VALVE CRACKING SETPOINT BYPASS TO RESERVOIR (NOTE 11 et.al.) S 120 PSI 827 kPa G R X X X X
OIL FILTER BYPASS VALVE BYPASS FILTER S 35 PSID 241 kPa G R X X X X X
OIL FILTER BYPASS VALVE BYPASS FILTER S 50 PSID 345 kPa G R GL500
OIL FILTER DIFFERENTIAL PRESSURE (H) ALARM 1 1/0, N.N 25 PSID 172 kPa G OIL FILTER DIFFERENTIAL PRESSURE - ALARM R X
OIL FILTER DIFFERENTIAL PRESSURE (H) ALARM 1 1/0, N.N 35 PSID 241 kPa G OIL FILTER DIFFERENTIAL PRESSURE - ALARM R X X X X
OIL TEMPERATURE REGULATING VALVE WATER FLOW MODULATION - 120 F 49C NA X X X X
OIL TEMPERATURE REGULATING VALVE HOT/COLD OIL MIX MODULATION - 120 F 49C NA X X X X
OIL COOLER FAN MOTOR TURN FAN ON/OFF (NOTE 11 et.al.) 1/0 105 / 95 F 41 / 35C OIL COOLER FAN ON / OFF R/F X X X X
OIL COOLER FAN MOTOR GK200 & GK190 TURN FAN ON/OFF 1/0 158 / 131 F 70 / 55C OIL COOLER FAN ON / OFF R/F X
OIL RESERVOIR TEMPERATURE (L/LL) ALARM & RUN AUX. PUMP / START INHIBIT 0 N. 60 / 50 F 16 / 10C LOW OIL TEMPERATURE - START INHIBIT F X X X X
OIL RESERVOIR TEMPERATURE (H/HH) ALARM / TRIP 0 N. 150 / 160 F 66 / 71C HIGH OIL RESERVOIR TEMPERATURE - ALARM / TRIP R X X X X
OIL RESERVOIR TEMPERATURE (H/HH) GK200 ALARM / TRIP 0 N. 212 / 220 F 100 / 104C HIGH OIL RESERVOIR TEMPERATURE - ALARM / TRIP R X
OIL RESERVOIR TEMPERATURE (H/HH) GK190 without OIL COOLER ALARM / TRIP 0 N. 202 / 212 F 94 / 100C HIGH OIL RESERVOIR TEMPERATURE - ALARM / TRIP R X
OIL RESERVOIR TEMPERATURE (H/HH) GK190 with OIL COOLER ALARM / TRIP 0 N. 165 / 176 F 74 / 80C HIGH OIL RESERVOIR TEMPERATURE - ALARM / TRIP R X
OIL PRESSURE (L/LL) TRIP 1 1/0, N.N 29 / 15 PSIG 200 / 103 kPa G LOW OIL PRESSURE - TRIP F X X
OIL PRESSURE (L/LL) TRIP 1 1/0, N.N 20 / 15 PSIG 138 / 103 kPa G LOW OIL PRESSURE - TRIP F X X
OIL PRESSURE (L) TRIP 1 1/0, N.N 15 PSIG 103 kPa G LOW OIL PRESSURE - TRIP F X
OIL PRESSURE (H) ALARM 1 N.N 150 PSIG 1034 kPa G HIGH OIL PRESSURE - ALARM R X X X X X
INLET / DISCHARGE TEMPERATURE AND PRESSURE
INLET TEMPERATURE (H/HH) ALARM / TRIP 0 N.N 120 / 130 F 49 / 54C HIGH INLET AIR TEMPERATURE - ALARM / TRIP R
INLET 1ST STAGE FILTER DIFF PRES (H) ALARM 2 1/0, N.NN 1" WC 0.25 kPa D HIGH INLET AIR PRE-FILTER DIFF PRESS - ALARM R
INLET 2ND STAGE FILTER DIFF PRES (H) ALARM 2 1/0, N.NN 1.5" WC 0.37 kPa D HIGH INLET AIR FILTER DIFF PRESS - ALARM R
INLET DIFFERENTIAL PRESSURE (H) ALARM 2 1/0, N.NN 4.2" WC 1.04 kPa D HIGH INLET AIR OVERALL DIFF PRESS - ALARM R
DISCHARGE TEMPERATURE (H/HH) ALARM / TRIP 0 N. NOTE 1 NOTE 3 OUTLET AIR TEMPERATURE - ALARM / TRIP R
DISCHARGE PRESSURE (H/HH) ALARM / TRIP 1 N.N NOTE 2 NOTE 4 OUTLET AIR PRESSURE - ALARM / TRIP R
NOTE 1: ALARM = DESIGN PRESSURE (PSIG) * 14 + MAX. INLET TEMP. (F); TRIP = ALARM + 10 F
NOTE 2: ALARM = DESIGN PRESSURE (PSIG) + 0.1 PSIG; TRIP = ALARM + 0.1 PSI
NOTE 3: ALARM =DESIGN PRESSURE (kPa G) * 1.13 + MAX INLET TEMP (C); TRIP = ALARM + 6
NOTE 4: ALARM = DESIGN PRESSURE (kPa G) + 0.7 kPa G; TRIP = ALARM + 0.7 kPa G
NOTE 5: For Bently Nevada systems, 20/25 mils pp, this is the limit of the detection system.
NOTE 6: Temperature degree symbol, type ALT+0176 or ALT+248 from the NUMLOCK keyboard
NOTE 7: GA / GL GEARBOXES
NOTE 8: GC GEARBOXES
NOTE 9: DE - Drive End, ODE - Opposite Drive End of Motor or Blower
NOTE 10: IMP END - Impeller End, OPP IMP END - Opposite Impeller End
NOTE 11: Num Dec. Places, i.e. 2=N.NN: S-Switch, 1/0-ON/OFF: 1/0, N.N is either switch or transmitter
NOTE 12: As Required for Job Specific Vibration System
NOTE 13: See Project Manager for dip switch setting documentation
NOTE 14: Reference Document for Terminology: Standard_Vibration_Terminology
2/28/2008
GK 190 OIL RESERVOIR TEMPERATURE TRANSMITTER RANGE
(NOTE 13)
DIP SWITCH SETTINGS 0 N. X -
ITEM C
RISING /
FALLING
RISING /
FALLING
GEARBOX SERIES
R
NUM. DEC. PLACES
NUM. DEC. PLACES
RISING /
FALLING NUM. DEC. PLACES
N.NNN
32 / 392 F 0 / 200C
Z:\Submittal\Master\Item_C_OperationDesc\Source Docs\Instrument_Setpoints.Feb 2008.xls Printed: 12/5/2008
REV DATE:
INSTRUMENT SETPOINTS (PAGE 2)
BLOWER / MOTOR TEMPERATURE (Note 9,10,14)
DESCRIPTION ACTION US SETPOINT SI SETPOINT OIT DESCRIPTION NOTATION GA GB GC GK GL OTHERS
BLOWER STRAIGHT BABBIT BLWR HS SHAFT IMP END BRG TEMP - ALARM / TRIP Blwr HIE
JOURNAL BEARING TEMPERATURE BLWR HS SHAFT OPP IMP END BRG TEMP - ALARM / TRIP Blwr HOIE
BLOWER INPUT SHAFT STRAIGHT BABBIT BLWR SS SHAFT ODE BRG TEMP - ALARM / TRIP Blwr SODE
JOURNAL BEARING TEMPERATURE BLWR SS SHAFT DE BRG TEMP - ALARM / TRIP Blwr SDE
BLOWER TILT-PAD JOURNAL BLWR HS SHAFT IMP END BRG TEMP - ALARM / TRIP Blwr HIE
BEARING TEMPERATURE BLWR HS SHAFT OPP IMP END BRG TEMP - ALARM / TRIP Blwr HOIE
BLWR HS SHAFT IMP END BRG TEMP - ALARM / TRIP Blwr HIE
BLWR HS SHAFT OPP IMP END BRG TEMP - ALARM / TRIP Blwr HOIE
BLOWER HIGH SPEED SHAFT THRUST BEARING TEMPERATURE ALARM / TRIP 0 N. 194 / 203 F 90 / 95C BLWR HS SHAFT THRUST BRG TEMP - ALARM / TRIP Blwr HZ R X X X X
MOTOR SLEEVE BEARING TEMPERATURE ALARM / TRIP 0 N. 194 / 203 F 90 / 95C MOTOR DE / ODE BRG TEMP - ALARM / TRIP Mtr ODE / DE R
MOTOR ANTI-FRICTION BEARING TEMPERATURE ALARM / TRIP 0 N. 212 / 221 F 100 / 105C MOTOR DE / ODE BRG TEMP - ALARM / TRIP Mtr ODE / DE R
MOTOR WINDING TEMPERATURE ALARM / TRIP 0 N. 320 / 329 F 160 / 165C MOTOR "A/B/C" WINDING TEMP - ALARM / TRIP Mtr W R
MOTOR AMPS
MOTOR AMPS LIMIT VD OPENING 0 N. MOTOR AMP LIMIT - LIMITING VD R
MOTOR AMPS REDUCE VD 0 N. MOTOR AMP LIMIT - REDUCING VD R
MOTOR AMPS TRIP 0 N. HIGH MOTOR AMPS - TRIP > (TRIP DELAY TIMER LENGTH) R
MOTOR AMPS TRIP DELAY TIMER 0 N. MOTOR TRIP DELAY TIMER NA
VIBRATION (Note 9,10,14)
DESCRIPTION ACTION US SETPOINT SI SETPOINT OIT DESCRIPTION NOTATION 2 5 10 22 44 66 80 100
BLOWER HIGH SPEED SHAFT RADIAL VIBRATION (X-Y) (NOTES 7,8) ALARM / TRIP 2 N.NN 3 / 5 MILS-PP 0.08 / 0.13 mm-pp BLWR HS SHAFT IMP END VIBRATION X / Y - ALARM / TRIP Blwr HIE R X X X X X X X X
BLOWER HIGH SPEED SHAFT RADIAL VIBRATION (X-Y) (NOTE 7) ALARM / TRIP 2 N.NN 3 / 5 MILS-PP 0.08 / 0.13 mm-pp BLWR HS SHAFT OPP IMP END VIBRATION X / Y - ALARM / TRIP Blwr HOIE R X X X X X X X X
BLOWER SLOW SPEED SHAFT RADIAL VIBRATION (X-Y) (NOTE 7) ALARM / TRIP 2 N.NN 3 / 5 MILS-PP 0.08 / 0.13 mm-pp BLWR SS SHAFT ODE VIBRATION X / Y - ALARM / TRIP Blwr SODE R X X X X X X X X
BLOWER SLOW SPEED SHAFT RADIAL VIBRATION (X-Y) (NOTE 7) ALARM / TRIP 2 N.NN 3 / 5 MILS-PP 0.08 / 0.13 mm-pp BLWR SS SHAFT DE VIBRATION X / Y - ALARM / TRIP Blwr SDE R X X X X X X X X
BLOWER HIGH SPEED THRUST POSITION PLUS (Z) ALARM / TRIP 2 N.NN 15 / 20 MILS-PP 0.38 / 0.51 mm-pp BLWR HS SHAFT THRUST Z POSITION (+) ALARM / TRIP Blwr HZ R X X X X X X X X
BLOWER HIGH SPEED THRUST POSITION MINUS (Z) ALARM / TRIP 2 N.NN - 15 / 20 MILS-PP 0.38 / 0.51 mm-pp BLWR HS SHAFT THRUST Z POSITION (-) ALARM / TRIP Blwr HZ R X X X
BLOWER HIGH SPEED THRUST POSITION MINUS (Z) (NOTE 5) ALARM / TRIP 2 N.NN - 25 / 30 MILS-PP
5
0.64 / 0.76 mm-pp BLWR HS SHAFT THRUST Z POSITION (-) ALARM / TRIP Blwr HZ R X X X X X
BLOWER GEARBOX VIBRATION ALARM / TRIP 2 N.NN 0.2/0.3 IPS-PK 5.1 / 7.6 mm/s-pk BLOWER GEARBOX VIBRATION - ALARM / TRIP Blwr GB R X X X X X X X X
BLOWER GEARBOX VIBRATION ALARM / TRIP 1 N.N 13 / 15 G'S 13 / 15 G's-pk BLOWER GEARBOX VIBRATION - ALARM / TRIP Blwr GB R X X X X X X X X
MOTOR SHAFT VIBRATION (X-Y RADIAL) ALARM / TRIP 2 N.NN 3 / 5 MILS-PP 0.08 / 0.13 mm-pp MOTOR SHAFT DE / ODE VIBRATION X / Y - ALARM / TRIP Mtr ODE / DE R
MOTOR BEARING VIBRATION ALARM / TRIP 2 N.NN 0.25/0.40 IPS-PK 6.4 / 10.2 mm/s-pk MOTOR BEARING DE / ODE VIBRATION - ALARM / TRIP Mtr ODE / DE R
SHAFT KEYPHASOR (NOTE 12) - - - - -
SEE PAGE 1 FOR NOTES
BLOWER ANTI-FRICTION BEARING TEMPERATURE ALARM / TRIP 0 N.
2/28/2008
NUM. DEC. PLACES
NUM. DEC. PLACES
98% FLA
102% FLA
105% FLA
NUM. DEC. PLACES
ITEM C
45 SEC
248 / 266 F 120 / 130C
N.
N.
N. 0
0
0
RISING /
FALLING
RISING /
FALLING
90 / 95C
99 / 107C 210 / 225 F
90 / 95C
COMPRESSOR SIZE (KA**)
GEARBOX SERIES RISING /
FALLING
R
R
R
R X
X
X
ALARM / TRIP
ALARM / TRIP
ALARM / TRIP
194 / 203 F
194 / 203 F
X
X
X
X
X
X
X X
Z:\Submittal\Master\Item_C_OperationDesc\Source Docs\Instrument_Setpoints.Feb 2008.xls Printed: 12/5/2008

Telephone (417) 864-5599
Facsimile (417) 866-0235

ITEM E
HI-TEMP COATING SYSTEM FOR
DISCHARGE TEMPERATURES UP TO 260C/500F

BASE/OIL RESERVOIR

Exterior

Surface Preparation:

SSPC-SP6 COMMERCIAL BLAST CLEAN

Primer:

One (1) Coat Sherwin Williams KEM 400 Metal Primer, B50-Z Series, 2.0-5.0 mils DFT

Oil Reservoir Interior


SSPC-SP10 NEAR WHITE METAL BLAST CLEANING

NOTE: Reservoir coating application required within 10 hours of media blasting

Oil Reservoir Coating: Two (2) Coats Devoe Coating Devchem 257Chemical Resistant Tank
Lining, to achieve 10.0 to 15 mils (254-381 m) DFT. Color Intermediate
White.

Coating Application Instructions

NOTE: Strict adherence to the manufacturers specification data sheets for
minimum and maximum self recoat time (based on ambient conditions) as
well as the directions for use is required.

1. Spray one (1) Coat of Devoe Devchem 257 to achieve 5.0-6.0 mils (127-152
m) DFT. Use a brush as necessary to ensure complete coverage of all hard
to reach areas.

2. After minimum recoat time has elapsed but not exceeding the maximum
(reference product data sheet), stripe coat all weld joints, gussets, corners
and any other hard to spray areas within the reservoir.

4. Immediately after stripe coating, spray one (1) coat of Devoe Devchem 257
to achieve 5.0-6.0 mils (127-152 m) DFT.

NOTE: Surface preparation and coating application by Detroit Tool.

2
COMPRESSOR/GEARBOX ASSEMBLY (AIR-END)


SSPC-SP2 HAND TOOL CLEANING

1. Solvent Clean; using water and a water based cleansing agent cleaner, (Hydrocarbon
Solvents Unacceptable)

2. Rinse Clean; rinse clean using water and a clean sponge, or clean cotton towel with a
blotting technique, leaving no lent behind.
Note: Do not force dry with pressurized shop air

3. Hand Scuff OEM Base Coat Surface; Using Red Scotch Bright pad to break the gloss of
the OEM base primer.

4. Rinse Clean; rinse clean using water and a clean sponge, or clean cotton towel with a
blotting technique, leaving no lent behind.

Primer:
One (1) Coat Sherwin Williams Hi-Temp Coatings No. 850 Primer, 1.0-1.3 mils DFT

Top Coat:
One (1) Coat Sherwin Williams Hi-Temp No. 850 Series, Black, 1.0-1.3 mils DFT

COMPRESSOR SKID ASSEMBLY


SSPC-SP1 SOLVENT CLEAN; using water and a water based cleansing agent cleaner,
(Hydrocarbon Solvents Unacceptable)

Primer:


Top Coat:


DISCHARGE CONE / BLOW-OFF SILENCER/ MISCELLANEOUS


SSPC-SP6 COMERCIAL BLAST CLEAN

Primer:


Top Coat:


3
COUPLING GUARD


SSPC-SP1 SOLVENT CLEAN; using water and a water based cleansing agent cleaner,
(Hydrocarbon Solvents Unacceptable)

Primer:

One (1) coat Sherwin Williams KEM 400 Metal Primer,
B50-Z Series, 2.0-5.0 mils DFT

Top Coat:

One (1) coats Sherwin Williams KEM 400 Enamel, F75-400 Series,
Safety Yellow, 1-1.5 mils DFT

ELECTRICAL ENCLOSURES AND TERMINAL BOXES IF COATED
FACTORY FINISH BY MANUFACTURER
ANSI 61 Gray Polyester Powder Coating

L:\Project_Engineering\Jobs\4607T\Engineering\Mechanical_Eng\O&M\Electronic_O&M\5044T Item E designed by Barry.doc.aj

Telephone (417) 864-5599
Facsimile (417) 866-0235

C:\Documents and Settings\beaty00b\Desktop\Blower_Performance_Test.doc
ITEM F

COMPRESSOR PERFORMANCE TEST

NOTE: The following is the STE compressor test procedure. The official performance test report will
be submitted in the final Operation and Maintenance Manual.

Document Name: 4607T-Item F Rev B

930930050US
Revision: 6
Page: 1 of (9)

TESTING OF TURBOCOMPRESSORS
OPTION: ASME PTC-10 PROCEDURE
Prepared by: We Date: 93.04.15
Latest revision: We Date: 98.03.31

1. Purpose

2. National and International Standards

3. Measuring Equipment, Instrumentation, and Calibration

4. Test Procedures/Standard Shop Test (SST)/Witnessed
Performance Test

5. Documentation

6. Additional Testing

1. Purpose

All testing is performed in order to measure operating data for evaluation of conformity with
specified data.

Before delivery, each HV-TURBO compressor is tested in accordance with HV-TURBO's
Standard Shop Test (SST) Specification. The test procedures have been developed during
decades of testing thousands of turbo-machines. The test must fulfil the following purposes:

a) provide sufficient test data over the entire specified operational range for the quality
approval procedure before delivery

b) provide documentation of the performance data and the performance range in terms of
a graphic presentation to the customer

c) provide conditioned data/software for the automated power saving program of SV-type
compressors

d) provide specific and statistic data as feedback for the compressor design program

e) ensure accurate, safe, and fast registration of all relevant test data in the shortest possi-
ble testing time and at the lowest possible cost.

2. National and International Standards/Norms

It is mandatory that especially all logging and evaluation of performance data conform with
the relevant national and international standards.

Item F

930930050US
Revision: 6
Page: 2 of (9)


HV-TURBO compressor testing procedures, as well as the testing equipment, instrumenta-
tion, and calibration are in conformity with the national and international norms of testing
turbo-compressors, as follows:

ISO 5389 : International standard: Turbocompressors - Performance Test Code.

ISO 5167 : International standard: Measurement of Fluid Flow.

ASME PTC-19.5 : USA-standard for flow measurement, based on the same type of
equipment and the same physical laws as ISO 5167, but more
complicated to handle due to non metric unites and traditional
methods. Compared to ISO 5167, the PTC-19.5 computations of
flow, measured by the same concentric orifice plate, will result in
flow figures which are equal or up to % higher than ISO 5167
computations. For the evaluation of test results HV-TURBO has
implemented the ISO 5167, which is assumed to be the most mod-
ern/updated standard, and which does not conflict with the PTC-
19.5.

ISO 10816-1 : Mechanical Vibration of Machines.

ISO 3744 : Determination of Sound Power Levels of Noise Sources. If free-
field conditions can not be established, ISO 3746 will apply.

ASME PTC-10 : Compressors and Exhausters, Power Test Codes (please see also
4.3).


3.1 Flow Measurements

All flow measurements during shop tests are carried out by means of straight, cylindrical
measuring pipes on which the entry of each pipe is equipped with a straightener. The pipe
length for inflow and outflow, the orifice plate design, and the pressure tappings are in accor-
dance with the specified standards. At the exhaust of each pipe, an electrically activated throt-
tle valve is installed in order to adjust the discharge pressure level. The pipe inlet temperature
is measured by 4 calibrated temperature probes. The measuring pipe is carefully insulated to
avoid heat losses = temperature errors. The pipe system pressure is measured by different
pressure probes. For different flow rates, measuring pipes of different dimensions are in-
stalled on the test bed.
The orifice plates are inspected, calibrated, sealed, and certified every year by the independ-
ent international inspection company SGS (Socit Gnrale de Surveillance).

The flow is computed from readings of pressure, temperature, and humidity. The method of
computation is described in the above mentioned standards ISO 5167/PTC-19.5.

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3.2 Measuring Shaft Power

The shaft power can be measured in various ways, depending on the test rig used.

3.2.1 Direct Method by Torquemeter

The torquemeter is an electronic torque measuring coupling installed between the drive motor
and the compressor. Different sizes of torquemeter couplings are available. The shaft power
is computed from the measurement of torque and RPM.

All torquemeter couplings are calibrated on standardized calibration rigs with certified
plummets. Calibration of the torquemeter couplings is inspected and certified once a year by
the SGS.

3.2.2 Indirect Method of Measurement

A. This method may be applied with compressors packaged with the job motor:

When the compressor is driven by an electric motor, the power input at the terminals
can be measured. The input power is multiplied by the motor efficiency, which equals
the shaft power. In order to obtain true data, two requirements must be fulfilled:

a) The motor power input must be measured with calibrated instruments.

b) The motor efficiency must be verified by a motor test, involving measuring of the
power input and of the shaft power with e.g. a calibrated torquemeter.

Alternatively, the motor efficiency can be determined by other methods equivalent to
those required when using the direct method.

The accuracy of the test data should always be documented by valid calibration cer-
tificates.

When measuring the motor power input HV-TURBO have six different power supply
systems (380V to 10 kV) at their disposal, with calibrated and sealed kWh-counters.
Valid calibration documents are provided by an authorized calibration office for kWh-
counters. In addition, each power supply line is monitored by independent meters for
kW, Amps and Volts.

B. The heat balance method of shaft power measuring is independent of any motor input
measuring or calibration of efficiency. When using the heat balance method, the shaft
power is computed from the measurements of the energy input into the gas, the mass
flow, the gear losses, bearing losses etc., in accordance with ISO 5389 and ASME
PTC-10.

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3.3 Temperature Measurement

Standard temperature measurements are carried out by 4 temperature probes at the compres-
sor intake and 4 similar probes at the compressor discharge.

The probes are thermocouples of an industrial design, wired to a high precision digital dis-
play. All temperature probes and wires are marked for identification, sealed by SGS, and cali-
brated in a laboratory calibration device. The calibration is performed with reference to cer-
tified thermometers. The calibration of temperature probes, incl. wiring and display, is
checked regularly and inspected and certified once a year by SGS.

3.4 Pressure Measurement

In general pressure measurements are carried out by means of high precision electronic
transmitters with digital reading. These instruments are always calibrated. U-tubes with water
or mercury filling are installed for the verification of these instruments.

3.5 Transmitters for the Automated Test Data Logging

The test facility is equipped with fast-logging multichannel data sampling units connected to
the test bed computer system. All test data are converted into electronic data for automatic
data logging. All transmitters involved are continuously checked and maintained in a cor-
rectly calibrated state. This system is supporting the SST, please see 4.2.

3.6 ISO - 9001 Procedures

HV-TURBO is operating a certified quality assurance system for a.o. continuous calibration
in conformity with the requirements of the international ISO 9001 standard. Also this test
procedure description including all stated commitments is a registered document within this
quality system.

3.7 Certification

In general, the a.m. certification of instrument calibration is carried out by SGS. For more
than a decade calibration of our test bed instruments have proven that calibration data for the
same instruments do not change by more than what is expected within the specified instru-
ment accuracy.

SGS (Socit Gnrale de Surveillance) is an independent international inspection company
with head office in Geneva, Switzerland, and with more than 100 assigned SGS-offices, pla-
ced all over the world. SGS certificates issued for a HV-TURBO calibration or compressor
test can be verified by any office of the SGS organisation.

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If other calibration procedures are required, this must be specified in the contract or agreed
upon within a suitable space of time prior to the scheduled testing.

4. Test Procedures

4.1 Planning and Preparation of Test

The schedule of testing is planned by the head of the project department in cooperation with
the production department and the engineers of the test department.

Each turbo compressor must pass the SST. If additional testing is specified, the test will be
scheduled and the customer as well as the test department will be informed by the project de-
partment well in advance.

4.2 Standard Shop Test (SST)

This procedure has been developed from the experience of testing thousands of turbocom-
pressors. Testing with atmospheric air will in general be conducted in an open loop test rig.

4.2.1 Mechanical/Operational Test

Before starting the motor, the lubricating-oil system is put into operation and the safety con-
trols are checked and adjusted.

During the initial start-up, the labyrinth seals are run into their final operating shape, which is
controlled by special procedures. During the first 15 minutes of operation the compressor is
running at low load and special attention is paid to the temperature rise of the bearing covers
and the labyrinth seal flanges, as well as to the vibrations.

During the SST each compressor is operated at maximum design load, and all essential oper-
ating data are checked and recorded. The housings, flanges, and pipes, incl. the lube oil sy-
stem, are checked for tightness.

For single-stage turbocompressors the duration of the SST is 6-18 operating hours, depending
on the compressor type.

4.2.2 Performance Test

This test is always performed and evaluated in accordance with ISO 5389 and ISO 5167.

The compressor is set up for testing and connected to the instrumentation of the automatic
test bed data logging and processing.

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The compressor guide vane setting and the system pressure will be adjusted step by step to
generate from 50 to 300 different operating points within a matrix of test data, where guide
vane positions, head and flow figures are altered and combined systematically. The test data
matrix is registered and computed individually for each compressor serial no., covering the
specific design operating range.

The data logging system is programmed to register data from calibrated instru-
ments/transmitters. All data are checked for steady state conditions before acceptance. Regis-
tered data are averaged from 4 series of readings.

The test matrix data are computed and evaluated versus the design data and will provide
documentation for the quality approval procedure (ISO 9001). The test matrix data also pro-
vide the basic software for the specific compressor control system (option) which automati-
cally can adjust the guide vanes to operate at best efficiency at required flow and head. Fi-
nally the test matrix data provide basic data to document operating curves as shown in the
HV-Turbo Performance Certificate (pls. see 5.1).

4.2.3 Vibration Measurements

Vibration measurements, with an accelerometer mounted in a representative point, are carried
out on each compressor at max. load, and the actual RMS-value of the vibration velocity is
recorded within the range 10-1000 Hz. The measurements must be evaluated and conform to
ISO 10816-1, range limit 2.8 mm/s for max. power below 400 kW and 4.5 mm/s for max.
power more than 400 kW. Furthermore, frequency analysis will be carried out, documented,
and evaluated with reference to our experience from equivalent equipment.

4.2.4 Noise Measurements

Noise measurements are carried out at least with one compressor of every order with equal
design data in accordance with ISO 3744/3746. A test bed assistant performs the sound pres-
sure measurements and records the data on a test form. A test engineer evaluates the test data
in relation to the specified data and data as measured on other compressors of equivalent de-
sign. If the compressor is packaged with the job motor, a noise certificate can be issued.

4.2.5 Approval and Preparation for Delivery

The SST must meet the requirements of 1. Testing of electrical or electronic controls, con-
nected to the compressor, is not part of the above. The adjustment, test, and inspection of
electrical control panels is carried out in accordance with other quality assurance procedures.

Having passed the SST with approval of the test results, the compressor is released for wit-
nessed testing (if specified) and/or to be prepared for delivery.

In case the test results are not approved of, a non-conforming compressor will be analyzed,
reworked, and retested.
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The preparation for delivery will a.o. include flushing of the gearbox, the bearings, etc. with
corrosion-preventive oil, long-term preservation (if specified), final adjustments of electronic
sensors, adjustment of the discharge flange for installation on site, painting/surface prepara-
tion, marking and packing up.

4.3 Additional Performance Testing: ASME PTC-10

Specified operating data can be verified by interpolation of test data from the SST (pls. see
4.2.2 and 5.1).

If the verification of specific performance data in accordance with ASME PTC-10 is a con-
tractual requirement, the following options for additional testing can be offered:

4.3.1 Witnessed Test

This test will be witnessed by the customer or by a representative appointed by the customer.

A precondition for setting up a witnessed test is that the SST has been finalized and SST data
have been evaluated and approved by the test engineer.

With uncooled single stage turbocompressors or tandem driven compressors with externally
piped intercooler for atmospheric air, the verification of guarantee points will be conducted as
follows, if no other requirements are specified:

- The genuine compressor(s) of the order will be tested.

- The test is conducted with atmospheric air.

- The test is conducted at specified RPM within a departure of 2%.

- The compressor will be adjusted to the specified volumetric flow within a departure of
2%.

- The discharge pressure will be adjusted equivalent to the specified isentropic head
within a departure of 1%.

- Recording of test data from calibrated instruments with a total uncertainty of meas-
urement within all limits of ISO 5389, table 5.

- Recording of 5 complete sets of test data at steady state conditions for every operating
point. Fluctuations of test readings to be within the figures of ASME PTC-10/Table 2.

- Computation of test data for every operating point with reference to specified operat-
ing data and in accordance with ASME PTC-10/ 5. With reference to API
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672/4.3.4.1, the test data for flow, pressure and power corrected to specified data must
be within the tolerance 0/+ 4%.

If it is not possible to adjust the test data within the above limits, the spotted operating point
will be bracketed (ASME PTC-10/3.13).

It is important that the witnessed performance test data are documented and signed by the
inspector, and for this reason all test data will be verified from calibrated instruments and
documented in a log sheet. During the test, the log sheet data will be computed for evaluation
in accordance with the standards mentioned above. A print will document the performance
data of the test points with reference to the specified guarantee conditions.

The number of guarantee points to be tested must be specified in advance and the test must be
scheduled.

A witnessed test will always be conducted by an experienced test engineer in cooperation
with the test bed foreman or his assistants.

4.3.2 Witnessed Certified Test

This test will be witnessed by third party inspection, i.e. an inspector from an independent
and neutral inspection company. The inspection company will on request issue a specific test
certificate.

The test procedure will be as described in 4.3.1.

4.3.3 Certified Test

This test will be conducted by an experienced HV-Turbo test engineer under the supervision
of the HV-Turbo Quality Department. Test log sheets will be signed by the test engineer and
stamped by the QA Department.


5. Documentation

5.1 Standard Documentation

In accordance with 1-b the test data of each compressor Serial No. are documented to the
customer in terms of a graphic presentation, i.e. the HV-TURBO Performance Certificate.
This certificate shows a relevant number of operational curves at different vane settings of the
inlet guide vanes, the variable diffuser vanes, or a combination. The curves will show dis-
charge pressure versus inlet volume flow and shaft power. The curves will relate to the speci-
fied operating conditions, and the curves will also be numbered in relation to the vane setting
pointer on the scale at the compressor.
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Furthermore, curves of the recorded vibration analysis for each serial No. will be docu-
mented.

As regards compressors which have been tested as a complete unit with their genuine motor,
the noise measurements will be documented in accordance with the standards mentioned.

If an ASME PTC-10 Test has been specified, a test report will document selected guarantee
points in accordance with ASME PTC-10/ 7C (class I) or 7D (class II).

5.2 Documentation from Witnessed Testing

Log sheets with test data in accordance with instrument readings and printed computer
evaluation from the same test data must be checked by the inspector and test engineer and
signed by both persons. Each participant of the test will receive copies of the test documents
as well as copies of the test rig system drawing and relevant copies of the instrument calibra-
tion certificates.

6. Budget and Schedule of Additional Testing

The HV-TURBO SST is mandatory and will always be conducted. The SST costs are in-
cluded in the budget of a compressor order. All additional tests will be conducted in accor-
dance with the requirements of the contract.

As the manufacturing schedule and the cost budget of a compressor order can easily get out
of control by unscheduled activities, we must avoid excessive and unscheduled testing. Op-
tional or other additional testing must be agreed to and specified in the contract, so that we
are able to plan, budget, schedule and conduct these activities to the satisfaction of our cu-
stomers.

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ASME PTC 10 1997 PROCEDURE
OPTION: TORQUEMETER TEST
Prepared by: CM Date: 03.01.03
Latest revision: CM Date: 03.01.03

1. Purpose



4. Test Procedures/Standard Shop Test (SST)/Witnessed
Performance Test

5. Documentation


1. Purpose

All testing is performed in order to measure operating data for evaluation of conformity with
specified data.

Before delivery, each HV-TURBO compressor is tested in accordance with HV-TURBO's
Standard Shop Test (SST) Specification. The test procedures have been developed during dec-
ades of testing thousands of turbo-machines. The test must fulfil the following purposes:

a) Provide sufficient test data over the entire specified operational range for the quality ap-
proval procedure before delivery

b) Provide documentation of the performance data and the performance range in terms of a
graphic presentation to the customer

c) Provide conditioned data/software for the automated power saving program of SV-type
compressors

d) Provide specific and statistical data as feedback for the compressor design program

e) Ensure accurate, safe and fast registration of all relevant test data in the shortest possible
testing time and at the lowest possible cost.


It is mandatory that especially all logging and evaluation of performance data conform to the
relevant national and international standards.

HV-TURBO compressor testing procedures, as well as the testing equipment, instrumentation,
and calibration are in conformity with the national and international norms of testing turbo-
compressors, as follows:

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ASME PTC 10 - 1997 PROCEDURE

ASME PTC 10-1997: Performance Test Code on Compressors and Exhausters. (Please
see 4.3).

ASME PTC 10 1997: Referenced Specifications:

ASME PTC 1 1999: General Instructions

ASME PTC 2 2001: Definitions and Values

ASME PTC 19.1 1998: Measurement Uncertainties

ASME PTC 19.2 1987 R: 1998: Pressure Measurement

ASME PTC 19.3 1974 - R: 1998: Temperature Measurement

ASME PTC 19.5 1972: Application Part II of Fluid Meters: Interim Supplement to PTC
19.5 on Instruments and Apparatus

ASME PTC 19.7 1980 R: 1988: Measurement of Shaft Power

ASME PTC 19.13 1961: Measurement of Rotary Speed {Withdrawn by ASME.}

ASME PTC 19.22 1986: Digital Systems Techniques

ISO 5389: 1992 International standard: Turbocompressors - Performance Test
Code.

VDI 2045 P1(E): 1993 Acceptance and Performance Tests on Turbo Compressors and
Displacement Compressors. Test Procedure and Comparison
With Guaranteed Values

API Standard 617
Seventh Edition, July 2002 Axial and Centrifugal Compressors and Expander-compressors
for Petroleum, Chemical and Gas Industry Services

ISO 5167-1: 1991/
Amd. 1:1998(E) Measurement of Fluid Flow by Means of Pressure Differential
Devices Part 1: Orifice Plates, Nozzles and Venturi Tubes In-
serted in Circular Cross-section Conduits Running Full

ISO 10816-1: 1995 Mechanical VibrationEvaluation of Machine Vibration by
Measurements on Non-Rotating PartsPart 1: General Guide-
lines

ISO 3744: 1994 AcousticsDetermination of Sound Power Levels of Noise
Sources Using Sound PressureEngineering Method in an Es-
sentially Free Field Over a Reflecting Plane. Used under free
field conditions.

ISO 3746: 1995 AcousticsDetermination of Sound Power Levels of Noise
Sources Using Sound PressureSurvey Method Using an En-
veloping Measurement Surface Over a Reflecting Plane Used
under non-free field conditions.

ISO 9000-2000 Quality Management Systems- Fundamentals and Vocabulary
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3.1 Methods of measuring and calculating PTC 10 1997 6.2.1.h & 6.2.6.a.

All results measured as calculated are based on the following:

The test logs may be print outs resulting from an automatic data recording system;
however they will be presented for the signature of witnessing parties Reference
3.14.

The test gas ambient air is treated as an ideal gas with constant specific heat, evalu-
ated at the inlet. The test gas composition will not be measured. The computation of
results will be via the Ideal Gas Method per section 5.2.1.

Pressure Transducer Calibration ( 4.6.5 ) All pressure transducers are calibrated
on a yearly basis consistent with international metrology standards by an outside
party.

Inlet Piping: ( 4.3.2 ) The inlet piping shall consist of an inlet filter silencer with
foam covered lamella to reduce test stand noise. Four orthogonal temperature
measurements are recorded upstream of the lamella. Inlet pressure is measured
downstream of the lamella.

The partial pressure of water vapor is found using the steam tables:
[ref. NBS/NCR Steam Tables ISBN 0-89116-353-0 paper] Reference 3.4.2

The Air specific heat ratio k = C
p
/C
v
are based on: VDI 2045 Part 2 formula (53) k
f

= k * (1 - 0,11* x), k = 1.4 for dry air, x = air humidity ratio. Reference: 3.4.2

Shaft power will be measured via torque meter installed at the compressor input
shaft. Reference: 4.13.1

The compressor performance is based on Total pressure and temperature. Refer-
ence: 5.4.2.5 and 5.4.4.2. Calculation based on static pressure and temperature
will not be treated by HV-TURBO A/S.

The compressor performance is calculated according to an isentropic process. Refer-
ence Table 5.1 Calculations based upon a polytropic process will not be treated by
HV-TURBO A/S.

All instruments, calculations, and equations utilize metric units. Values will be con-
verted according to appendix H SI Units ASME PTC 10-1997.

The volume flow rate is based upon the mass flow rate, measured at the discharge.
The leakage flow is not a part of this flow. There are no secondary flow streams.
Reference 4.8.2.
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Witnessed testing is only to verify specified test point conditions, agreed upon prior
to the test. Para. 3.11.4 in the PTC 10 1997 code will not be fulfilled; however the
fluctuation of test readings will comply with table 3.4. The test procedure will be as
described in 4.3.1. Performance curves are not a part of the witnessed test. Per-
formance curves will be measured during the Standard Shop Test.

Reference 4.8.1

ASME PTC-19.5 standard for flow measurement is based on the same type of
equipment and the same physical laws as ISO 5167, but more complicated to handle
due to non metric unites and traditional methods. For the evaluation of test results
HV-TURBO has implemented the ISO 5167, which is assumed to be the most mod-
ern/updated standard, and which does not conflict with the PTC-19.5. ASME PTC-
19.5 is under review by ASME and draft versions reference ISO 5167 methods.

Specified Operating Conditions Notes Reference: 6.2.3

a) Gas composition and source for properties

b) Inlet gas state

Total pressure
Total temperature
Total density
Relative humidity

c) Gas flow rate

Discharge mass flow rate
Inlet volume flow rate
Capacity

d) Discharge total pressure

e) Coolant type, properties, flow rate, and temperature for cooled compressors

f) Speed

e) Others as needed

Expected Performance at specified Operating Conditions Notes Reference: 6.2.4

a) Developed head
b) Efficiency
c) Power requirement
d) Discharge total temperature
e) Other as needed
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All flow measurements during shop tests are carried out by means of straight, cylindrical
measuring pipes on which the entry of each pipe is equipped with a straightener. The
pipe length for inflow and outflow, the orifice plate design, and the pressure tappings are
in accordance with the specified standards. At the exhaust of each pipe, an electrically
activated throttle valve is installed in order to adjust the discharge pressure level. Four
calibrated temperature probes measure the pipe inlet temperature. The measuring pipe is
carefully insulated to avoid heat losses = temperature errors. Different pressure probes
measure the pipe system pressure. For different flow rates, measuring pipes of different
dimensions are installed on the test bed.

The orifice plates are inspected, calibrated, sealed, and certified every year by the inde-
pendent international inspection company SGS (Socit Gnrale de Surveillance).

The flow is computed from readings of pressure, temperature, and humidity. The method
of computation is described in the above-mentioned standards ISO 5167/PTC-19.5.

3.2 Measuring Shaft Power. Direct Method by Torquemeter

The torquemeter is an electronic torque-measuring coupling installed between the drive
motor and the compressor. Different sizes of torquemeter couplings are available. The
shaft power is computed from the measurement of torque and RPM.

All torquemeter couplings are calibrated on standardized calibration rigs with certified
plummets. Calibration of the torquemeter couplings is inspected and certified once a
year by the SGS.


Four temperature probes at the compressor intake and four similar probes at the com-
pressor discharge carry out standard temperature measurements.

The probes are thermocouples of an industrial design, wired to a high precision digital
display. All temperature probes and wires are marked for identification, sealed by SGS,
and calibrated in a laboratory calibration device. The calibration is performed with refer-
ence to certified thermometers. The calibration of temperature probes, incl. wiring and
display, is checked regularly and inspected and certified once a year by SGS.


In general, pressure measurements are carried out by means of high precision electronic
transmitters with digital reading. These instruments are always calibrated. U-tubes with
water or mercury filling are installed for the verification of these instruments.
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The test facility is equipped with fast logging multichannel data sampling units con-
nected to the test bed computer system. All test data are converted into electronic data
for automatic data logging. All transmitters involved are continuously checked and
maintained in a correctly calibrated state.


HV-TURBO is operating a certified quality assurance system for a.o. Continuous cali-
bration in conformity with the requirements of the international ISO 9000 standard.
Also, this test procedure description including all stated commitments is a registered do-
cument within this quality system.

3.7 Certification

In general, the a.m. certification of instrument calibration is carried out by SGS. For
more than a decade, calibration of our test bed instruments have proven that calibration
data for the same instruments do not change by more than what is expected within the
specified instrument accuracy.

SGS (Socit Gnrale de Surveillance) is an independent international inspection com-
pany with head office in Geneva, Switzerland, and with more than 100 assigned SGS-
offices, placed all over the world. SGS certificates issued for an HV-TURBO calibration
or any office of the SGS organization can verify compressor test.

If other calibration procedures are required, this must be specified in the contract or
agreed upon within a suitable space of time prior to the scheduled testing.

4. Test Procedures


The head of the project department in cooperation with the production department and
the engineers of the test department plan the schedule of testing.

Each turbocompressor must pass the SST. If additional testing is specified, the test will
be scheduled and the project department, well in advance, will inform the customer, as
well as the test department.

4.2 Standard Shop Test (SST)

This procedure has been developed from the experience of testing thousands of turbo-
compressors. Testing with atmospheric air will in general be conducted in an open loop
test rig.

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Before starting the motor, the lubricating-oil system is put into operation and the
safety controls are checked and adjusted.

During the initial start-up, the labyrinth seals are run into their final operating
shape, which is controlled by special procedures. During the first 15 minutes of
operation, the compressor is running at low load and special attention is paid to
the temperature rise of the bearing covers and the labyrinth seal flanges, as well
as to the vibrations.

During the SST, each compressor is operated at maximum design load, and all
essential operating data are checked and recorded. The housings, flanges, and
pipes, incl. the lube oil system, are checked for tightness.

For single-stage turbocompressors, the duration of the SST is 6-18 operating
hours, depending on the compressor type.


This test is always performed and evaluated in accordance with the standards de-
tailed under Item 2.

The compressor is set up for testing and connected to the instrumentation of the
automatic test bed data logging and processing.

The compressor guide vane setting and the system pressure will be adjusted step
by step to generate from 50 to 300 different operating points within a matrix of
test data, where guide vane positions, head and flow figures are altered and com-
bined systematically. The test data matrix is registered and computed individu-
ally for each compressor serial no., covering the specific design operating range.

The data logging system is programmed to register data from calibrated instru-
ments/transmitters. All data are checked for steady state conditions before accep-
tance. Registered data are averaged from four series of readings.

The test matrix data are computed and evaluated versus the design data and will
provide documentation for the quality approval procedure (ISO 9000). The test
matrix data also provide the basic software for the specific compressor control
system (option), which can automatically adjust the guide vanes to operate at
best efficiency at required flow and head. Finally, the test matrix data provides
basic data to document operating curves, as shown in the HV-Turbo Perform-
ance Certificate (pls. see 5.1).
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Vibration measurements, in vertical direction with an accelerometer mounted in
a representative point, are carried out on each compressor at max. Load, and the
actual RMS-value of the vibration velocity are recorded within the range 10-
1000 Hz. The measurements must be evaluated and conform to ISO 10816-1,
range limit 2.8 mm/s for max. Power below 400 kW and 4.5 mm/s for max.
Power more than 400 kW. Furthermore, frequency analysis will be carried out,
documented, and evaluated with reference to our experience from equivalent
equipment.


Noise measurements are carried out at least with one compressor of every order
with equal design data in accordance with ISO 3746. A test bed assistant per-
forms the sound pressure measurements and records the data on a test form. A
test engineer evaluates the test data in relation to the specified data and data as
measured on other compressors of equivalent design. If the compressor is pack-
aged with the job motor, a noise certificate can be issued.


The SST must meet the requirements of 1. Testing of electrical or electronic
controls, connected to the compressor, is not part of the above. The adjustment,
test, and inspection of electrical control panels are carried out in accordance with
other quality assurance procedures.

Having passed the SST with approval of the test results, the compressor is re-
leased for witnessed testing (if specified) and/or to be prepared for delivery.

In case the test results are not approved of, a non-conforming compressor will be
analyzed, reworked, and retested.

The preparations for delivery will a.o. Include flushing of the gearbox, the bear-
ings, etc. with corrosion-preventive oil, long-term preservation (if specified), fi-
nal adjustments of electronic sensors, adjustment of the discharge flange for in-
stallation on site, painting/surface preparation, marking and packing up.

4.3 Additional Performance Testing: ASME PTC 10 - 1997

Specified operating data can be verified by interpolation of test data from the SST (pls.
see 4.2.2 and 5.1).

If the verification of specific performance data in accordance with ASME PTC 10
1997 is a contractual requirement, the following options for additional testing can be of-
fered:
ITEM F

930030001UK
Revision: 0
Page: 9 of (11)



This test will be witnessed by the customer or by a representative appointed by
the customer.

A precondition for setting up a witnessed test is that the SST has been finalized
and SST data have been evaluated and approved by the test engineer.

With uncooled single-stage turbocompressors or tandem driven compressors
with externally piped intercooler for atmospheric air, the verification of guaran-
tee points will be conducted as follows, if no other requirements are specified:

- The genuine compressor(s) of the order will be tested.

- The test is conducted with atmospheric air.

- A Type 1 test ( para. 3.2.1 ) is typically conducted. Atmospheric condi-
tions on the day of the test control whether test points fall into a Type 1 or
2 category. We cannot control the inlet pressure or ambient temperature.

- The test is conducted at specified RPM within a departure of 2%. Refer-
ence Table 3.1.

- The compressor will be adjusted to the specified volumetric flow within a
departure of 2%. Reference Table 3.1.

- The discharge pressure will be adjusted equivalent to the specified isentropic
head within a departure of 1%. Reference Table 3.1.

- Recording of test data from calibrated instruments/ datalogger with a total
uncertainty of measurement, calculated according to PTC 19.1 1998 within
all limits of ISO 5389, table 5.

- According to ASME PTC 10 1997: Recording of three complete sets of
test data at steady state conditions for every operating point 3.11.2. The
minimum duration of a test point, after stabilization, shall be 15 minutes from
the first set of readings to the third set 3.11.3. Fluctuations of test readings
to be within the figures of Table 3.4.

- Computation of test data for every operating point with reference to specified
operating data and in accordance with ASME PTC 10 1997 / 5. With ref-
erence to API Standard 617 seventh edition, July 2002, Chapter 3, Integrally
geared compressors 4.3.3.1.2.: For variable speed or variable vane ma-
chines, head and capacity shall have zero negative tolerance at the normal
operating point (or other point as specified), and the power at this point shall
not exceed 104% of the vendor predicted shaft power value. This tolerance
shall be inclusive of all test tolerances. Surge shall comply with provisions of
2.1.1.1.
ITEM F

930030001UK
Revision: 0
Page: 10 of (11)


If it is not possible to adjust the test data within the above limits, the spotted op-
erating point will be bracketed ( ASME PTC 10 1997 / 3.11.4 ).

It is important that the witnessed performance test data are documented and
signed by the inspector, and for this reason all test data will be verified from
calibrated instruments and documented in a log sheet. During the test, the log
sheet data will be computed for evaluation in accordance with the standards men-
tioned above. A print will document the performance data of the test points with
reference to the specified guarantee conditions.

The number of guarantee points to be tested must be specified in advance and the
test must be scheduled.

An experienced test engineer will always conduct a witnessed test in cooperation
with the test bed foreman or his assistants.


This test will be witnessed by third party inspection, i.e. an inspector from an in-
dependent and neutral inspection company. The Inspection Company will on re-
quest issue a specific test certificate.



An experienced HV-Turbo test engineer under the supervision of the HV-Turbo
Quality Department will conduct this test. Test log sheets will be signed by the
test engineer and stamped by the QA Department.


5. Documentation


In accordance with 1-b the test data of each compressor Serial No. are documented to
the customer in terms of a graphic presentation, i.e. the HV-TURBO Performance Cer-
tificate. This certificate shows a relevant number of operational curves at different vane
settings of the inlet guide vanes, the variable diffuser vanes, or a combination. The
curves will show discharge pressure versus inlet volume flow and shaft power. The
curves will relate to the specified operating conditions, and the curves will also be num-
bered in relation to the vane setting pointer on the scale at the compressor.

Furthermore, curves of the recorded vibration analysis for each serial No. will be docu-
mented.

ITEM F

930030001UK
Revision: 0
Page: 11 of (11)


As regards compressors, which have been tested as a complete unit with their genuine
motor, the noise measurements will be documented in accordance with the standards
mentioned.

If an ASME PTC 10 1997 Test has been specified, a test report will document selected
guarantee points in accordance with ASME PTC 10 1997 Section 6 and this document
930030001UK.


Log sheets with test data in accordance with instrument readings and printed computer
evaluation from the same test data must be checked by the inspector and test engineer
and signed by both persons. Each participant of the test will receive copies of the test
documents as well as copies of the test rig system drawing and relevant copies of the in-
strument calibration certificates.


The HV-TURBO SST is mandatory and will always be conducted. The SST costs are included
in the budget of a compressor order. All additional tests will be conducted in accordance with
the requirements of the contract.

As the manufacturing schedule and the cost budget of a compressor order can easily get out of
control by unscheduled activities, we must avoid excessive and unscheduled testing. Optional or
other additional testing must be agreed to and specified in the contract, so that we are able to
plan, budget, schedule and conduct these activities to the satisfaction of our customers.

ITEM F
930970029UK
Revision: 1 HV-TURBO
Page: 1 of (6) STANDARD COMPRESSOR TEST
ITEM F


1. Purpose
4. Test Procedures (Standard Shop Test (SST)/Witnessed Performance Test, etc.)
5. Documentation

1. Purpose

All testing is performed in order to measure operating data for evaluation of conformity with specified data.

Before delivery, each HV-TURBO compressor is tested in accordance with the HV-TURBO Standard Shop Test
(SST) procedure. The test procedures have been developed from the experience of testing thousands of turbo-
machines during more than three (3) decades. The test must fulfill the following purposes:

a) Provide sufficient test data over the entire specified operational range for the quality approval procedure
before delivery.

b) Provide documentation of the performance data and the performance range in terms of a graphic presentation
to the customer.

c) Provide conditioned data/software for the automated power saving program of SV-type compressors.

d) Provide specific and statistic data as feedback for the compressor design program.

e) Ensure accurate, safe, and fast registration of all relevant test data in the shortest possible testing time and at
the lowest possible cost.


HV-TURBO compressor testing procedures, as well as the testing equipment, instrumentation, and calibration are
based on national and international standards as follows:

ISO 5389: International standard: Turbocompressors - Performance Test Code.

ISO 5167: International standard: Measurement of Fluid Flow.

ISO 10816-1: Mechanical Vibration of Machines.

ISO 3744: Determination of Sound Power Levels of Noise Sources. If free-field conditions cannot be
established, ISO 3746 will apply.

DIN 1952: Durchflumessung.

DIN 45635: Geruschmessung an Maschinen (Verdranger-, Turbo und Strahlverdichter)
(Teil 13)

VDI 2045: Abnahme- und Leistungsversuche an Verdichtern.

VDI 2056: Beurteilungsmastbe fr mechanische Schwingungen von Maschinen.

API Standard
672/4.3.4.1: Packages, Integrally Geared Centrifugal Air Compressors for General Refinery Service:
Combined Mechanical and Performance Test.

930970029UK
ITEM F




All flow measurements during shop tests are carried out by means of straight, cylindrical measuring pipes
on which the entry of each pipe is equipped with a straightener. The pipe length for inflow and outflow,
the orifice plate design, and the pressure tapping is in accordance with international standards. At the
exhaust of each pipe, an electrically activated throttle valve is installed in order to adjust the discharge
pressure level. The pipe inlet temperature is measured by four (4) calibrated temperature probes. The
measuring pipe is carefully insulated to avoid heat losses = temperature errors.

The pipe system pressure is measured by different pressure probes. For different flow rates, measuring
pipes of different dimensions are installed on the test bed.

The orifice plates are inspected, calibrated, sealed, and certified every year by the independent
international inspection company SGS (Socit Gnrale de Surveillance).

The flow is computed from readings of pressure, temperature, and humidity in accordance with ISO 5167.


Temperature measurements are carried out by four (4) temperature probes at the compressor intake and
four (4) similar probes at the compressor discharge.

The probes are thermocouples of an industrial design, wired to a high precision digital display. All
temperature probes and wires are marked for identification, sealed by SGS, and calibrated in a laboratory
calibration device. The calibration is performed with reference to certified thermometers. The calibration
of temperature probes (including wiring and display) is checked regularly, and inspected and certified
once a year by SGS.


In general, pressure measurements are carried out by means of electronic transmitters with digital
reading. These instruments are always calibrated by means of U-tube manometers. U-tubes with water
or mercury filling are installed for the verification of the electronic instruments.

3.4 Shaft Power

The shaft power is computed from the measurements of the energy input into the gas, the mass flow, the
gear losses, and the bearing losses. Conversion of test results to guarantee conditions are done
according to international standards.


The test facility is equipped with fast-logging multi-channel data sampling units connected to the test bed
computer system. All test data is converted into electronic data for automatic data logging. All
transmitters involved are continuously checked and maintained in a correctly calibrated state.


HV-TURBO is operating a certified quality assurance system for a.o. continuous calibration in conformity
with the requirements of the international ISO 9001 standard. Also, this test procedure description,
including all stated commitments, is a registered document within this quality assurance system.

930970029UK
ITEM F


3.7 Certification

In general, the a.m. certification of instrument calibration is carried out by SGS once a year. For more
than a decade, calibration of our test bed instruments has proven that calibration data for the same
instruments does not change by more than what is expected, within the specified instrument accuracy.

SGS (Socit Gnrale de Surveillance) is an independent international inspection company with its head
office in Geneva, Switzerland, and with more than 100 assigned SGS-offices, placed all over the world.
SGS certificates issued for an HV-TURBO calibration or for specific compressor testing can be verified by
any office of the SGS organization.

If other calibration procedures are required, this must be specified in the contract or agreed upon within a
suitable space of time prior to the scheduled testing.

4. Test Procedures


The schedule of testing is planned by the head of the project department in cooperation with the
production department and the engineers of the test department.

Each turbocompressor must pass the SST. If additional testing is specified, the test will be scheduled
and the customer, as well as the test department, will be informed by the project department well in
advance.

4.2 Stand Shop Test (SST)


Testing with atmospheric air will, in general, be conducted in an open loop test rig.

Before starting the motor, the lubricating-oil system is put into operation and the safety controls are
checked and adjusted.

During the initial start-up, the labyrinth seals are run into their final operating shape, which is controlled by
special procedures. During the first 15 minutes of operation, the compressor is running at low load and
special attention is paid to the temperature rise of the bearing covers and the labyrinth seal flanges, as
well as to the vibrations.

During the SST, each compressor is operated at maximum design load, and all essential operating data
is checked and recorded. The housings, flanges, and pipes, including the lube oil system, are checked
for tightness.

For single-stage turbocompressors, the duration of the SST is 6-18 operating hours, depending on the
compressor type.


The compressor is set up for testing and connected to the instrumentation of the automatic test bed data
logging and processing.

930970029UK
ITEM F


The compressor guide vane setting and the system pressure will be adjusted step-by-step to generate
from 50 to 300 different operating points within a matrix of test data, where guide vane positions, head
and flow figures are altered and combined systematically. The test data matrix is registered and
computed individually for each compressor serial no., covering the specific design operating range.

The data logging system is programmed to register data from calibrated instruments/transmitters. All data
is checked for steady state conditions before acceptance. Registered data is averaged from four (4)
series of readings.

The test matrix data is computed and evaluated versus the design data, and will provide documentation
for the quality approval procedure (ISO 9001). The test matrix data also provides the basic software for
the specific compressor control system (option), which can automatically adjust the guide vanes to
operate at best efficiency at required flow and head.

Finally, the test matrix data provides basic data to document operating curves as shown in the HV-Turbo
Performance Certificate (please see 5.1).


Vibration measurements, with an accelerometer mounted in a representative point, are carried out on
each compressor at maximum load, so that the actual RMS-value of the vibration velocity is recorded
within the range 10-1000 Hz. The measurements must be evaluated and conform to ISO 10816-1.
Range limit 2,8 mm/s if maximum power is below 400 kW, and 4,5 mm/s if maximum power is more than
400 kW. Furthermore, frequency analysis will be carried out, documented, and evaluated.


Noise measurements are carried out at least with one compressor of every order with equal design data
in accordance with ISO 3744/3746. A test bed assistant performs the sound pressure measurements and
records the data on a test form. A test engineer evaluates the test data in relation to the specified data,
and data as measured on other compressors of equivalent design. If the compressor is packaged with
the job motor, a noise certificate can be issued.


The SST must meet the requirements of 1. Testing of electrical or electronic controls, connected to the
compressor, is not part of the above. The adjustment, test, and inspection of electrical control panels are
carried out in accordance with other quality assurance procedures.

Having passed the SST with approval of the test results, the compressor is released for witnessed testing
(if specified) and/or to be prepared for delivery.

In case the test results are not approved, a non-conforming compressor will be analyzed, reworked, and
retested.

The preparation for delivery will a.o. include flushing of the gearbox, the bearings, etc. with corrosion-
preventive oil, long-term preservation (if specified), final adjustments of electronic sensors, adjustment of
the discharge flange for installation on site, painting/surface preparation, marking, and packing.

4.3 Additional Performance Testing

Specified operating data can be verified by interpolation of test data from the SST (please see 4.2.2 and
5.1).

930970029UK
ITEM F


If the verification of selected guarantee points is a contractual requirement, the following options for
additional testing can be offered.


This test will be witnessed by the customer or by a representative appointed by the customer.

A pre-condition for setting up a witnessed test is that the SST has been finalized, and SST data has been
evaluated and approved by the test engineer.

With non-cooled single-stage turbocompressors, or tandem driven compressors with externally piped
intermediate cooler for atmospheric air, the verification of guarantee points will be conducted as follows, if
no other requirements are specified:

The genuine compressor(s) of the order will be tested.

The test is conducted with atmospheric air.

The test is conducted at specified RPM within a departure of + 4%.

The compressor will be adjusted to the specified volumetric flow within a departure of +4%.

The discharge pressure will be adjusted equivalent to the specified isentropic head within a departure
of + 4%.

Recording of test data from calibrated instruments with a total uncertainty of measurement within the
limits of ISO 5389, Table 5.

Recording of one (1) complete set of test data at steady state conditions for every operating point.

Computation of test data for every operating point with reference to specified operating data and in
accordance with ISO 5389, Diagram D8, and within the tolerances of - 0/+ 4% for flow, pressure, and
power in accordance with API 672/4.3.4.1.

If it is not possible to adjust the test data within the above limits, ISO 5389 7.2.7 shall apply.

If it is not possible to avoid fluctuation within + 1% of the average magnitude of the test data in question,
ISO 5389 7.2.8 shall apply.

It is important the witnessed performance test data is approved and signed by the inspector, and for this
reason, the test data will be read from the calibrated instruments and set down in a log sheet. During the
test, the log sheet data will be computed for evaluation in accordance with the standards mentioned
above. A print will document the performance data of the test points with reference to the specified
guarantee conditions.

The number of guarantee points to be tested must be specified in advance, and the test must be
scheduled.

A witnessed test will always be conducted by an experienced test engineer in cooperation with the test
bed foreman or his assistants.


This test will be witnessed by third party inspection, i.e. an inspector from an independent and neutral
inspection company. The inspection company will, on request, issue a specific test certificate.
930970029UK
ITEM F




This test will be conducted by an experienced HV-TURBO test engineer under the supervision of the HV-
TURBO Quality Department. Test log sheets will be signed by the test engineer and stamped by the QA
Department.


5. Documentation


In accordance with 1-b, the test data of each compressors serial number is documented to the customer
in terms of a graphic presentation, i.e. the HV-TURBO Performance Certificate. The certificate shows a
relevant number of operational curves at different vane settings of the inlet guide vanes, the variable
diffuser vanes, or a combination. The curves will show discharge pressure versus inlet volume flow and
shaft power. The curves will relate to the normal operating conditions, and the curves will also be
numbered in relation to the vane setting pointer on the scale at the compressor.

Furthermore, curves of the recorded vibration analysis for each serial number will be documented.

As regards, compressors that have been tested as a complete unit with their genuine motor, the noise
measurements will be documented in accordance with the standards mentioned.

If additional performance testing has been specified, the test data will be documented as mentioned
above.


Log sheets with the test data and the computer evaluation print from the same test data must be checked
by the inspector and test engineer, and signed by both persons. Each participant of the test will receive
copies of the test documents, as well as copies of the test rig system drawing and relevant copies of the
instrument calibration certificates.


The HV-TURBO SST is mandatory and will always be conducted. The SST costs are included in the budget of a
compressor order. All additional tests will be conducted in accordance with the requirements of the contract.

As the cost budget and schedule of a compressor order can easily get out of control by unscheduled activities, we
must avoid excessive and unscheduled testing. Optional or other additional testing must be agreed to and
specified in the contract, so that we are able to plan, budget, schedule, and conduct these activities to the
satisfaction of our customers.

U:\Sub-O&M\Std Compressor Test Proc.doc
I T E M F
ITEM F.b
TECO-Westinghouse Motor Company -
Induction Motor Test Agenda Horizontal
0Q01AA
TURBLEX
1 Okoye, Latetia
6/8/2009
Shop Order:
Customer:
Motor Number: Electrical Engineer:
Test Date:
General/Nameplate Information
4000
6600
288
60
1.15
3
2
Wye
CCW
T1:T3:T2
5616
WP2
N/R
D094611-02
Rated Power:
Rated Line Voltage:
Rated Line Current:
Operating Frequency:
Service Factor:
Number of Phases:
# Poles/Full Load RPM:
Winding:
Rotation Direction (NDE):
Phase Sequence:
Frame:
Enclosure:
Stator Number:
Rotor Number:
Summary of Customer Purchased Tests
(Purchased Items are indicated with a )
Description : NEMATest Package
Standard Commercial Tests (Performed on All Machines)
Resistance Measurements: Stator Winding, Heater and Temperature Detector Circuits
Air Gap Measurement: Average
Magnetic Center Determination(Sleeve Bearing Machines Only)
Bearing Temperature Rise at Running Speed
Shaft Voltage at Rated Voltage and Running Speed
No Load Electrical Characteristics: Volts, Amps, KiloWatts
No Load Vibration Measurements: Brackets and Shaft
Final High Potential and/or Megger Test of Insulation Integrity
No Load Saturation Characteristics
Locked Rotor Test:
Dual Frequency Temperature Run
One Point Locked Rotor Test
Coast Down Vibration Plot
Speed Torque
Supplemental Bearing Inspection Following No Load Vibration Test
Sound Measurement per IEEE 85
Octave Band Sound Measurement per IEEE 85
1/3 Octave Band Sound Measurement per IEEE 85
Hot Vibration
Bearing Modulation
Residual Unbalance
Engineering Tests (Performed if Specified) IEEE 112, Method F(1) for Performance Determination
Standard Options (Performed if Specified)
5 Voltage Settings at Rated Frequency
3 Voltage Settings at 25% Rated Frequency
Vibration Spectrum (FFT) Analysis
DC High Potential Test of Insulation Integrity
FINAL REPORT
Time Rating: Continuous
/ 3556
LR kVA Code: F
Ambient Temp: 50
F Insulation Class:
Overspeed Test
1 Page of 7
ITEM F.b
Induction Motor Test Report Horizontal
0Q01AA
TURBLEX
1 Okoye, Latetia
6/8/2009
Shop Order:
Customer:
Test Date:
Resistance Measurements
Line to Line Stator Resistance
(at 25 Degrees C)
Measured Value
(Ohms)
Line 1
Line 2
Line 3
0.1284
0.1286
0.1286
Average: 0.1285
0.1284 Max Deviation:
Max Deviation From Average (%): -0.13
Soft Foot Measurements:
Heater Resistance (if applicable):
Heater 1
Measured Value
(Ohms)
16.48
Measurement Temperature (Deg C.): 23.54
Final HI-POT (VAC)
Spec
Measured
Stator:
ETD's:
Space Heaters:
Final One-Minute HI-POT and Insulation
Resistance:
Stator Temp Detector Circuit (if applicable):
Final Insulation
Resistance Value
Applied
Volts
Resistance
(MOhms)
Stator:
ETD's:
Space Heaters:
Temperature (Degrees C):
ETD 1:
ETD 2:
ETD 3:
ETD 4:
ETD 5:
ETD 6:
ETD 7:
Note: Measurement Performed After Final HIPOT and Megger.
14200
1500
2200
14200
1500
2200
5000
500
1000
3119.75
917
5620
112.43
112.56
112.31
112.35
112.35
112.40
112.50
100 Ohm Platinum
31.33
N/A
TECO-Westinghouse Motor Company - FINAL REPORT
(RTD) Installed Temperature Detector:
Measured Value (Ohms)
*
Spec
2 Page of 7
* Resistance is corrected to 40 Deg C.
ITEM F.b
Air Gap Measurements
NonDriveEnd Air Gap
DriveEnd Air Gap
Measured Value (Inches)
Quadrant 1
Quadrant 2
Quadrant 3
Quadrant 4
Quadrant 1
Quadrant 2
Quadrant 3
Quadrant 4
Average
Average
0.115
0.110
0.110
0.115
0.110
0.110
0.105
0.110
0.113
0.109
Magnetic Center
Measured Value (inches)
Float In (Ref 1)
Float Out (Ref 1)
Magnetic Center (Ref 1)
Magnetic Center Dev (Ref 2)
Total End Play
Ref 1: Value determined by measuring distance from shaft shoulder to bearing housing face.
Ref 2: Value determined with respect to Mid End Play Line, where:
Mid End Play=1/2 * (Float Out - Float In) + Float In
Mag Center Dev (Ref 2)=Magnetic Center(Ref 1) -
Mid End Play
5.500
6.050
5.750
-0.025
0.550
0Q01AA
TURBLEX
1 Okoye, Latetia
6/8/2009
Shop Order:
Customer:
Test Date:
FINAL REPORT
4.444 Maximum Deviation (%)
4.598
Maximum Deviation (%)
3 Page of 7
Measured Value (mm)
Measured Value (mm)
2.921
2.794
2.794
2.921
2.794
2.794
2.667
2.794
2.858
2.762
4.444
4.598
Measured Value (mm)
139.700
153.670
146.050
-0.635
13.970
ITEM F.b
TURBLEX
1 Okoye, Latetia
6/8/2009
Shop Order:
Customer:
Test Date:
0Q01AA
FINAL REPORT
4 Page of 7
NonDrvEnd Brg Temp (Deg C)
DrvEnd Brg Temp (Deg C)
NonDrvEnd Thrust Temp (Deg C)
DrvEnd Thrust Temp (Deg C)
DrvEnd Ref Temp(Ref1 Deg C)
NonDrvEnd Brg Temp Rise (Deg C)
DrvEnd Brg Temp Rise (Deg C)
NonDrvEnd Thrust Temp Rise (Deg C)
DrvEnd Thrust Temp Rise (Deg C)
Elapsed Running Time (Hrs)
NonDrvEnd Water Temp In
DrvEnd Water Temp In
NonDrvEnd Water Temp Out
DrvEnd Water Temp Out
NonDrvEnd Water GPM
DrvEnd Water GPM
NonDrvEnd Water PSI
DrvEnd Water PSI
NonDrvEnd Oil Temp In
DrvEnd Oil Temp In
NonDrvEnd Oil Temp Out
DrvEnd Oil Temp Out
NonDrvEnd Oil GPM
DrvEnd Oil GPM
NonDrvEnd Oil PSI
DrvEnd Oil PSI
NonDrvEnd Ref Temp (Ref1 Deg C)
Final Run
Ref 1: Inlet oil temp if flood lube system,
ambient if not flood lube.
Ref 2: Inlet water temp if bearing cooled
by water system, otherwise refer to ref 1
41.00
44.10
31.40
31.80
9.60
12.30
1.00
31.40
31.80
38.50
38.10
0.60
0.90
46.50
34.30
No Load Electrical Characteristics
Frequency (Hz) V T1:T2 V T2:T3 V T3:T1 A2 A3 KiloWatts A1
60 6600.60 6606.00 6603.00 34.22 35.72 34.80 44.50
No Load RPM =
Average No Load Line Volts =
3600.00
6603.20
Average No Load Line Amps 34.91
Shaft Voltage
Measurement Performed at Rated Voltage and
Running Speed
Shaft End to Shaft End Voltage= 0.2320
Bearing Inspection
Bearing Insulation (Meg Ohms)
N/A
N/A
(I0)=
Direction of Rotation as Viewed from NonDriveEnd (as tested) = CCW
- Not Reqd
- Not Reqd
ITEM F.b
TURBLEX
1 Okoye, Latetia
6/8/2009
Shop Order:
Customer:
Test Date:
0Q01AA
FINAL REPORT
Bearing Temperature Rise at Running Speed (Metric)
5 Page of 7
NonDrvEnd Water LPM
DrvEnd Water LPM
NonDrvEnd Water PSI
DrvEnd Water PSI
DrvEnd Oil Temp In
DrvEnd Oil Temp Out
NonDrvEnd Oil LPM
DrvEnd Oil LPM
NonDrvEnd Oil PSI
DrvEnd Oil PSI
Final Run
41.00
44.10
31.40
31.80
9.60
12.30
1.00
31.40
31.80
38.50
38.10
2.27
3.41
46.50
34.30
60 6600.60 6606.00 6603.00 34.22 35.72 34.80 44.50
No Load RPM =
3600.00
6603.20
Shaft Voltage
Running Speed
Bearing Inspection
N/A
N/A
(I0)=
- Not Reqd
- Not Reqd
ITEM F.b
Shop Order: Motor Number: 0Q01AA 1
TURBLEX
Okoye, Latetia
6/8/2009 Customer:
Electrical Engineer:
Test Date:
FINAL REPORT
6 Page of 7
Measurements
Location Direction UF 1/2 X 1X UF 1/2 X 1X 2X 2X
Vibration Test: No Load Final
Displacement (mils p/p) Velocity (in/sec)
Specifications Displacement (mils p/p) Velocity (in/sec)
Spec Type: NEMA
(F) NonDriveEnd Bracket Horizontal 0.1000
(F) NonDriveEnd Bracket Vertical 0.1000
(F) NonDriveEnd Bracket XAxial 0.1000
(R) DriveEnd Bracket Horizontal 0.1000
(R) DriveEnd Bracket Vertical 0.1000
(R) DriveEnd Bracket XAxial 0.1000
Shaft (F) NonDriveEnd Horizontal 2.0000
Shaft (F) NonDriveEnd Vertical 2.0000
Shaft (R) DriveEnd Horizontal 2.0000
Shaft (R) DriveEnd Vertical 2.0000
ITEM F.b
TURBLEX
Okoye, Latetia
6/8/2009 Customer:
Test Date:
FINAL REPORT
7 Page of 7
Measurements
Vibration Test (metric): No Load Final
Displacement (mm) Velocity (mm/sec)
Specifications Displacement (mm) Velocity (mm/sec)
Spec Type: NEMA
ITEM F.b
ITEM F.b
0Q01AA
TURBLEX
2 Okoye, Latetia
6/5/2009
Shop Order:
Customer:
Test Date:
4000
6600
288
60
1.15
3
2
Wye
CCW
T1:T3:T2
5616
WP2
N/R
D094611-01
Rated Power:
Rated Line Voltage:
Rated Line Current:
Service Factor:
Number of Phases:
Winding:
Phase Sequence:
Frame:
Enclosure:
Stator Number:
Rotor Number:
Locked Rotor Test:
Speed Torque
Hot Vibration
Bearing Modulation
Residual Unbalance
FINAL REPORT
/ 3556
LR kVA Code: F
Ambient Temp: 50
F Insulation Class:
Overspeed Test
1 Page of 7
ITEM F.b
0Q01AA
TURBLEX
2 Okoye, Latetia
6/5/2009
Shop Order:
Customer:
Test Date:
(at 25 Degrees C)
Measured Value
(Ohms)
Line 1
Line 2
Line 3
0.1282
0.1285
0.1284
Average: 0.1283
Heater 1
Measured Value
(Ohms)
16.56
Final HI-POT (VAC)
Spec
Measured
Stator:
ETD's:
Space Heaters:
Resistance:
Final Insulation
Resistance Value
Applied
Volts
Resistance
(MOhms)
Stator:
ETD's:
Space Heaters:
ETD 1:
ETD 2:
ETD 3:
ETD 4:
ETD 5:
ETD 6:
ETD 7:
14200
1500
2200
14200
1500
2200
5000
500
1000
4692.68
218000
278000
112.25
112.16
111.87
112.08
111.96
111.88
111.90
100 Ohm Platinum
30.88
N/A
*
Spec
2 Page of 7
ITEM F.b
NonDriveEnd Air Gap
DriveEnd Air Gap
Quadrant 1
Quadrant 2
Quadrant 3
Quadrant 4
Quadrant 1
Quadrant 2
Quadrant 3
Quadrant 4
Average
Average
0.115
0.120
0.120
0.115
0.115
0.125
0.120
0.115
0.118
0.119
Magnetic Center
Float In (Ref 1)
Float Out (Ref 1)
Total End Play
Mid End Play
5.500
6.050
5.780
0.005
0.550
0Q01AA
TURBLEX
2 Okoye, Latetia
6/5/2009
Shop Order:
Customer:
Test Date:
FINAL REPORT
8.421
3 Page of 7
Measured Value (mm)
Measured Value (mm)
2.921
3.048
3.048
2.921
2.921
3.175
3.048
2.921
2.985
3.016
4.255
8.421
Measured Value (mm)
139.700
153.670
146.812
0.127
13.970
ITEM F.b
TURBLEX
2 Okoye, Latetia
6/5/2009
Shop Order:
Customer:
Test Date:
0Q01AA
FINAL REPORT
4 Page of 7
NonDrvEnd Water GPM
DrvEnd Water GPM
NonDrvEnd Water PSI
DrvEnd Water PSI
DrvEnd Oil Temp In
DrvEnd Oil Temp Out
NonDrvEnd Oil GPM
DrvEnd Oil GPM
NonDrvEnd Oil PSI
DrvEnd Oil PSI
Final Run
42.20
44.80
31.70
30.30
10.50
14.50
8.28
31.70
30.30
37.30
38.40
0.70
1.00
60.90
40.40
60 6600.00 6602.40 6600.00 34.56 35.38 35.21 43.20
No Load RPM =
3600.00
6600.80
Shaft Voltage
Running Speed
Bearing Inspection
N/A
N/A
(I0)=
- Not Reqd
- Not Reqd
ITEM F.b
TURBLEX
2 Okoye, Latetia
6/5/2009
Shop Order:
Customer:
Test Date:
0Q01AA
FINAL REPORT
5 Page of 7
NonDrvEnd Water LPM
DrvEnd Water LPM
NonDrvEnd Water PSI
DrvEnd Water PSI
DrvEnd Oil Temp In
DrvEnd Oil Temp Out
NonDrvEnd Oil LPM
DrvEnd Oil LPM
NonDrvEnd Oil PSI
DrvEnd Oil PSI
Final Run
42.20
44.80
31.70
30.30
10.50
14.50
8.28
31.70
30.30
37.30
38.40
2.65
3.79
60.90
40.40
60 6600.00 6602.40 6600.00 34.56 35.38 35.21 43.20
No Load RPM =
3600.00
6600.80
Shaft Voltage
Running Speed
Bearing Inspection
N/A
N/A
(I0)=
- Not Reqd
- Not Reqd
ITEM F.b
TURBLEX
Okoye, Latetia
6/5/2009 Customer:
Test Date:
FINAL REPORT
6 Page of 7
Measurements
Spec Type: NEMA
ITEM F.b
TURBLEX
Okoye, Latetia
6/5/2009 Customer:
Test Date:
FINAL REPORT
7 Page of 7
Measurements
Spec Type: NEMA
ITEM F.b
ITEM F.b
0Q01AA
TURBLEX
3 Okoye, Latetia
6/8/2009
Shop Order:
Customer:
Test Date:
4000
6600
288
60
1.15
3
2
Wye
CCW
T1:T3:T2
5616
WP2
N/R
D094611-03
Rated Power:
Rated Line Voltage:
Rated Line Current:
Service Factor:
Number of Phases:
Winding:
Phase Sequence:
Frame:
Enclosure:
Stator Number:
Rotor Number:
Locked Rotor Test:
Speed Torque
Hot Vibration
Bearing Modulation
Residual Unbalance
FINAL REPORT
/ 3556
LR kVA Code: F
Ambient Temp: 50
F Insulation Class:
Overspeed Test
1 Page of 7
ITEM F.b
0Q01AA
TURBLEX
3 Okoye, Latetia
6/8/2009
Shop Order:
Customer:
Test Date:
(at 25 Degrees C)
Measured Value
(Ohms)
Line 1
Line 2
Line 3
0.1284
0.1286
0.1286
Average: 0.1285
Heater 1
Measured Value
(Ohms)
16.52
Final HI-POT (VAC)
Spec
Measured
Stator:
ETD's:
Space Heaters:
Resistance:
Final Insulation
Resistance Value
Applied
Volts
Resistance
(MOhms)
Stator:
ETD's:
Space Heaters:
ETD 1:
ETD 2:
ETD 3:
ETD 4:
ETD 5:
ETD 6:
ETD 7:
14200
1500
2200
14200
1500
2200
5000
500
1000
3211.39
1860
6130
110.66
110.51
110.73
110.69
110.74
110.73
110.74
100 Ohm Platinum
26.85
N/A
*
Spec
2 Page of 7
ITEM F.b
NonDriveEnd Air Gap
DriveEnd Air Gap
Quadrant 1
Quadrant 2
Quadrant 3
Quadrant 4
Quadrant 1
Quadrant 2
Quadrant 3
Quadrant 4
Average
Average
0.120
0.125
0.125
0.120
0.120
0.125
0.125
0.120
0.123
0.123
Magnetic Center
Float In (Ref 1)
Float Out (Ref 1)
Total End Play
Mid End Play
5.470
6.020
5.750
0.005
0.550
0Q01AA
TURBLEX
3 Okoye, Latetia
6/8/2009
Shop Order:
Customer:
Test Date:
FINAL REPORT
4.082
3 Page of 7
Measured Value (mm)
Measured Value (mm)
3.048
3.175
3.175
3.048
3.048
3.175
3.175
3.048
3.112
3.112
4.082
4.082
Measured Value (mm)
138.938
152.908
146.050
0.127
13.970
ITEM F.b
TURBLEX
3 Okoye, Latetia
6/8/2009
Shop Order:
Customer:
Test Date:
0Q01AA
FINAL REPORT
4 Page of 7
NonDrvEnd Water GPM
DrvEnd Water GPM
NonDrvEnd Water PSI
DrvEnd Water PSI
DrvEnd Oil Temp In
DrvEnd Oil Temp Out
NonDrvEnd Oil GPM
DrvEnd Oil GPM
NonDrvEnd Oil PSI
DrvEnd Oil PSI
Final Run
42.80
45.30
32.50
33.10
10.30
12.20
1.47
32.50
33.10
37.70
40.00
0.60
1.00
46.60
34.00
60 6600.00 6607.20 6601.20 34.73 35.59 34.91 42.98
No Load RPM =
3600.00
6602.80
Shaft Voltage
Running Speed
Bearing Inspection
N/A
N/A
(I0)=
- Not Reqd
- Not Reqd
ITEM F.b
TURBLEX
3 Okoye, Latetia
6/8/2009
Shop Order:
Customer:
Test Date:
0Q01AA
FINAL REPORT
5 Page of 7
NonDrvEnd Water LPM
DrvEnd Water LPM
NonDrvEnd Water PSI
DrvEnd Water PSI
DrvEnd Oil Temp In
DrvEnd Oil Temp Out
NonDrvEnd Oil LPM
DrvEnd Oil LPM
NonDrvEnd Oil PSI
DrvEnd Oil PSI
Final Run
42.80
45.30
32.50
33.10
10.30
12.20
1.47
32.50
33.10
37.70
40.00
2.27
3.79
46.60
34.00
60 6600.00 6607.20 6601.20 34.73 35.59 34.91 42.98
No Load RPM =
3600.00
6602.80
Shaft Voltage
Running Speed
Bearing Inspection
N/A
N/A
(I0)=
- Not Reqd
- Not Reqd
ITEM F.b
TURBLEX
Okoye, Latetia
6/8/2009 Customer:
Test Date:
FINAL REPORT
6 Page of 7
Measurements
Spec Type: NEMA
ITEM F.b
TURBLEX
Okoye, Latetia
6/8/2009 Customer:
Test Date:
FINAL REPORT
7 Page of 7
Measurements
Spec Type: NEMA
ITEM F.b

Telephone (417) 864-5599
Facsimile (417) 866-0235

ITEM F

FUNCTIONAL/ON-SITE TEST PROCEDURE

I) TEST SET-UP (Turblex Shop)

Interconnect Wiring
The blower package, remote mount control panels, and all electrical accessories will be properly
electrically connected.

Lubrication
The oil reservoir will be filled with sufficient oil for the oil pump to properly function.

II) PRELIMINARY CHECK-OUT (Turblex Shop)

All switches and transmitters will be checked to verify the proper signal is being received by the
LCP and calibrated as required.

III) ROTATIONAL/OPERATIONAL CHECK-OUT (Turblex Shop)

All motors (except main drive motor) and actuators will be operated one (1) at a time to ensure
proper rotation and/or operation.

IV) FUNCTIONAL TEST (Turblex Shop)

Each of the following operating sequences and alarm/functions will be tested to verify that proper
sequences and shutdown procedures are followed for proper operation. Manually tripping the
switches and manipulating the PLC setpoints will be utilized to simulate the alarms.

1) Service Mode Operations
2) Normal Start Sequence
3) Normal Stop Sequence
4) Soft Stop Sequence
5) Emergency Stop Sequence
6) Soft Stop Alarms
7) Emergency Stop Alarms
8) Sequence Failure Alarm
9) Warning Alarms
10) Alarm Acknowledge
11) Alarm Reset

V) ON-SITE PREPARATION (Pre-Startup Checklist)

Prior to Turblex start-up service, all mechanical and electrical connections must be completed by
contractor. Also, the Compressor (Blower) Pre-Startup Inspection Checklist must be completely
filled out and returned to Turblex with a request for start-up service.
ITEM F

FUNCTIONAL/ON-SITE TEST PROCEDURE

2

VI) ON-SITE TESTING

Turblex' start-up personnel will make a preliminary inspection in order to verify that the contractor is
ready for start-up services. Should the contractor not be ready for start-up, personnel will notify all
parties and return to their home office. The contractor will be billed for Turblex services provided at
the time. Should the Turblex inspection pass, start-up will continue until completed.

All items of Sections II and III will be repeated prior to unit start-up. In addition, signals from the
field-connected items will be checked. Items 1 through 5 of Section IV will also be repeated prior to
start-up with the LCP in "TEST" mode. These and any other checks as deemed necessary by the
Turblex Start-Up Engineer will be completed prior to unit start-up.

The motor to blower coupling will be removed, alignment checked, and the motor started and run for
a minimum of one (1) hour to verify its operation and rotation. The coupling will then be reinstalled.
The initial start will be aborted after the motor has reached full speed. The Turblex Start-Up
Engineer will be looking and listening for abnormal items. Upon successful completion of these
steps, the unit will be started and allowed to run for about 12 hours, being observed for anything
abnormal.

Z:\Submittal_O&M\Master_Sub\Item_F_Testing\Source_Docs\Functional_On-Site_Test_Proc.doc
FORM: 98012802.QAS COMPRESSOR (BLOWER) PRE-STARTUP
REV: 7 INSPECTION CHECKLIST
REV DATE: 6/15/07 1635 W. Walnut Street
APPRVD. BY: Springfield, MO 65806
Ph: 417-864-5599/Fax: 417-866-0235
PAGE 1 OF 2 ITEM G
SCOPE:
Turblex Compressor Serial Number
Customer Compressor ID Number
1.
2.
3.
4.
5.
6.
7. Discharge expansion joint installed within manufacturer's limits
8.
9.
10.
11. Downstream air piping supported and clear for blower air flow
12.
13.
14. Blow-off piping supported & restrained properly to prevent motion
15.
16.
17. Water pressure available between 60-150 PSIG
18.
24. Shipped loose pressure and temperature transmitters installed
25. Shipped loose pressure and temperature gauges installed
26. Shipped loose sound enclosure installed
27.
1.
(To Be Completed by the Contractor)
Air filter elements installed
Inlet air piping clean/certified of all dirt, rust, sand, etc.
Blower mounted and leveled on vibration isolators
Inlet and discharge of blowers certified clean of debris
Inlet filter silencer installed
Inlet flex connector installed
Discharge diffuser cone installed
Discharge check valve installed per manufacturer's
recommendation
Discharge isolation valve(s) installed
The following items must be completed by the Installing Contractor prior to start-up of Turblex-supplied equipment. All
items must be signed-off as completed, inspected, and accepted (for EACH unit) with a signed copy forwarded (via mail
or fax) to Turblex before start-up is intiated by Turblex. Advance notification of 10 working days is requested for
scheduling and making travel arrangements for Turblex start-up personnel to proceed to the jobsite.
Upon arrival at the jobsite, delays in start-up work or additional visits to the jobsite specifically caused by deficient or
uncompleted items detailed in this document will be invoiced in accordance with Turblex's standard service rate
schedule (copy attached).
Blower S/N
Checkmark to Confirm Mechanical Items
N/A if Not Applicable
Water piping installed
Blow-off discharge area clear of ladders, trash, etc.
Blow-off valve installed
Blow-off silencer installed
Water drain path clear
21. Motor oil/grease reservoir filled with lubricant per manufacturer's
specification
22.
19.
Pressure line tubing from high side of differential pressure
transmitter attached to total pressure tap in discharge cone
Shipped loose oil cooler installed and oil piping connected to
blower skid lube system
20. Compressor oil reservoir filled with oil per manufacturer's
specification - Type oil used: __________
Clean area in the vicinity of the blowers
Power for main motor live to MCC
Pressure line tubing from low side of differential pressure
transmitter attached to inlet piping or filter silencer shroud
23.
Blower S/N
Electrical Items Checkmark to Confirm
2. Main motor MCC feedback wired and start/stop wiring dry
checked
3. If MCC has the capability of starting the motor locally, please
remove this capability and verify that it has been done
4. If PFCC is provided for the motor, verify interconnect wiring is
complete
Document Name: 4607T-Item G Rev 0
8144 8145 8146
FORM: 98012802.QAS COMPRESSOR (BLOWER) PRE-STARTUP
REV: 7 INSPECTION CHECKLIST
REV DATE: 6/15/07 1635 W. Walnut Street
APPRVD. BY: Springfield, MO 65806
Ph: 417-864-5599/Fax: 417-866-0235
PAGE 2 OF 2 ITEM G
7.
14.
15. Supply power is run to blow-off valve and discharge valve
16. Control power is run to blow-off valve and discharge valve
17. Remote transmitters are connected to respective control panels
18.
19.
21.
Date: ____________________
X:\ISO9001_2000\Revisions_In_Progress\ENG_Compressor_Pre-Startup_Inspection_Checklist.xls
Skid is grounded per NEC Article: 250
Electrical Items (Continued)
Signature: ____________________________________
Control panel to DCS wires are connected
Control panel, oil pump, valve and instrument supply power
available for service
20.
Contractor/Customer:
Checkmark to Confirm
Blower S/N
5. Main drive motor interconnect wiring integrity verified via Megger
or Hi Pot
Main motor Smart relay [Westinghouse IQ 1000, or equal]
programmed and ready for start
Main motor power leads are enclosed in liquid-tite from stub up to
motor terminal box
ALL ITEMS PER THIS CHECKLIST HAVE BEEN COMPLETED AND
START-UP OF TURBLEX-SUPPLIED EQUIPMENT IS AUTHORIZED
10.
All interconnection between remote mount local control panel
(LCP) and skid is complete per "As Built" drawings
9.
Auxiliary oil pumps are connected to control panel or other source,
as applicable
12.
8.
6.
11. All interconnection between local control panel (LCP) and field
instrument is complete per "As Built" drawings
13. All interconnection between local control panel and sound
enclosure
Communication cable installed
Forward completed storage requirement log, if applicable
All interconnection between local control panel (LCP) and blow-off
valve and discharge valve is complete per "As Built" drawings
Supply power is run to all control panels
Z:\Submittal_O&M\Master_Sub\Item_H_Warranty\Source_Docs\Warranty.DOC April 2007
ITEM H

LIMITED WARRANTY

WARRANTY
For the benefit of the original user only, Turblex warrants that the equipment and software of our manufacture will be
free from defects in material and workmanship when installed, operated and maintained under design conditions and in
accordance with our written instructions. Turblex will replace or repair, FOB our factories or other locations designated
by us, any parts or defective software returned which examination shall show it to have failed under normal use and
service by the original user, normal wear and tear excepted. Warranties will expire eighteen (18) months after
shipment or twelve (12) months after start-up (which shall be the Turblex certified date the equipment is available for
beneficial use), whichever occurs first. Expendable items such as V-belts and filter media are excluded from this warranty.
This warranty, including the stated remedies, is expressly made by Turblex and accepted by Purchaser in lieu
of all other warranties, and Turblex disclaims any implied warranty of merchantability or fitness for any
particular purpose. We will not be liable for any consequential, incidental, or liquidated damages, and in no
event shall be liable for any amount in excess of the purchase price of the equipment.
This warranty shall not apply to equipment or parts thereof which have been altered or repaired outside of a Turblex factory,
or damaged by improper installation, application, erosion or corrosion of any sort, or subjected to misuse, abuse, neglect,
or accident. Turblex will make no allowance or reimbursement for repairs, alterations, replacements or work of any kind,
done or ordered by others without Turblex' prior, written authorization. This warranty does not include any installation,
removal, or freight expenses that might be associated with warranty repair or replacement. Repair, replacement, or
refund of the purchase price by Turblex, at our sole option, shall be the exclusive remedy for breach of this warranty.
Turblex makes no warranty with respect to parts, accessories, or components manufactured by others. The
warranty applicable to such items is that offered by their respective manufacturers and will be passed through
Turblex to the original user.
Turblex warrants for each item of Technical Services that (i) the advice, recommendations and performance of its personnel
will reflect competent knowledge and judgment and (ii) the technical information, reports and analyses transmitted by
Turblex will reflect competent knowledge and judgment, beginning with the start of the item of Technical Services and
ending one (1) year after completion of Technical Services by Turblex (the Technical Services Warranty Period).
If during the Technical Services Warranty Period, Turblex is promptly notified in writing that any portion of the Technical
Services fails to conform to the Technical Services Warranty, Turblex will promptly reperform the nonconforming
portion of the Technical Services.
The purchaser shall supply, at their own expense, all labor, material, replacement parts (other than defective parts still
covered by warranty), tools (other than special tools and instruments which must be supplied by Turblex), equipment
cranes, rigging tools, outside balancing/machining, and facilities required to perform the physical work on the
equipment. Free and clear access to the equipment shall be provided for Turblex warranty repair work.

STARTUP AND SERVICE
Unless specifically stated in our quotation, installation, startup, service supervision, and training are not included in our
pricing. These responsibilities shall be the exclusive responsibility of the Purchaser.
A trained factory serviceman is available at the rate stated in our quotation and/or Turblex' standard Service Rate
Schedule, with all travel and living expenses billed accordingly. Service charges are based on a standard eight (8)
hour workday with time charged from date of departure from his home office to the date of his return. Overtime, travel
time, hold time and weekend travel will be charged per our quotation and/or Turblex' standard Service Rate Schedule.


Telephone: (417) 864-5599
Facsimile: (417) 866-0235

Document Name: 4607T-Item H Rev 0

Document Name: 4607T COMP LIST Rev C
JOB NO. 4607T COMPONENTS LIST ITEM I

TURBLEX TID Unit 1 Tags Unit 2 Tags Common Unit Tags QUANTITY DESCRIPTION TURBLEX P/N
COMPRESSOR & MAIN MOTOR
0010 3 COMPRESSOR/GEARBOX: KA66S-GL400 4607TBLWR
0020 AF1-SOP-MKL-03 AF2-SOP-MKL-03 AFC-SOP-MKL-03 3 MAIN MOTOR: 4000 HP, 3600 RPM, 6600/60/3 4607TMTR
0040 AF1-SOP-TQ AF2-SOP-TQ AFC-SOP-TQ 3 OIL RESERVOIR
0070 3 COUPLING 4607TCPLG
INLET & DISCHARGE ACCESSORIES
0100 3 SOUND ENCLOSURE 4607TSE
0110 AF1-SOP-FILT-01 AF2-SOP-FILT-01 AFC-SOP-FILT-01 3 INLET LOUVER: 152" H x 156" W 4607TLVR
0130 AF1-SOP-SIL-01 AF2-SOP-SIL-01 AFC-SOP-SIL-01 3 DISCHARGE INLINE SILENCER 4607TSIL30
0140 AF1-SOP-SIL-02 AF2-SOP-SIL-02 AFC-SOP-SIL-02 3 BLOW-OFF SILENCER: 10" 71575
0160 AF1-SOP-FILT-01 AF2-SOP-FILT-01 AFC-SOP-FILT-01 3 INLET FILTER/SILENCER: 4H X 6W 4607TIFS
0200 42 VIBRATION ISOLATOR: XLW-3000 74420
0300 3 INLET SPOOL PIECE 4607TSPOOL
0310 AF1-SOP-FILT-01 AF2-SOP-FILT-01 AFC-SOP-FILT-01 3 INLET PLENUM 4607TPLNM
0320 3 DISCHARGE CONE/SILENCER: 16" X 30" WITH 10" BOV 71677
0405 6 INLET FLEX CONNECTOR: 46.75" 74138
0430 AF1-SOP-JUNEX AF2-SOP-JUNEX AFC-SOP-JUNEX 3 EXPANSION JOINT: 16" 4607TEJ
0520 AF1-SOP-VV-BOFF1 AF2-SOP-VV-BOFF1 AFC-SOP-VV-BOFF1 3 BLOW-OFF VALVE: 10", 480/60/3 4607TBTRVLV10
0530 AF1-SOP-VV-BRBA-02 AF2-SOP-VV-BRBA-02 2 DISCHARGE VALVE: 30", 480/60/3 4607TBTRVLV30
0530 AFC-SOP-VV-BRBA-03 1 CROSS-OVER DISCHARGE VALVE: 30", 480/60/3 4607TBTRVLV30
0530 AFC-SOP-VV-BRBA-04 1 CROSS-OVER DISCHARGE VALVE: 30", 480/60/3 4607TBTRVLV30
0540 AF1-SOP-VV-RET-01 AF2-SOP-VV-RET-01 AFC-SOP-VV-RET-01 3 CHECK VALVE: 30" 73676
LUBE OIL COOLER
0705 AF1-SOP-BB-LUB-02 AF2-SOP-BB-LUB-02 AFC-SOP-BB-LUB-02 3 AUXILIARY OIL PUMP, 54.6 GPM 70818
0705 AF1-SOP-MKL-2 AF2-SOP-MKL-2 AFC-SOP-MKL-2 3 AUXILIARY OIL PUMP MOTOR, 10 HP 71411
0740 AF1-SOP-FILT-02 AF2-SOP-FILT-02 AFC-SOP-FILT-02 3 OIL FILTER, DUPLEX WITH VISUAL & ELECTRICAL INDICATOR 74103
0750 AF1-SOP-PRV-3101 AF2-SOP-PRV-3201 AFC-SOP-PRV-3301 3 OIL RELIEF VALVE, 1.5" 300# FLANGE, SET @ 120 PSI 73079
0770 AF1-SOP-LI-3101 AF2-SOP-LI-3201 AFC-SOP-LI-3301 3 LUBE OIL LEVEL INDICATOR 77519
0772 3 OIL RESERVOIR BREATHER 4607TBREATHER
0780 AF1-SOP-TCV-01 AF2-SOP-TCV-01 AFC-SOP-TCV-01 3 OIL TEMPERATURE CONTROL VALVE: SET @ 110
o
F 78457
0785 AF1-SOP-PCV-3101 AF2-SOP-PCV-3201 AFC-SOP-PCV-3301 3 MOTOR LUBE OIL PRESSURE REGULATOR 72133
0800 AF1-SOP-RESF AF2-SOP-RESF AFC-SOP-RESF 3 OIL - WATER COOLER 4607TCOOLER
INSTRUMENTATION
1110
AF1-SOP-TE-3101
AF1-SOP-TE-3119
AF2-SOP-TE-3201
AF2-SOP-TE-3119
AFC-SOP-TE-3301
AFC-SOP-TE-3119 6 INLET TEMPERATURE RTD 78408
1110
AF1-SOP-TT-3101
AF1-SOP-TT-3119
AF2-SOP-TT-3201
AF2-SOP-TT-3119
AFC-SOP-TT-3301
AFC-SOP-TT-3119 6 INLET TEMPERATURE TRANSMITTER: RANGE 0 - 130
o
F (0-54
o
C) 78409
1120 AF1-SOP-PDT-3103 AF2-SOP-PDT-3203 AFC-SOP-PDT-3303 3 COMPRESSOR DIFFERENTIAL PRESSURE TRANSMITTER 78410
1140 AF1-SOP-TE-3108 AF2-SOP-TE-3208 AFC-SOP-TE-3308 3 OIL TEMPERATURE RTD 78411
1140 AF1-SOP-TT-3108 AF2-SOP-TT-3208 AFC-SOP-TT-3308 3 OIL TEMPERATURE TRANSMITTER: RANGE 0-200
o
F (0-93
o
C) 78412
1190 AF1-SOP-TT-3102 AF2-SOP-TT-3202 AFC-SOP-TT-3302 3 ACOUSTICAL ENCLOSURE TEMPERATURE TRANSMITTER 78412
1190 AF1-SOP-TE-3102 AF2-SOP-TE-3202 AFC-SOP-TE-3302 3 ACOUSTICAL ENCLOSURE TEMPERATURE RTD 74360
1270
AF1-SOP-TT-3103
AF1-SOP-TT-3104
AF1-SOP-TT-3105
AF1-SOP-TT-3106
AF1-SOP-TT-3107
AF2-SOP-TT-3203
AF2-SOP-TT-3204
AF2-SOP-TT-3205
AF2-SOP-TT-3206
AF2-SOP-TT-3207
AFC-SOP-TT-3303
AFC-SOP-TT-3304
AFC-SOP-TT-3305
AFC-SOP-TT-3306
AFC-SOP-TT-3307 15 COMPRESSOR BEARING RTD TRANSMITTER: RANGE 0-300
o
F (0-149
o
C) 78413
1280
AF1-SOP-TT-3109
AF1-SOP-TT-3117
AF2-SOP-TT-3209
AF2-SOP-TT-3217
AFC-SOP-TT-3309
AFC-SOP-TT-3337 6 MOTOR BEARING RTD TRANSMITTER: RANGE 0 - 300 F (0-149
o
C) 78413

Document Name: 4607T COMP LIST Rev C
JOB NO. 4607T COMPONENTS LIST ITEM I

TURBLEX TID Unit 1 Tags Unit 2 Tags Common Unit Tags QUANTITY DESCRIPTION TURBLEX P/N
1290
AF1-SOP-TT-3111
AF1-SOP-TT-3112
AF1-SOP- TT-3113
AF1-SOP-TT-3114 (No Transmitter)
AF2-SOP-TT-3211
AF2-SOP-TT-3212
AF2-SOP-TT-3213
AFC-SOP-TT-3311
AFC-SOP-TT-3312
AFC-SOP-TT-3313
AFC-SOP-TT-3314 (No Transmitter)
AFC-SOP-TT-3315 (No Transmitter)
AFC-SOP-TT-3316 (No Transmitter) 9 MOTOR WINDING RTD TRANSMITTER: RANGE 0-400
o
F (0-204
o
C) 78414
1340
AF1-SOP-PDT-3101
AF1-SOP-PDT-3102
AF2-SOP-PDT-3201
AF2-SOP-PDT-3202
AFC-SOP-PDT-3301
AFC-SOP-PDT-3302 6 INLET FILTER DIFFERENTIAL PRESSURE TRANSMITTER: RANGE: 1 - 20 mbar 78415
1350 AF1-SOP-PSL-3101 AF2-SOP-PSL-3201 AFC-SOP-PSL-3301 3 LOW OIL PRESSURE SWITCH: SET @ 29 PSIG (2 bar) 71790
1355 AF1-SOP-PT-3101 AF2-SOP-PT-3201 AFC-SOP-PT-3301 3 OIL PRESSURE TRANSMITTER: RANGE 2.3 - 232 PSIG (.16-16 bar) 78416
1370 AF1-SOP-PSH-3101 AF2-SOP-PSH-3201 AFC-SOP-PSH-3301 3 SURGE SWITCH 72508
1375 AF1-SOP-LSL-3101 AF2-SOP-LSL-3201 AFC-SOP-LSL-3301 3 OIL LEVEL SWITCH 71801
1395 AF1-SOP-XS-3101 AF2-SOP-XS-3201 AFC-SOP-XS-3301 3 ZERO SPEED SWITCH 72508
1410 AF1-SOP-TI-3101 AF2-SOP-TI-3201 AFC-SOP-TI-3301 3 INLET TEMPERATURE GAUGE: RANGE 0 - 200 F (0-93
o
C) 78417
1420 AF1-SOP-TI-3102 AF2-SOP-TI-3202 AFC-SOP-TI-3302 3 OIL TEMPERATURE GAUGE: RANGE 0 - 200 F (0-93
o
C) 78419
1430 AF1-SOP-TI-3109 AF2-SOP-TI-3209 AFC-SOP-TI-3309 3 COOLING WATER IN TEMPERATURE GAUGE: RANGE 0-200
o
F (0-93
o
C) 78419
1435 AF1-SOP-TI-3103 AF2-SOP-TI-3203 AFC-SOP-TI-3303 3 COOLING WATER OUT TEMPERATURE GAUGE: RANGE 0-200
o
F (0-93
o
C) 78419
1520 AF1-SOP-PI-3101 AF2-SOP-PI-3201 AFC-SOP-PI-3301 3 DISCHARGE PRESSURE GAUGE: 1/2" NPT, RANGE 0 - 30 PSI (0-2 bar) 78418
1540 AF1-SOP-PI-3103 AF2-SOP-PI-3203 AFC-SOP-PI-3303 3 MOTOR FORCED LUBE OIL PRESSURE GAUGE: 1/2" NPT, RANGE 0 - 30 PSI (0-2 bar) 78420
1540 AF1-SOP-PI-3102 AF2-SOP-PI-3202 AFC-SOP-PI-3302 3 LUBE OIL PRESSURE GAUGE: 1/2" NPT, RANGE 0 - 160 PSI (0-11 bar) 78421
1820 AF1-SOP-FI-3101 AF2-SOP-FI-3201 AFC-SOP-FI-3301 3 LUBE OIL FLOW INDICATOR 71257
1820
AF1-SOP-FI3102
AF1-SOP-FI3103
AF2-SOP-FI3102
AF2-SOP-FI3103
AFC-SOP-FI3102
AFC-SOP-FI3103 6 MOTOR LUBE OIL FLOW INDICATOR 71257
1910 AF1-SOP-FT-3101 AF2-SOP-FT-3201 AFC-SOP-FT-3301 3 DISCHARGE FLOW METER 4607TFLWMTR
VIBRATION MONITORING SYSTEM
2000
AF1-SOP-VTX-3101
AF1-SOP-VTY-3101
AF2-SOP-VTX-3201
AF2-SOP-VTY-3201
AFC-SOP-VTX-3301
AFC-SOP-VTY-3301 6 BLOWER X-Y VIBRATION TRANSMITTER 74460
2000
AF1-SOP-VEX-3101
AF1-SOP-VEY-3101
AF2-SOP-VEX-3201
AF2-SOP-VEY-3201
AFC-SOP-VEX-3301
AFC-SOP-VEY-3301 6 RADIAL "X-Y" VIBRATION PROXIMITY PROBES 75249
2000 AF1-SOP-VTZ-3101 AF2-SOP-VTZ-3201 AFC-SOP-VTZ-3301 3 BLOWER "Z" THRUST VIBRATION TRANSMITTER 74332
2000 AF1-SOP-VEZ-3101 AF2-SOP-VEZ-3201 AFC-SOP-VEZ-3301 3 THRUST "Z" VIBRATION PROXIMITY PROBE 74508
2000
AF1-SOP-VTX-3101
AF1-SOP-VTY-3102
AF1-SOP-VTX-3103
AF1-SOP-VTY-3104
AF2-SOP-VTX-3201
AF2-SOP-VTY-3202
AF2-SOP-VTX-3203
AF2-SOP-VTY-3204
AFC-SOP-VTX-3301
AFC-SOP-VTY-3302
AFC-SOP-VTX-3303
AFC-SOP-VTY-3304 12 MOTOR "X-Y" VIBRATION TRANSMITTER 74460
2000
AF1-SOP-VEX-3101
AF1-SOP-VEY-3102
AF1-SOP-VEX-3103
AF1-SOP-VEY-3104
AF2-SOP-VEX-3201
AF2-SOP-VEY-3202
AF2-SOP-VEX-3203
AF2-SOP-VEY-3204
AFC-SOP-VEX-3301
AFC-SOP-VEY-3302
AFC-SOP-VEX-3303
AFC-SOP-VEY-3304 12 MOTOR "X-Y" VIBRATION PROXIMITY PROBE 76094
OPERATOR INTERFACE & PLC
2500 3 OPERATOR INTERFACE 78250
3000 3 PLC 78153
4510 AF1-SOP-IE-3101 AF2-SOP-IE-3201 AFC-SOP-IE-3301 3 CURRENT TRANSFORMER 72258
4510 AF1-SOP-IT-3101 AF2-SOP-IT-3201 AFC-SOP-IT-3301 3 CURRENT TRANSDUCER 72019

Telephone (417) 864-5599
Facsimile (417) 866-0235

Turblex 4607T Item 0010 Compressor O&M:

Please note: The Item 0010 O&M will be available in the Final Turblex Operation and Maintenance Manual.
I T E M 0 0 1 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
I T E M 0 0 2 0
TECO-WESTINGHOUSE MOTOR COMPANY
ROUND ROCK, TEXAS U.S.A.

CUSTOMER TURBLEX DATE - DEC 30, 2008
CUSTOMER ORDER NO. 42866-4607T
APPLICATION CENTRIFUGAL COMPRESSOR
S.O. 0Q01AA

DATA FOR WORLD SERIES, HORIZONTAL, BRACKET TYPE INDUCTION MOTOR

1. RATING

HP 4000 HERTZ 60 INSUL CLASS F
RPM FL 3556 SERVICE FACTOR 1.15 KVA CODE F
VOLTS 6600 RISE C (1.00 SF) 70 DUTY CONTINUOUS
AMPS FL 288 METHOD RES
PHASES 3 AMBIENT C 50

2. MECHANICAL

FRAME 5616 BRG TYPE SLEEVE END PLAY INCH 0.50
ENCL TYPE WP2 LUBE TYPE FLOOD MOTOR WK SQ 918
ROTATION(FROM NDE) CCW LOAD WK SQ 814

3. STARTING PERFORMANCE NOMINAL
100% VOLTS 65% VOLTS
AMPS (LR) 1820 1106
AMPS (LR) % 631 384
POWER FACTOR % 22.3 20.8
START TORQUE % 118 44
ACCELERATION SEC 2.9 10.5

SAFE LOCK SEC FROM HOT 7.2 19.6
SAFE LOCK SEC FROM COLD 8.5 23.0

PULLOUT TORQUE AT 100% VOLTS = 268 %

4. EFFICIENCY - NOMINAL

LOAD % 115 100 75 50
EFFICIENCY % 95.60 95.85 96.08 95.81

5. POWER FACTOR - NOMINAL

LOAD % 115 100 75 50
POWER FACTOR % 93.9 94.4 94.8 94.0

6. POWER FACTOR CORRECTION

MAX KVAR = 310 MAX FL P.F. = 97.0 %

7. Motor is capable of starting across the line or with a soft starter. Speed
torque and thermal limit curves have been provided to allow the customer to set
the motor acceleration time for the soft starter. Motor is not suitable for use
with soft starter if power factor correction capacitors or surge capacitors are
connected to motor leads.
Page 1 of 10
Document Name: 4607T-0020 Rev 0
ITEM 0020

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ITEM 0020

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ITEM 0020

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ITEM 0020

1355 mm
C = 417 mm
RESERVOIR LENGTH (A):
TIMES RESERVOIR WIDTH (B):
TIMES OIL LEVEL HEIGHT (C):
= VOLUME (mm
3
)
EQUALS TO TOTAL LITERS REQUIRED = VOLUME (m
3
)
TIMES 1000 RESERVOIR CAPACITY (LITERS)
TIMES 0.8798 Kg/L = TOTAL OIL WEIGHT
LITERS PER MINUTE REQUIRED (L/min)
ACTUAL OIL RETENTION TIME (MINUTES):
206.66 L/min
5.03 min.
1.04 m3
1,039.96 L
915 kg.
1,039.96
1842 mm
1355 mm
417 mm
1,039,957,153 mm^3
OIL RESERVOIR VOLUME DATA CALCULATION SHEET (SI UNITS)
1575 mm
4607T
PAUL WURTH
KA66S-GL400
1842 mm
3962 mm
JOB NUMBER:
J0B NAME:
BLOWER MODEL:
ITEM 0040
OIL LEVEL
OIL RESERVOIR
AREA
RESERVOIR SIDE VIEW
RESERVOIR TOP VIEW
C
B
A

Telephone (417) 864-5599
Facsimile (417) 866-0235

Turblex 4607T Item 0100 Sound Enclosure O&M:

Please note: The Item 0100 O&M will be available in the Final Turblex Operation and Maintenance Manual.
ALL STATED SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE OR OBLIGATION.
3900 Dr. Greaves Rd. Kansas City, MO 64030 (816) 761-7476 FAX (816) 765-8955
ELF811DD STATIONARY LOUVER
DOUBLE DRAINABLE BLADE
EXTRUDED ALUMINUM
STANDARD CONSTRUCTION
FRAME
4" (102) deep, 6063T5 extruded aluminum
with .090" (2.3) nominal wall thickness.
Downspouts and caulking surfaces provid-
ed.
BLADES
6063T5 extruded al umi num wi th .081"
(2.1) nominal wall thickness. Double drain-
able blades are positioned at 45angle and
spaced approximately 5
3
/32" (129) center to
center.
SCREEN
3
/4" x .051" (19 x 1.3) expanded, flattened
aluminum bird screen in removable frame.
Screen adds approximately
1
/2" (13) to lou-
ver depth.
FINISH
Mill.
MINIMUM SIZE
12"w x 12"h (305 x 305).
APPROXIMATE SHIPPING WEIGHT
4 lbs. per sq. ft.
MAXIMUM FACTORY ASSEMBLY SIZE
Shall be 75 sq. ft. (7m
2
) per section, not to
exceed 120"w x 90"h (3048 x 2286) or 90"w
x 120"h (2286 x 3048).
Louvers larger than the maximum factory
assembly size will require field assembly of
smaller sections.
SUPPORTS
Louvers may be provided with rear mounted
blade supports that increase overall louver
depth depending on louver size, assembly
configuration or windload.
Consult Ruskin for additional information.
Spec ELF811DD-396/Replaces ELF811DD-692 Ruskin Manufacturing 1996
FEATURES
The ELF811DD offers:
Published performance ratings based on
testing in accordance with AMCA Publica-
tion 511.
Double drain gutters in each blade and
downspouts in jambs and mullions to drain
water from louver for minimum water cas-
cade from blade to blade.
Architecturally styled hidden mullions allow-
ing continuous line appearance up to 120"
(3048).
All aluminum construction for low mainte-
nance and high resistance to corrosion.
Low pressure drop and low water penetra-
tion.
VARIATIONS
Variations to the basic design of this louver are
available at additional cost. They include:
Extended sill.
Hinged frame.
Front or rear security bars.
Filter racks.
A variety of bird and insect screens.
Selection of finishes: prime coat, baked
enamel (modified fluoropolymer), epoxy,
Acrodize, Kynar, clear and color anodize.
(Some variation in anodize color consistency
is possible.)
Consult Ruskin for other special requirements.
INTEGRAL FLANGE
B*
A*
4"
(102)
Bird
Screen
Varies A* x B*
1
1
/2" (38)
1" (25)
SIZE
TAG QTY. FRAME
A*-WIDE B*-HIGH
VARIATIONS
PROJECT LOCATION
ARCH./ENGR. CONTRACTOR
REPRESENTATIVE DATE
*Units furnished
1
/4" (6) smaller than given opening dimensions. Dimensions in inches, parenthesis ( ) indicate millimeters.
FRAME CONSTRUCTION
STANDARD
ITEM 0110
3
78" 76" 4 Flange

FOUR (4) LOUVERS PER COMPRESSOR MAKES TOTAL SIZE 156" WIDE X
152" HIGH
Furnish and install louvers as hereinafter specified where shown on
plans or as described in schedules. Louvers shall be stationary
double drainable with drain gutters in each blade and downspouts
in jambs and mullions. Stationary drainable blades shall be con-
tained within a 4" (102) frame. Louver components (heads, jambs,
sills, blades & mullions) shall be factory assembled by the louver
manufacturer. Louver sizes too large for shipping shall be built up
by the contractor from factory assembled louver sections to provide
overall sizes required. Louver design shall limit span between visi-
ble mullions to 10 ft. (3) and shall incorporate structural supports
required to withstand a wind load of 20 lbs. per sq. ft. (.96kPa)
(equivalent of a 90 mph wind [145 KPH] - specifier may substitute
any loading required).
Louvers shall be Ruskin Model ELF811DD extruded 6063T5 alu-
minum alloy construction as follows:
Frame: .090" (2.3) wall thickness.
Blades: .081" (2.1) wall thickness at 45 angle on approxi-
mately 5
3
/32" (129) centers.
Screen:
3
/4" x .051" (19 x 1.3) expanded, flattened aluminum
bird screen in removable frame.
Finish: Select finish specification from Ruskin Finishes
Brochure.
Published louver performance data bearing the AMCA Certified
Ratings Seal for Air Performance & Water Penetration must be
submitted for approval prior to fabrication and must demonstrate
pressure drop and water penetration equal to or less than the
Ruskin model specified.
SUGGESTED SPECIFICATION
PERFORMANCE DATA
WATER PENETRATION
Test size 48" wide x 48" high (1219 x 1219)
Beginning point of water penetration at .01 oz./sq. ft. is 974 fpm (297 m/min).
AMCA Standard 500 provides a reasonable basis for testing and
rating louvers. Testing to AMCA 500 is performed under a certain
set of laboratory conditions. This does not guarantee that other
conditions will not occur in the actual environment where louvers
must operate.
The louver system should be designed with a reasonable safety
factor for louver performance. To ensure protection from water
carryover, design with a performance level somewhat below maxi-
mum desired pressure drop and .01 oz./sq. ft. of water penetration.
O
z
.

W
a
t
e
r
/
f
t
2
a
n
d

(
o
u
n
c
e
s

w
a
t
e
r
/
m
2
)

o
f

F
r
e
e

A
r
e
a
1
5

m
i
n
.

t
e
s
t

p
e
r
i
o
d
900
(274)
1000
(305)
1100
(335)
1200
(366)
0.3
(3.23)
0.25
(2.69)
0.2
(2.15)
0.15
(1.61)
0.1
(1.08)
0.05
(.54)
0
Free Area Velocity in feet and (meters) per minute
Standard air .075 lb/ft
3
ITEM 0110
TYPICAL INSTALLATION DETAILS

Accessories at additional cost.
Masonry
Wall
Wood
Installation
Metal Panel
Wall
Flange
Mount
3900 Dr. Greaves Rd.
Kansas City, MO 64030
(816) 761-7476
FAX (816) 765-8955
CMU
Louver
Extended
Sill
CMU
Louver
Integral
Flange
Frame
Fasteners
(by others)
Louver
Extended
Sill
Metal
Siding
Drip
Cap
Insulation
Louver
Siding
Sheating
ITEM 0110
Installation, Operation and
Maintenance Instructions for
U2, U5 and SU Series Silencers
1999 Universal Silencer
Form No. 94-1337, 11/07
Description
The U2 and U5 series are straight-through
absorptive silencers. The SU series is an annular
flow path absorptive silencer with the premium
grade SU5 providing a blocked line-of-sight.
These silencers provide varying degrees of noise
reduction and are most appropriate in fan,
blower, compressor and turbine applications
where their high frequency insertion loss will be
most effective. The standard unit in these series
is designed for applications where the
temperature does not exceed 325F, the
pressure does not exceed 15 psig and/or vacuum
does not exceed 15Hg. There are no moving
parts in the operation of these silencer units.
Receiving Inspection
Upon receipt of the unit , check the nameplate
against the packing list to verify the correct part
numbers are received.
Keep the shipping container to protect the unit
until installation.
Prior to unpacking, check for damage.
Advise Universal Silencer of shipping damage
within three days.
Storage
Leave any cardboard boxing, plywood covering,
crating, and/or plastic covering intact until ready
to install.
Be sure that all openings are closed so that no
debris, vermin, rain, snow and/or ice can get into
unit.
Store unit on blocks, a minimum of 4 high so that
air can freely circulate around unit.
Do not store in contact with the ground or in a wet
or flooded area.
Indoor ambient temperature storage is preferable,
especially for these units which have internal
absorptive material. If this is not possible, keep
the unit covered and protected from the weather.
Clean unit prior to installation. Remove any
minor corrosion and refinish per paint
manufacturers recommendations. If major
corrosion has occurred such that the integrity of
the unit is in question, contact Universal Silencer.
Mounting and alignment
Insure that the necessary equipment to install the
unit, including anchor and/or support bolts, flange
bolts, saddles and expansion joints, are available
before beginning installation.
Anchor and/or support bolting and grouting is not
included with the unit.
Align the unit with the piping or ducting
connections.
+ I MPORTANT: The unit is not designed to serve
as a support for any piping, additional
mounting pads or additional loads on the inlet
or outlet other than those stated in the
Universal Silencer drawing or product
bulletin.
Mount the unit securely to the foundation,
adjacent piping and/or appropriate hangers.
Use thread lubricant on all bolted joints.
Use all gaskets provided with the unit.
If you replace or add bolts or gaskets, use the
same size and material as the originals.
Ensure that the unit is firmly mounted
immediately prior to startup of the equipment, and
again 24 hours after startup to verify that
supports and/or flange bolts have not vibrated
loose.
Inspection and maintenance
Components are either complete weldments or
permanently assembled having no replaceable
parts.
Spare parts are not required.
Periodically inspect exterior paint finish for
damage or deterioration. NOTE: Minor
localized damage may be touched up using
touch-up paint. Areas with extensive damage or
deterioration may require spot blasting and
recoating. Consult paint manufacturers
recommendations.
Examine connecting flanges and support/
anchor bolting at least annually. Retighten loose
nuts as required.
Safety Issues
C CA AU U T TI I O ON N - All personnel working near high-
temperature components during operation and
cool down period should use care to prevent
injury due to contact with high temperature
surfaces.
If performing any work internal to the silencer or
adjacent components, ensure that all confined
space requirements are met and that all tools
and other materials are removed once work is
completed.
ITEM 0130
1
7
5
2
.
6

m
m
9
1
4
.
4

m
m
1
3
4
6
.
2

m
m
I
T
E
M

0
1
3
0
7
2
1
.
2
1
1

k
g

Telephone (417) 864-5599
Facsimile (417) 866-0235

16"
2"
41
3
4
"
42
13
16
"
46
13
16
"
10
3
4
"
1"
REF
(12) 1" HOLES ON
A 14 1/4" B.C. DIA
ANSI 150#, 10" PIPE
CONNECTION SIZE

BLOW-OFF SILENCER 10

ELEVATION VIEW ISOMETRIC VIEW

NOTES:

1. FASTENERS, NUTS & GASKETS
(NOT BY TURBLEX).

2. BLOW OFF SILENCER,
SHIP LOOSE, INSTALLATION
NOT BY TURBLEX.

3. PLEASE REFER TO TAB E FOR
PAINT SPECIFICATIONS.

4. BLOW-OFF VALVE\ACTUATOR &
BLOW-OFF SILENCER TO BE
SUPPORTED BY CUSTOMER
PIPING.

5. MATERIAL TO BE A36 CARBON
BOTTOM VIEW STEEL

6. WEIGHT: 635 LBS

K:\STD DRAWINGS\BLOW OFF SILENCER\BOS-10IN-SUB.

ITEM 0140
Document Name: 4607T-0140 Rev A
1060.45 mm
1189.03 mm
1087.43 mm
273.05 mm
406.4 mm
25.4 mm
288.03 kg
50.8 mm
3p glide/pack
Camfil Farr Product sheet
3P Glide/Pack
2401-0302
Camfil Farrclean air solutions
The Camfil Farr 3P Glide/Pack
has set the standard for

side-access housing integrity for over 20 years. With its
integral universal final filter holding frame virtually all of the
air seen by the filter will be treated by the filter. Each Cam-
fil Farr 3P Glide/Pack includes:
16-gauge galvanized steel construction with pre-drilled
standing flanges to mate to existing HVAC equipment.
All components are weatherproof for interior or exte-
rior installation
Dual-access doors for filter service from either side of
the unit. The doors swing-open and are engineered to
be square to the housing flange. UV resistant star-
style handles assure a tight seal each time the access
doors are opened and closed
High-memory sponge neoprene door gaskets to en-
sure door-to-filter seal (less than one half of 1% hous-
ing to ambient leakage)
A poly sponge door gasket to assure a proper door-to-
filter seal
A polypropylene fin seal on the main filter track to
eliminate filter air bypass (less than 1/2 of 1% leakage
across the final filter assembly at rated airflow)
An integral pneumatic fitting for the installation of an
optional static pressure gauge capable of evaluating
any single stage or multiple stages of installed filters
An aluminum filter track allowing for filtration combi-
nations that include:
A 2 nominal size prefilter track (with filter slide
rails to facilitate easier prefilter service)
A 6 or 12 deep box-style final filter with 1
nominal size header or full size box style filter
in a frame assembly
A pocket style final filter with header for frame
or track installation
A 12 deep box style carbon filter for gaseous
contaminant removal
For those that are concerned about air quality and desire a
housing that assures that the system contaminant removal
efficiency is the same as the rated filter efficiency the Cam-
fil Farr Glide/Pack continues to set the standard by which
other HVAC components are judged.
Less than of 1% air
bypass/leakage guaranteed
Two-Stage Side-Access Filter Housing

Top left: Poly fin seal assures a
tight seal under demanding
conditions.
Top right: Bolt-together construc-
tion and weeping flanges for water
run-off.
Bottom left: UV resistant star
handle forming a new door to
housing seal upon each door
closure.
Bottom right: Static tap allows
pressure drop evaluation of prefil-
ter, final filter, or both.
ITEM 0160
PERFORMANCE DATA
SPECIFICATIONS
03/02 Camfil Farr http://www.camfilfarr.com
Represented by:

Camfil Farr has a policy of continuous research, development
and product improvement. We reserve the right to change de-
signs and specifications without notice.
Camfil Farr, Inc.
United States Tel: (973) 616-7300 Fax: (973) 616-7771
Canada Tel: (450) 629-3030 Fax: (450) 662-6035
E-mail: camfilfarr@camfilfarr.com
3P GLIDE/PACK

Housing Dimensions & Airflow Capacities
1.0 General

1.1 - Filter housing shall be two-stage filter system con-
sisting of 16-gauge galvanized steel enclosure, alumi-
num filter mounting track, universal filter holding frame,
dual-access doors, static pressure tap, filter gaskets and
seals. In-line housing depth shall not exceed 21.
1.2 - Sizes shall be as noted on enclosed drawings or
other supporting materials.

2.0 Construction

2.1 - The housing shall be constructed of 16-gauge gal-
vanized steel with pre-drilled standing flanges to facilitate
attachment to other system components. Corner posts of
Z-channel construction shall ensure dimensional adher-
ence. The housing shall be weatherproof and suitable for
rooftop/outdoor installation.
2.2 - The housing shall incorporate the capability of two
stages of filtration without modification to the housing. A
filter track, of aluminum construction shall be an integral
component of housing construction. The track shall ac-
commodate either a 2 deep prefilter, a 6 or 12 deep
rigid final filter, or a pocket filter with header.
2.3 - Dual access doors, swing-open type, shall include
high-memory sponge neoprene gasket to facilitate a door-
to-filter seal. Each door shall be equipped with adjustable
and replaceable positive sealing UV-resistant star-style
knobs and replaceable door hinges.
2.4 - A universal holding frame constructed of 18-gauge
galvanized steel, equipped with centering dimples, multi-
ple fastener lances, and polyurethane filter sealing gasket,
shall be included to facilitate installation of high-efficiency
filters.
2.5 - The housing shall include a pneumatic fitting to allow
the installation of a static pressure gauge to evaluate pres-
sure drop across a single filter or any combination of in-
stalled filters.

3.0 Performance

3.1 - Leakage at rated airflow, upstream to downstream of
filter, holding frame, and slide mechanism shall be less
than 1% at 3.0 w.g. Leakage in to or out of the housing
shall be less than one half of 1% at 3.0 w.g.
3.2 - Accuracy of pneumatic pressure fitting, when to
evaluate a single-stage, or multiple filter stages, shall be
accurate within 3% at 0.6 w.g.
Available Options:
Stainless steel construction
High-pressure construction (to 8.0 w.g.)
Double-wall with insulation
Transitions to standard HVAC equipment.
Contact factory for more information.
DATA NOTES:
Airflow rated at 500 fpm, may be operated to 625 fpm.
Standard housing operational to 6.0 w.g.
Contact your Camfil Farr representative for shipping and installed housing weight.
NUMBER OF
FILTERS
HIGH
HEIGHT
NUMBER OF FILTERS WIDE
1/2 1 1-1/2 2 2-1/2 3 3-1/2 4 4-1/2 5 5-1/2 6
1/2 1 3-1/4 1000 2000 3000 4000 5000 6000
1 2 3-1/4 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000
1-1/2 3 3-1/2 3000 6000 9000 12000 15000 18000
2 4 3-1/2 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000 24000
2-1/2 5 3-3/4 5000 10000 15000 20000 25000 30000
3 6 3-3/4 6000 9000 12000 15000 18000 21000 24000 27000 30000 33000 36000
3-1/2 7 4 7000 14000 21000 28000 35000 42000
4 8 4 8000 12000 16000 20000 24000 28000 32000 36000 40000 44000 48000
WIDTH 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 0 10 0 11 0 12 0
ITEM 0160
Meeting Todays Standards
The Camfil Farr Aeropleat

III pleated filter offers
medium grade ASHRAE efficiency and sets the
performance standard for those upgrading from
lower efficiency throw-aways or pads. Combining
electrostatic and mechanical particle capture prin-
ciples, the Aeropleat III is a MERV 6 filter when
evaluated per ASHRAE Standard 52.2-1999.
For Todays Applications
As a stand-alone filter, the Aeropleat III will remove
many of the contaminants associated with todays
indoor air quality concerns. Available in 1, 2 and 4
depths, its increased media area offers an extended
service life when compared to lower efficiency throw-
aways or pads. Applications include commercial
buildings, educational facilities and specialty
manufacturing. As a pre-filter, the Aeropleat III
offers protection for the higher efficiency final filters
required for todays high-technology applications.
Built for Todays HVAC Systems
10 pleats per linear foot (2 deep model) in a
radial pleat design for full use of media area
100% synthetic blend media provides
medium grade ASHRAE performance and
increased dust-holding capacity
Welded wire media grid is treated for
corrosion resistance and prevents media
oscillation or pull-away
High wet-strength beverage board frame
creates a rigid and durable filter pack
Available in 1, 2 and 4 depths
aeropleat III
Camfil Farr - clean air solutions

Initial Resistance vs Airflow 24 X 24
The Aeropleat III - the economical
choice for those requiring
ASHRAE MERV 6 efficiency for
their HVAC applications.
Aeropleat III B-1305-16B
Standard-Capacity Pleated Panel Filter
ITEM 0160
Air Filters Air filters shall be 1, 2 or 4 deep
disposable type. Each filter shall consist of a synthetic
media blend, a welded wire media support grid and a
high wet-strength beverage board frame. The filter
shall be capable of withstanding 2.0 w.g. without
distortion of the media pack or filter failure. The filter
shall be rated by Underwriters Laboratories as Class 2.
Filter Media Filter media shall be a blend of
synthetic fibers, incorporating a mechanical efficiency
and an electret charge. The media shall be formed in a
radial pleat design to ensure full utilization of the
media area. When tested in accordance with ASHRAE
Standard 52.2-1999, the filter shall have a minimum
efficiency reporting value (MERV) of 6. When tested in
accordance with ASHRAE Standard 52.1-1992, the
filter shall have an average dust spot efficiency of
25-30%*.
4 INCH The filter face area shall not be less than
nine pleats per linear foot. Initial resistance at 500 feet
per minute shall not exceed 0.21 w.g.
2 INCH The filter face area shall not be less than 10
pleats per linear foot. Initial resistance at 500 feet per
minute shall not exceed 0.23 w.g.
1 INCH The filter face area shall not be less than 12
pleats per linear foot. Initial resistance at 350 feet per
minute shall not exceed 0.23 w.g.
Media Support Grid The media support grid shall
be of welded wire construction, spot welded on one-
inch centers, and post-treated for corrosion resistance.
The welded wire grid shall be bonded to the media to
eliminate oscillation or pull-away and formed in such a
manner that it supports a radial pleat configuration.
Enclosing Frame The enclosing frame shall be
assembled of a high wet-strength 24-point beverage
board. It shall be bonded around the entire periphery,
eliminating the possibility of air bypass. Diagonal
support members of the same construction shall be
bonded to each pleat to ensure pleat spacing
and stability.
SPECIFICATIONS
PERFORMANCE DATA
Camfil Farr has a policy of uninterrupted research, development and
product improvement and reserves the right to change design and
specifications without notice.
07/01 Camfil Farr www.camfilfarr.com Printed in U.S.A. on Recycled Paper
Represented by:
Camfil Farr
2201 Park Place
El Segundo, CA 90245
800-333-7320 310-727-6300
310-643-9086 Fax
* The Camfil Farr Aeropleat III is categorized as a 25-30%
efficiency filter. Average efficiencies may vary 5 points. These
variances are not uncommon when tested in accordance with
ASHRAE Standard 52.1-1992.
(1) 4 and 2 filters are rated at 250 fpm (medium) and 500 fpm (high). 1 filters are rated at 175 fpm (medium) and 350 fpm (high).
Maximum recommended final resistance for all sizes is 1.0 w.g. System velocity and design may dictate a different final pressure drop.
Camfil Farr Aeropleats are rated by Underwriters Laboratories as Class 2.
AEROPLEAT III
HEIGHT WIDTH DEPTH MEDIUM HIGH MEDIUM HIGH
20 x 16 x 4 19.38 15.38 3.75 560 1110 0.07 0.21 12.6
20 x 20 x 4 19.38 19.38 3.75 695 1390 0.07 0.21 15.7
24 x 12 x 4 23.38 11.38 3.75 500 1000 0.07 0.21 12.3
24 x 20 x 4 23.38 19.38 3.75 835 1670 0.07 0.21 18.9
24 x 24 x 4 23.38 23.38 3.75 1000 2000 0.07 0.21 22.7
25 x 16 x 4 24.38 15.38 3.75 695 1390 0.07 0.21 15.7
25 x 20 x 4 24.38 19.38 3.75 870 1740 0.07 0.21 19.7
20 x 16 x 2 19.50 15.50 1.75 560 1110 0.08 0.23 6.5
20 x 20 x 2 19.50 19.50 1.75 695 1390 0.08 0.23 8.6
24 x 12 x 2 23.38 11.38 1.75 500 1000 0.08 0.23 6.1
24 x 20 x 2 23.50 19.50 1.75 835 1670 0.08 0.23 10.3
24 x 24 x 2 23.38 23.38 1.75 1000 2000 0.08 0.23 12.1
25 x 16 x 2 24.50 15.50 1.75 695 1390 0.08 0.23 8.1
25 x 20 x 2 24.50 19.50 1.75 870 1740 0.08 0.23 10.7
20 x 16 x 1 19.50 15.50 0.88 390 780 0.11 0.23 4.3
20 x 20 x 1 19.50 19.50 0.88 485 970 0.11 0.23 5.4
24 x 12 x 1 23.50 11.50 0.88 350 700 0.11 0.23 3.8
24 x 20 x 1 23.50 19.50 0.88 585 1170 0.11 0.23 6.5
24 x 24 x 1 23.50 23.50 0.88 700 1400 0.11 0.23 7.8
25 x 16 x 1 24.50 15.50 0.88 485 970 0.11 0.23 5.4
25 x 20 x 1 24.50 19.50 0.88 610 1215 0.11 0.23 6.7
CAPACITIES
(cfm)
RESISTANCE AT
CAPACITY
(1)
(inches w.g.)
TOTAL MEDIA
AREA
(sq. ft.)
PLEATS PER
LINEAR FOOT
NOMINAL
FILTER
DEPTH
NOMINAL
SIZE
(inches)
4"
ACTUAL SIZE
(inches)
2"
1"
9 pleats per
linear foot
10 pleats per
linear foot
12 pleats per
linear foot
ITEM 0160
riga-flo

The Camfil Farr P-Series Riga-Flo
PH provides high-
efficiency ASHRAE air filtration performance in a
compact, supported media design for installation into
side-access housings with 1 nominal filter tracks. The
materials of construction preclude contaminant
amplification as all components are inert with respect to
supporting the growth of captured bacteria or other viable
contaminants. The P-Series Riga-Flo PH:
Is available in three efficiencies
Includes an air laid synthetic microfiber media with a
spun-bonded air entering and air exiting sandwich
scrim. The combination offers efficiencies similar to
traditional filter fiber technology with a reduced
resistance to airflow.
Includes a welded-wire media grid that is bonded to
the media to support and maintain tapered radial
pleats and prevent media oscillation during varying
system airflows.
Includes a continuous adhesive bond around the
inside of the enclosing frame to eliminate air bypass.
The media is mechanically bonded to the frame to
assure integrity to 10 w.g.
Includes an enclosing frame of steel, coated with an
aluminum-zinc alloy, to provide 50% higher corrosion
resistance than standard galvanized steel.
Includes all-metal contour media stabilizers on the air
entering and air existing sides to assure pleat
support through turbulent or varying airflows.
Includes all-metal diagonal support braces to assure
filter rigidity and media pack protection. The braces
are mechanically bonded to the contour stabilizers to
assist in maintaining a rigid and durable filter pack.
Includes a nominal 1 deep header for slide-in slide-
out installation in side-access filter housings.
The Riga-Flos supported media is excellent for VAV
systems or todays energy conscious HVAC applications.
The Camfil Farr P-Series Riga-Flo
PH offers a low-pressure drop,
synthetic microfiber performance,
in a supported media package for
side-access housing installations.
Model
ASHRAE
52.2-1999
MERV
ASHRAE
52.1-1992
(Dust Spot)
Eurovent
Riga-Flo P65 11 60-65% F6
Riga-Flo P85 13 80-85% F7
Riga-Flo P95 14 90-95% F8
High-Lofted Supported Synthetic Media Air Filter
For Side-Access Applications
P-Series Riga-Flo
PH 1403PH-0302
Camfil Farrclean air solutions

Values are MERVs when evaluated per ASHRAE 52.2.
p-series ph
ITEM 0160
PERFORMANCE DATA
SPECIFICATIONS
03/02 Camfil Farr http://www.camfilfarr.com
Represented by:

Camfil Farr has a policy of uninterrupted research, develop-
ment and product improvement. We reserve the right to
change designs and specifications without notice.
Camfil Farr, Inc.
United States Tel: (973) 616-7300 Fax: (973) 616-7771
Canada Tel: (450) 629-3030 Fax: (450) 662-6035
P-SERIES RIGA-FLO

PH
DATA NOTES:
Standard header is for 1 nominal filter track.
Recommended final resistance is 1.5 w.g. System design may
dictate a lower change-out point.
Maximum continuous operating temperature is 160 F (70 C).
Air Filters1.0 General

1.1 - Air filters shall be high-efficiency ASHRAE high
lofted supported synthetic media headered disposable
type assembled in a compact and secure enclosing
frame.
1.2 Sizes shall be as noted on drawings or other sup-
porting materials.

2.0 Construction

2.1 - Filter media shall be of microfiber core laminated
between spun-bonded scrim to form a uniform lofted me-
dia blanket.
2.2 - The media blanket shall be formed into uniform ta-
pered radial pleats and bonded to a welded wire media
support grid, which is spot-welded on one-inch centers,
and treated for corrosion resistance.
2.3 - The media shall be mechanically and chemically
bonded to the inside periphery of the enclosing frame to
prevent air bypass.
2.4 - The enclosing frame shall be constructed of an alloy of
zinc, aluminum, and steel. Media support contour stabiliz-
ers, of the same construction, shall be mechanically fas-
tened to diagonal support members to create a rigid and
durable filter enclosure. There shall be a minimum of four
contour stabilizers on the air entering side and six on the air
exiting side.
2.5 - The filter shall include an integral header for installa-
tion in a standard 1 nominal filter track.

3.0 Performance

3.1 - The filter shall have a Minimum Efficiency Reporting
Value of MERV (11, 13, 14)* when evaluated under the
guidelines of ASHRAE Standard 52.2-1999. It shall have an
average dust spot efficiency of (60-65%, 80-85%, 90-95%)*
when evaluated under ASHRAE Standard 52.1-1992.
3.2 - Initial resistance to airflow shall not exceed (0.30,
0.44, 0.60)* w.g at an airflow of 500 fpm.
3.3 - Filter shall be rated by Underwriters Laboratories as
UL Class 2.
3.4 - The filter shall be capable of withstanding 10 w.g.
without failure of the media pack.

Supporting Data - Provide product test reports for each
listed efficiency including all details as prescribed in ASH-
RAE Standards 52.1 and 52.2.

Items in parentheses ( ) require selection.
Options:
Available without a header (Bulletin 1403-0302).
1.12 header version also available.
FILTER
EFFICIENCY
PART NUMBER
ACTUAL DIMENSIONS
H x W x D
(inches)
AIRFLOW
CAPACITY
(cfm)
MEDIA
AREA
(ft
2
)
INITIAL
(ins. w.g.)
FINAL**
(ins. w.g.)
P-95 PH
90-95%

122557-004 23.31 x 23.31 x 11.50 2000 .60 1.5 50
122557-014 23.31 x 11.31 x 11.50 1000 .60 1.5 22
122557-024 23.31 x 19.31 x 11.50 1670 .60 1.5 43
122557-034 19.31 x 19.31 x 11.50 1400 .60 1.5 33
P-85 PH
80-85%

122557-003 23.31 x 23.31 x 11.50 2000 .44 1.5 50
122557-013 23.31 x 11.31 x 11.50 1000 .44 1.5 22
122557-023 23.31 x 19.31 x 11.50 1670 .44 1.5 43
122557-033 19.31 x 19.31 x 11.50 1400 .44 1.5 33
P-65 PH
60-65%

122557-002 23.31 x 23.31 x 11.50 2000 .30 1.5 50
122557-012 23.31 x 11.31 x 11.50 1000 .30 1.5 22
122557-022 23.31 x 19.31 x 11.50 1670 .30 1.5 43
122557-032 19.31 x 19.31 x 11.50 1400 .30 1.5 33
RESISTANCE
ITEM 0160
100%Synthetic, corrosion free and
humidity-resistant product
High Dirt Holding Capacity provides exceptional
extended life
Designed for Leak Free Operation even in the
most rigorous air pressure and high dust-laden
environments
Very Low Resistance results in greatly reduced
operating costs
DE SCRI PT I ON
Filtrairs PF Series Rigid Pockets are a premium high efficiency
air filter designed for critical or harsh air handling units.
Filtrair pockets are extremely durable and will perform
flawlessly over a long period of time.
The synthetic fiber based pocket filter was developed and
manufactured at Filtrairs own high tech production facility.
The use of high performance fibers in a progressive density
multi-layering technique ensures high depth loading with
optimal lowest pressure drop performance.
F E AT URE S AND BE NE F I TS
MOLDED HEADER does not corrode and can be
incinerated
RIGID DESIGN AND SYNTHETIC CONSTRUCTION allows
pockets to withstand 100%humidity environments
HIGH DUST HOLDING CAPACITY and low resistance make the
PF Series pocket filters an excellent prefilter
UL900Class2conforms to US fire classifications
LOW RESISTANCE DESIGN greatly reduces operating costs
FULL ADHESIVE SATURATIONproprietary process
prevents unloading
APPL I C AT I ONS
Filtrairs PF Series Rigid Pocket filters are designed for use
as final filters in general ventilation and air conditioning
equipment installed in offices, shopping centers, theatres,
hotels, industrial plants, food processing plants and
laboratories.
Also as a pre-filter in the supply air units for car paint spray
cabins, electrical equipment, electric motors, and superfine
and absolute (HEPA) filtration systems.
100% high performance
synthetic fibers
Rigid pocket
design for
VAV systems
PFS, PFM, PFL RIGID POCKET FILTERS
Corrosion free
molded header
ITEM 0160
600 Railroad Avenue
York, SC 29745
Phone: 803-684-3533
Fax: 803-684-7856
www.filtrair.com
Filtrair 04/05
DISTRIBUTED BY
National
Air
Filtration
Association
PFS, PFM, PFL RIGID POCKET FILTERS
FRACTIONAL EFFICIENCY vs PARTICLE DIAMETER (PFL 1/1)
(2000 cfm)
PRESSURE DROP vs AIR FLOW RATE
PFS, PFM, PFL RIGID POCKET FILTER TECHNICAL DATA
PFS PFM PFL
Sizes Units 1/1 5/6 1/2 1/1 5/6 1/2 1/1 5/6 1/2
Standard
Holding Frame in 24 x 24 20 x 24 12 x 24 24 x 24 20 x 24 12 x 24 24 x 24 20 x 24 12 x 24
Pocket Depth in 12 12 12 20 20 20 24 24 24
Number
of Pockets 6 5 3 8 6 4 6 5 3
Weight lb 3.8 3.3 2.2 5.3 4.4 2.7 5.3 4.4 2.7
Header Size in 23.43 x 23.43 19.41 x 23.43 11.38 x 23.43 23.43 x 23.43 19.43 x 23.43 11.38 x 23.43 23.43 x 23.43 19.43 x 23.43 11.38 x 23.43
PFS 1/1 PFM 1/1 PFL 1/1
Performance Unit Value Value Value
Rated Air Flow cfm 2000 2000 2000
Media Area ft
2
23 51 45
Initial Resistance* "w.g. 0.27 0.15 0.12
Final Resistance* "w.g. 1.5 1.5 1.5
MERV* 8 8 8
DHC @ 1.5"w.g. Final Resistance* g 600 1100 1100
Initial Resistance @ 2500 cfm* "w.g. 0.38 0.20 0.17
Temperature Resistance F 160 160 160
Short Peaks F 200 200 200
Burst Strength "w.g. >12 >12 >12
* Test performed according to ASHRAE Test Standard 52.2-1999
Initial Efficiency
After 1st Loading
After 2nd Loading
After Final Loading
PFS 1/1
PFM 1/1
PFL 1/1
Aerodynamic pocket
separators for uniform
air flow and maximum
media usage.
Filtrair pocket filters
remain rigid during
repetitive fan shut-downs
to prevent captured
particle migration.
ITEM 0160

Telephone (417) 864-5599
Facsimile (417) 866-0235
Filter Installation

Primary Filter
Sealing Angle
ITEM 0160
P/N: 074227003
P/N: 78947-00
2

ITEM 0160
P/N: 060120001
3

Step 2:
Insert spring clip
into hole in filter,
as shown. Four
clips per filter.
ITEM 0160
4

Step 3:
Insert filter frame
into filter rack.

ITEM 0160
5

Step 4:
Insert sealing angle
into filter rack for
primary filter.
ITEM 0160
6

Step 5:
Slide primary filter
over until contact
with angle.

ITEM 0160

Telephone (417) 864-5599
Facsimile (417) 866-0235

TURBLEX P/N: 71188
NOTES:

1. VIBRATION ISOLATORS, SHIP LOOSE,
INSTALLATION NOT BY TURBLEX.

2. PLEASE REFER TO TAB A FOR
INSTALLATION INSTRUCTIONS.

3. PLEASE REFER TO TAB E FOR
SURFACE PREPERATION & PAINT.

4. PLEASE TO REFER TO TAB D
CONSTRUCTION NOTES DRAWING
FOR LOCATIONS.

5. SEALANT KIT, TO BE PROVIDED IS
LOCTITE 20252 DEPEND.

6. MAXIMUM LOAD = 3000 LBS
DETAIL ITEM 1
MOUNTING PLATE
SEE NOTE 4
6
5
8
" FREE
6" LOADED
3
4
" MNTG. PL.
2
1
4
"
3"
3"
6"
4
5
16
" 4
5
16
"
6" 6"
12"
C
L
C
L
SHOULDER SCREW TO TIGHTEN AS
RUBBER JUST STARTS TO SQUEEZE.
IF NEEDED USE TWO FLAT WASHERS.
5
4
2 3 4
1
DRILL & TAP
3
8
"-16 UNC
THRU HOLES
(TYP. 2 PLCS.)
C
L
XLW-3000 VIBRATION ISOLATOR

ITEM QTY KIT/PN DESCRIPTION
1 1 73394 PL., X 6 X 12 LG., GR. 5, A36,
2 1 81209 HHCS, -13 UNC X 1 LG., GR. 5, ZINC PLTD.
3 1 80221 WASHER, LOCK, , ZINC PLTD.
4 3 70742 WASHER, FLAT, , ZINC PLTD.
5 2 73354 SHSB, X , 3/8-16 UNC THRD., BLACK
ITEM 0200
ISOMETRIC VIEW
ELEVATION VIEW
TOP VIEW
304.8 mm
152.4 mm
Adhesive: Loctite 32430
Activator: Loctite 21088

Telephone (417) 864-5599
Facsimile (417) 866-0235

(16) 1 1/8" HOLES ON A 21 1/4" B.C. DIA
ANSI 150#, 16" PIPE CONNECTION SIZE
ROTATING PLATE FLANGE
(28) 1 3/8" HOLES ON A 36" B.C. DIA
ANSI 150#, 30" PIPE CONNECTION SIZE
1
2
"
35"
23"
73
7
8
"
13"
23
1
2
"
3
4
"
A
I
R

F
L
O
W
1/2" NPTF
TYP (2) PLCS
FOR PRESSURE
DEVICES ONLY
3
4
"
38
3
4
"
(12) 1" HOLES ON
A 14 1/4" B.C. DIA
ANSI 150#, 10" PIPE
CONNECTION SIZE
BLOW OFF CONNECTION
3/4" NPTF
TYP (2) PLCS
FOR TEMP.
DEVICES ONLY
16"
1
1
4
"

DISCHARGE CONE 16x30x10 B.O.

TOP VIEW

ISOMETRIC VIEW

ELEVATION VIEW RIGHT VIEW NOTES:

1. FASTENERS, NUTS & GASKETS
(NOT BY TURBLEX).

2. DISCHARGE CONE, SHIP LOOSE,
INSTALLATION NOT BY
TURBLEX.

3. PLEASE REFER TO TAB E
FOR PAINT SPECIFICATIONS.

4. DISCHARGE CONE SUPPORTED
BY CUSTOMER PIPING.

BOTTOM VIEW 5. MATERIAL TO BE A36 CARBON
STEEL.

6. WEIGHT: 666 LBS.

K:\STD DRAWINGS\Discharge Cone\16x30x10-short-SUB

ITEM 0320
Tag Material: 304L SS

Telephone (417) 864-5599
Facsimile (417) 866-0235

6"
FOAM RUBBER MUST
MAKE CONTACT 1"
BEFORE CLAMP IS TIGHT
46
3
4
"

INLET FLEX CONNECTOR KA66S & SV

ISOMETRIC VIEW

ELEVATION VIEW

NOTES:

1. FOR KA66 MODEL MACHINES
WITH 45 7/8 DIAMETER INLET

2. CLAMP MATERIAL IS 10GA
GALVANIZED STEEL

3. WEIGHT: 17.2 LBS.

K:\STD DRAWINGS\Inlet Flex Connector\Flex-Conn-KA66S & SV

ITEM 0405

JOB NO. 4607T - Paul Wurth

Required Qty : 3 SHIPPING RESTRAINTS
Air Flow : 31,488.00 SCFM
Pressure: 30.00 PSIG
Disch. Temp: 400.00 F
FLUID: AIR
Blower Type: KA66
150 LBS FLOATING FLANGE
1 time x RPM 10,141.60 rpm
Blade Pass 4,056.64 Hz
Vane Pass 0.00 Hz
Fax = Forces in the discharge pipe direction.
Flat = Forces perpendicular to Fax.
M = Moment in any direction.
FAX FLAT M
LB. LB. IN. LB.
KA66 2248 675 13275
PLEASE SUBMIT YOUR BELLOWS DESIGN ANALYSIS AND DRAWINGS WITH YOUR QUOTATION VIA E-MAIL
NOTE: INNER SLEEVE
(LINER) TO BE WELDED TO
EXPANSION JOINT
METAL EXPANSION JOINT SIZE ID = 16"
Exiting Frequencies
THE MINIMUM
LINER ID NEEDS
TO BE
EQUIVALENT TO
PIPE SCHEDULE
80THE LINER ID
NEEDS TO BE
MAXIMIZE YET
ALLOW SPEC.
MOVEMENT
UNIVERSAL UNRESTRAINED DISCHARGE EXPANSION JOINT SELECTION SHEET
BLOWER TYPE
MATERIALS
1. BELLOWS AISI 321 STN STL
2. INNER SLEEVE AISI 321 STN STL
3. FLANGES ANSI 1015 C STL
SUPPLY EXPANSION JOINT WITH WELDED BAR
SHIPPING RESTRAINTS. RESTRAINTS TO BE
PAINTED YELLOW FOR EASY IDENTIFICATION. A
TAG IS TO BE AFFIXED TO THE RESTRAINTS
STATING " RESTRAINTS TO BE REMOVED AT TIME
OF TURBLEX COMPRESSOR START-UP ONLY".
PROVIDE AN ARROW FOR FLOW DIRECTION ON
SHIPPING RESTRAINTS.
FLOW
FLOW
LINER WELDED
TO INLET SIDE
15 ANGLE
150 LBS ANSI
FLANGE
LENGTH
TBD BY
VENDOR
ITEM 0430
150 LBS ANSI
FIXED
Flat
Fax
M
1. THE REQUIRED LATERAL STATIC DISPLACEMENT IS +/- 1/2"
2. THE SPECIFIED LINER ID NEEDS TO BE THE FIRST DESIGN CRITERIA
3. THE MINIMUM REQUIRED AXIAL DISPLACEMENT IS +/- 1/4"
DESIGN CRITERIA
14"
ITEM 0430

1
Expansion Joint Systems, Inc.
10035 Prospect Avenue, Suite 202, Santee, CA 92071 (619) 562-6083 Fax (619) 562-0636
E-mail: tech@ejsus.com Website: www.ejsus.com

METAL EXPANSION JOINT
INSTALLATION AND HANDLING INSTRUCTIONS
M:\proceed\install\standards\instal.doc
Last Updated 07/00

Metal Expansion Joints come in many configurations- from simple to highly
complex. This document covers generic applications. For detailed information,
we recommend that you contact EJS directly and inquire about your specific
installation.

Units are packaged on skids or crated for transportation. Do not remove the
unit(s) from packaging until you are ready to install. The unit(s) should be
stored in a clean, dry area. Long term storage should be done under
controlled atmosphere.

Unpack the units carefully. The bellows portion of the expansion joint is
easily damaged and cannot usually be repaired.

Inspect the units directly after unpacking has been completed. Report any
damage immediately to your Engineering/Inspection Department for correct
disposition. EJS will accept no liability for damage after this point.

Do not remove the shipping bars, which are normally painted yellow and
marked Remove after Installation but prior to system start up.

Shipping bars can be of various types, i.e. horseshoe, channel and
angle. On Hinged and Gimbal type joints, the hinge plates are locked at the
hinge point. All shipping bars will be marked with yellow paint with removal
information on them.

The intent of shipping bars is to hold the unit at its installation position.
Before attempting to fit the unit into the system, ensure the mating
equipment is aligned correctly. The expansion joint should not be used
for field alignment! It was never designed to do so. Resulting damage to
the expansion joint can be catastrophic.

More complex unit
Simple unit
ITEM 0430

2

Last Updated 07/00

Do not lift the expansion joint by the shipping bars. Lift at the lift points
provided or by the clevis pins attached. If the lift point clevis pins are not
apparent, use correct industry practice to lift and position the joint safely.
Bellows can be damaged easily with chains and improper procedures.

If the expansion joint is fitted with internal liners, ensure flow direction is
correct. The Open end of liner should be towards the downstream side.
Flow arrows are shown on the exterior of the unit. Occasionally, the liner
may be marked with the flow direction.

Some expansion joints are fitted with permanent covers. These should not
be removed unless necessary for installation. If covers have to be removed,
ensure they are re-fitted as soon as possible.

Installation/Construction covers are removed before the system is started.
They can be left in place while construction is continuing around the
expansion joint. Removing the construction covers should be done carefully.
Simple metal straps around the cover retain these covers. Cut through the
strap and remove the cover and plastic wrap under the cover.

Any convolution distortion should be reported to EJS at the earliest
opportunity. Due to the complexity of some designs and design
considerations, some bellows may be very thin. These types of bellows may
not have convolutions that are evenly spaced or have equal pitch. If in doubt
please call EJS.

Shipping Bars
Ensure dimension is
correct.
Ensure alignment
Ensure flanges/weld
ends are parallel
ITEM 0430

3

Last Updated 07/00

Any field alteration to the expansion joint will void the warranty. If an
expansion joint has been designed for field alignment it will be stipulated on
the drawing. Find a copy of the drawing before installing the expansion joint.
Field adjusted expansion joints usually come with supplemental instructions.

Flanged Units
Care should be taken to ensure that mating flanges are correctly
aligned. Torsion loads imposed on an expansion joint due to bolt-hole
misalignment or other causes can lead to reduced cycle life and in
some extreme cases, catastrophic failure.

Ensure liners will clear the inside diameter of the mating flange and
pipe.

When bolting the joint, care should be taken not to damage the outside
diameter of the end convolutions which may be very close to the
flange. Test fit the wrench to ensure when you are pulling the unit tight
the wrench is not touching the bellows.

Weld End Units
Always protect the bellows element from weld spatter. Cover the
bellows with suitable high temperature cloth or insulation. Never
strike an arc on the bellows. Weld spatter on the bellows will void
any warranty.

Care should be taken when welding the unit not to cause an out of
round condition due to weld shrinkage.

Seal off the open end of liner. Use duct tape or other suitable
material. After welding inside the unit, remove all pieces of weld rod
and spatter which could penetrate the bellows during operation.

BELLOWS ARE HIGHLY SUSCEPTIBLE TO DAMAGE.
DENTS, SCRATCHES, WELD SPATTER AND MECHANICAL
DAMAGE ARE NOT ACCEPTABLE.
TREAT THE BELLOWS LIKE IT WAS A PIECE OF FINE
PORCELAIN.

ITEM 0430

4

Last Updated 07/00

Hinged Joints. (Tied Universal Joints with only two Tie Rods)
Hinged Joints are only designed to move in one plane. Ensure the
hinge pins are in the correct plane. Extra care should be taken with
Tied Units that only have two Tie Rods. These units may have been
designed to accept angulation in one plane. The orientation of the tie
rods and hinges is of the utmost importance. Install the hinge pins
normal to direction of movement.

Cold Set/Sprung (preset) units
If the unit has been factory pre-set, or if the unit is going to be pre-set
in the field, ensure the offset is toward the direction from which the
thermal growth occurs.

Unrestrained Expansion Joints
Joints that do not have Tie Rods, Hinges or Pressure Balanced
Assemblies exert Pressure Thrust onto the system. Ensure all anchor
guides and equipment can withstand the Pressure Thrust. Apply the
pressure gradually and ensure the length of the joint does not
increase.

Restrained/Pressure Balanced Expansion Joints
Restrained (Tied) or Pressure Balanced Expansion Joints are
designed to absorb the pressure thrust within the expansion joint. Do
not remove the tie rods or hinge pins. Without the tie rods the unit will
not function correctly.

It is impossible for EJS to cover all the requirements and methods of installing
expansion joints in this document. We will be happy to answer any question you
may have. Please call EJS at anytime.

When the installation is complete remove the shipping bars. Check all anchors,
guides and pipe supports and then apply test pressure to system. If the test
pressure is greater than 1.5 x the design pressure of the expansion joint, contact
EJS prior to applying pressure.

During testing there should be little to no movement of the bellows or piping. If
movement occurs, immediately lower the pressure and re-check the installation.
Never test a system with air or other gases when an expansion joint is installed
unless consulting EJS.

ITEM 0430

5

Last Updated 07/00

SUPPLEMENTAL INSTALLATION INSTRUCTIONS FOR
RECTANGULAR/CIRCULAR STEAM CONDENSER/
TURBINE JOINTS

Landing Bars should be used to accommodate any misalignment from the
Turbine to the Condenser. Moving the bellows to accommodate any such
misalignment will be detrimental to the life of the unit.

Avoid painting the bellows area of the expansion joint. Some types of paint
can cause stress corrosion cracking.

During initial start up of the system under vacuum conditions, monitor the
bellows and ensure that they do not start to deflect inwards. Shut the system
down immediately if this occurs and contact EJS.

Ensure the bellows area is covered during any welding operations above the
bellows area. Weld spatter on the bellows can cause pre-mature failure or
vacuum leaks.

In some instances the shipping bars are fitted internally, ensure they are
removed before system start up.

Monitor the bellows center spool for flow induced vibration during start up.
ITEM 0430
FLOWSEAL
MANUAL AND AUTOMATED
HIGH PERFORMANCE BUTTERFLY VALVES
INSTALLATION
and
MAINTENANCE
INSTRUCTIONS
A Crane Co. Company

ITEM 0520
FLOWSEAL 9860 Johnson Road, Montgomery, TX 77316
936/588-4447
FAX 936/588-4427
CONTENTS
Introduction
Valve Description................................................................................................................................... 3
Valve Design Features .......................................................................................................................... 3
Flange Compatibility .............................................................................................................................. 3
Gasket Compatibility.............................................................................................................................. 3
Pipe Schedule Compatibility .................................................................................................................. 3
Product Identification ............................................................................................................................. 3
Operating Pressures.............................................................................................................................. 3
Seat Alternatives ................................................................................................................................... 4
Offset Disc Design ................................................................................................................................. 4
Seat Retainer Alternatives ..................................................................................................................... 5
Installation Recommendations
Valve Ratings ........................................................................................................................................ 6
Seat Upstream vs Seat Downstream .................................................................................................... 6
Disc Clearances .................................................................................................................................... 6
Opening Rotation................................................................................................................................... 6
Installation Position................................................................................................................................ 6
Valve and Flange Preparation ............................................................................................................... 6
Installation Tools.................................................................................................................................... 6
Required Bolting .................................................................................................................................... 6
Unpacking and Storage Instructions...................................................................................................... 6
Pre-Installation Procedure ..................................................................................................................... 7
Valve Installation Procedure .................................................................................................................. 7
Bolting Dimensions ............................................................................................................................ 8, 9
Maintenance Instructions
Safety Precautions .............................................................................................................................. 10
General Maintenance .......................................................................................................................... 10
Packing Replacement .......................................................................................................................... 10
End Cap Seal Replacement ................................................................................................................ 10
Standard Soft Seat Replacement .................................................................................................. 10, 11
Fire-Flow and Metal Seat Replacement .............................................................................................. 12
Disc, Shaft and Bearing Replacement ................................................................................................. 12
Ratchet Handle Mounting Procedure .................................................................................................. 13
Manual Gear Mounting Procedure ...................................................................................................... 13
Remote Actuator (Male Drive) Mounting Procedure............................................................................ 13
Remote Actuator (Female Drive) Mounting Procedure ....................................................................... 14
Parts List .............................................................................................................................................. 15
Body Rating Charts............................................................................................................................... 16
Flowseal Figure Number System .......................................................................................... Back Cover
2
ITEM 0520
FLOWSEAL
9860 Johnson Road, Montgomery, TX 77316
936/588-4447
FAX 936/588-4427
3
INTRODUCTION
Valve Description
The Flowseal High Performance Butterfly Valve (HPBV) is
designed for ASME Class 150, 300 and 600 piping systems
and is available in both Wafer and Lug style body designs.
The standard size range available is as follows:
ASME Class 150 ............................... 2" through 48"
Valve Design Features
Flowseal's HPBV's feature a double offset (or double
eccentric) shaft design to minimize seat abrasion and
lower torque. This double offset design allows the disc to
lift off and cam away from the seat as it rotates open.
The Flowseal valve always rotates clockwise to close
(when viewed from above) and counterclockwise to open.
The valve body has an Overtravel Stop which prevents the
disc from over rotating into the wrong quadrant. This stop
is not to be used as a disc position stop; if the disc
contacts the Overtravel Stop, this means it has rotated
beyond the seat
The Flowseal valve is bi-directional, but the preferred
installation position is with the seat in the upstream
position (SUS). Note the arrow on the metal tag attached
to the valve body for preferred direction of flow.
Flange Compatibility
The Flowseal valve is designed to fit between flanges as
follows:
MSS SP-44 Class 150 ..................... 30" through 48"
MSS SP-44 Class 300 ..................... 30"
Gasket Compatibility
The Flowseal valve is designed to accomodate the use of
standard fiber gaskets (such as non-asbestos, flexible graph-
ite, asbestos or equivalent gasket materials) of
1
16" or less,
meeting the dimensional requirements of ASME
B16.21. Thick elastomeric gaskets are not recommended.
Metallic wound (Flexitallic) gaskets may be used with the
wedge ring retainer configuration.
SERIAL NO.
FIGURE NO.
SIZE/CLASS
STEM/PINS
SEAT
BODY
DISC
BRGS
PSI
PSI
PSI
TAG NO.
BODY COLD WORKING PRESSURE
MAX. SHUTOFF PRESS. @ 100 F
F
FLOWSEAL
P
R
E
F
E
R
R
E
D

F
L
O
W

D
I
R
E
C
T
I
O
N
@
Operating Pressures
All Flowseal HPBV's may be applied to full ASME ratings.
However, different materials of construction may affect the
rated pressure. The shut-off pressure rating is determined
by the valve shaft and disc materials as well as the seat
design, and is reflected on the metal identification tag
attached to the valve.
Product Identification
SECTION 1
Every Flowseal valve has a metal identification tag attached
to the valve body. Information on this tag includes the valve
Figure Number, Size and Pressure Class, Materials of
Construction, and Operating Pressures and Temperatures.
The metal tag also includes a Serial Number. This number,
unique for each valve, is recorded by the Flowseal Quality
Control Department along with the valve hydrostatic test
results and material certification data for individual traceabil-
ity and verification of every valve produced.
Pipe Schedule Compatibility
The Flowseal valve is designed to allow the disc edge to
rotate into the open position without interference with pipe of
a schedule equal to or lighter to those shown below:
Size ASME 150 ASME 300 ASME 600
2" 12" SCH 80 SCH 80 SCH 120
14" 24" SCH 40 SCH 80 SCH 120
30" SCH 30 SCH 80
36" 42" STD WT
48" XS
ITEM 0520
FLOWSEAL 9860 Johnson Road, Montgomery, TX 77316
936/588-4447
FAX 936/588-4427
INTRODUCTION
4
Seat Alternatives
Flowseal HPBV's have three seat alternatives, all of which
are bi-directional.
Soft Seats provide tight shut-off to zero leakage specifica-
tions. Standard Soft Seat material includes virgin TFE or
reinforced TFE (RTFE).
Soft Seat Profile
Fire-FlowSeats are designed for critical piping applica-
tions in installations such as Refinery and Petrochemical
Plants. These seats are a combination of both metal and soft
seats with the metal seat being designed to function during
and after a fire. Valves of this type are referred to as Fire-
Safe and are tested to meet API 607 Fire-Safe specifica-
tions and operation criteria.
Fire-Flow Seat Profile
Metal Seats are well suited for higher temperature applica-
tions and provide shut-off to ASME B16.104 Class IV.
Disc
Body
Seat
Retainer
Disc
Body
Seat
Retainer
Metal Seat Profile
Disc
Body
Seat
Retainer
Offset Disc Design
All Flowseal HPBV's have both off-set discs and eccentric
shafts. The off-set is applicable to the disc edge seating
surface relative to the shaft center line. By off-setting the
seating surface from the rotational center line, a contact with
the seat is possible throughout the 360 circumference. The
shaft is eccentric in the body by 0.060 inches and this
enhances seat life by imparting a camming action to the disc
as it rotates both in and out of the seat. Seat wear points are
eliminated at the top and bottom of the disc and operating
torque is reduced.
ITEM 0520
FLOWSEAL
936/588-4447
FAX 936/588-4427
(
5
INTRODUCTION
Disc
Body
Seat
Retainer
Set Screw
Wedge Ring
Wedge Ring Retainer (Wafer and old-style lug valves)
(
Disc
Body
Seat
Retainer
Cap Screw
C
which, when assembled, becomes part of the raised face
flange mating surface. Two types of seat retainer fastening
designs are used in Flowseal HPBFV's.
Seat Retainer Alternatives
Flowseal HPBV's are designed to be easily maintained and,
in particular, to allow rapid and simple replacement of the
seat. The seat is held in the valve body by a seat retainer
Cap Screw Retainer (Double-Deadend lug style)
This wedge ring design is for wafer and old design standard lug style valves. A wedge ring is forced
outward into a groove machined in the body by the insertion of set screws in the face of the retainer.
The cap screws in retainer rings on double deadend service lug valves. The retainer is held to the
valve body by cap screws recessed in the retainer face.
ITEM 0520
FLOWSEAL
936/588-4447
FAX 936/588-4427
Valve Ratings
Flowseal HPBV's are intended for use at the pressure and
temperatures indicated on the metal nameplate attached to
each individual valve. Check the valve operating tempera-
ture and pressure ratings on the valve nameplate before
proceeding with installation.
6
INSTALLATION RECOMMENDATIONS
Installation Tools
The only tool required in the installation of a Flowseal
HPBFV is a wrench suitable for tightening the flange bolts
and/or nuts required to secure the valve in-line. A hoist may
be required to help manipulate valves 10" and larger. Smaller
sized valves can usually be installed by hand. Temporary
pipe supports may be used to keep mating flange faces
parallel in order to aid in valve installation.
SECTION 2
Valve and Flange Preparation
If the valve and mating pipe are properly prepared for
installation, future problems can be avoided. All valve and
pipe flange faces should be free of dirt, grit, dents, or surface
irregularities which may disrupt flange sealing and cause
external leakage. The valve seat and disc sealing surface
should also be inspected to eliminate any dirt or foreign
material that will adversely affect the operation of the valve.
Required Bolting
The tables outlined on the following pages are furnished to
provide information regarding the size, type, and quantity of
bolting recommended for the installation of Flowseal
HPBFV's. These tables are intended for use as a planning
and procurement guide. All recommendations are based on
pipe flanges in accordance with ASME B16.5 for 2" through
24" valves and MSS-SP-44 for valves 30" and larger. Flange
bolting is not included with the valve shipment.
1.
2.
3.
4.
5.
6.
7.
8.
Check the packing list against the valve received to
verify that the size, material, and trim are correct.
Check to make sure that the valve and operator were not
damaged during shipment.
When lifting the valve, take care to avoid damage to the
flange faces, disc sealing edge, or operator. On larger
valves, lifting holes are provided on the periphery of the
valve body to aid in valve handling.
If the valve is to be stored before being installed, it should
be protected from harsh environmental conditions.
Store the valve with the disc in the closed position to
protect the sealing edge and the seat.
Keep the valve in a clean location, away from dirt, debris
and corrosive materials.
Keep the valve in a dry area with the flange protectors
attached and on a suitable skid or pallet.
Keep the valve in a cool location if possible, out of direct
sunlight.
Seat Upstream vs Seat Downstream
Although all Flowseal seat designs are completely bi-direc-
tional, every effort should be made to install the valve with
pressure and flow from the seat side of the valve (seat
upstream). Positive shutoff will be achieved with the valve in
either orientation. However, installation with the seat in the
upstream position will result in longer service life and lower
torque valves.
Disc Clearances
Prior to installing the valve, it is important to make sure the
ID of the pipe and pipe flanges is large enough to allow the
disc edge to swing into the opening without interference.
Damage to the disc edge can severly affect the performance
of the valve. Pipe schedule compatibility for Flowseal valves
is shown in Section 1 of this manual.
Opening Rotation
The Flowseal valve is designed to open with counterclock-
wise rotation of the shaft, and to close with clockwise rotation
of the shaft when viewed from above with the shaft in the
vertical position. An over-travel stop is provided in the body
to prevent over-travel of the disc in the wrong direction. This
stop is not to be used as a disc position stop. Contact with
this stop means the disc has travelled past the seat.
Installation Position
To prevent damage during installation the valve disc must be
fully closed before installing the valve in the line. It is
preferable to install HPBV's with the shaft horizontal. This is
important for valves applied to fluids which contain particu-
lates. For HPBV's 16" and larger, installation should always
be made with the shaft horizontal.
Unpacking and Storage Instructions
ITEM 0520
FLOWSEAL
936/588-4447
FAX 936/588-4427
5. Cycle the valve to the fully open position, then back to the
fully closed position, checking the actuator travel stop
settings for proper disc alignment.
6. Check the valve identification tag for valve class, materi-
als, and operating pressure to be sure they are correct for
the application.
7. Check the flange bolts or studs for proper size, threading,
and length.
The Flowseal High Performance Butterfly Valve can be
installed in the pipeline with the shaft in the vertical, horizon-
tal, or other intermediate position. Based on applications
experience, however, in media with concentrations of solid or
abrasive particles or media subject to solidification buildup,
valve performance and service life will be enhanced by
mounting the valve with the shaft in the horizontal position.
All Flowseal valves are bi-directional and can be mounted in
the pipeline in either flow direction; however, the preferred
flow direction for all seat styles and materials is with the seat
retainer ring located upstream (SUS) to provide maximum
seat protection.
1. For Wafer Style Valves:
a. Loosely install the lower flange bolts to form a cradle
between the flanges. (See Figure 1.)
b. Noting the flow direction arrow on the tag, place the
valve and flange gaskets between the flanges, making
sure the arrow on the tag points in the direction of the
flow.
c. Install the remaining flange bolts, shifting the valve as
necessary to permit the bolts to pass by or through the
valve body.
1. Remove the protective flange covers from the valve.
2. Inspect the valve to be certain the waterway is free from
dirt and foreign matter. Be certain the adjoining pipeline is
free from any foreign material such as rust and pipe scale
or welding slag that could damage the seat and disc
sealing surfaces.
3. Actuators should be mounted on the valve prior to instal-
lation to facilitate proper alignment of the disc in the valve
seat.
4. The valve should be in the closed position. Make sure
the open and closed positions of the actuator correspond
to the counter-clockwise to open direction of rotation of
the valve.
For Lug Style Valves:
a. Noting the flow direction arrow on the tag, place the
valve between the flanges, making sure the arrow on
the tag points in the direction of the flow.
b. Install the lower flange bolts loosely, leaving space for
the flange gaskets.
c. After inserting the flange gaskets, install the remaining
bolts.
2. Using the sequence shown in Figure 2, tighten the flange
bolts evenly to assure uniform gasket compression.
3. If an actuator is to be used, air hoses or electricity should
be connected to the unit as specified by the actuator
manufacturer.
4. The valve is now ready for operation.
7
CAUTION!
Remember: Install the valve with the disc in the
FULL CLOSED POSITION.
Valve Installation Procedure
Pre-Installation Procedure
1
1
1
15
8
12
4
10
6
14 2
16
7
11
3
9
5
13
8
4
6 2
7
3
5
1
8
4
6 2
11
7
3
9
5
10
12
2
3
4
Figure 1
Figure 2
Personal injury or property damage
may result if the valve is installed
where service conditions could ex-
ceed the valve ratings.
WARNING!
The Flowseal valve should be centered
between the flanges and gaskets to
prevent damage to the disc edge and
shaft as a result of the disc striking the
flange, gasket, or pipe.
ITEM 0520
FLOWSEAL
936/588-4447
FAX 936/588-4427
INSTALLATION RECOMENDATIONS
8
F G
Body
Flange Flange
B* A*
LUG BODY
STUDS & NUTS
LUG BODY
HEX HEAD MACHINE BOLTS
BOLTING DIMENSIONS
Body
WAFER BODY
STUDS & NUTS
C D
Body
VALVE
SIZE
30"
36"
42"
48"
2" J
5
/8-11 4 .940 4 .570 4 2.50 4 2.12 4 1.75 4 1.50 4 5.00
2
1
/2" J
5
/8-11 4 .960 4 .680 4 2.62 4 2.38 4 2.00 4 1.62 4 5.25
3" J
5
/8-11 4 1.139 4 .725 4 3.00 4 3.00 4 1.88 4 1.62 4 6.00
4" J
5
/8-11 8 1.071 8 .745 8 3.00 8 3.00 8 2.00 8 1.62 8 6.00
5" J
3
/4-10 8 1.220 8 .790 8 3.12 8 2.62 8 2.25 8 1.75 8 6.00
6" J
3
/4-10 8 1.401 8 .839 8 3.50 8 2.75 8 2.38 8 1.75 8 6.50
8" J
3
/4-10 8 1.492 8 .948 8 3.75 8 3.00 8 2.50 8 2.00 8 6.50
10" J
7
/8-9 12 1.752 12 1.000 12 4.50 12 3.25 12 2.62 12 2.38 12 7.50
12" J
7
/8-9 12 2.147 12 1.025 12 4.50 12 3.25 12 3.38 12 2.25 12 8.00
14" J 1-8 12 2.330 12 1.210 12 5.00 12 3.75 12 3.62 12 2.62 12 9.00
16" J 1-8 16 2.648 16 1.270 16 5.25 16 4.00 16 4.00 16 2.62 16 10.00
18" J 1
1
/8-8 16 2.723 16 1.645 16 5.50 16 4.50 16 4.25 16 3.12 16 10.50
J 1
1
/8-8 16 3.396 20 1.434 16 6.25 20 4.50 16 5.12 20 3.19 16 11.00
J 1
1
/8-8 4** 2.325 4** 5.25 4** 4.06 8** 5.25
J 1
1
/4-8 20 3.690 20 2.250 20 6.75 20 5.25 20 5.50 20 4.12 20 12.50
H 1
1
/4-8 24 3.471 24 3.159 24 7.75 24 7.50 24 6.47 24 6.15 24 15.25
H 1
1
/4-8 4** 1.908 4** 1.592 4** 6.00 4** 5.75 4** 4.91 4** 4.59 8** 6.00
H 1
1
/2-8 28 3.760 28 3.740 28 9.00 28 9.00 28 7.19 28 5.25 28 18.25
H 1
1
/2-8 4** 1.760 4** 1.740 4** 6.75 4** 6.75 4** 5.25 4** 5.25 8** 6.75
H 1
1
/2-8 32 4.160 32 4.090 32 9.75 32 9.50 32 6.62 32 4.25 32 19.25
H 1
1
/2-8 4** 1.782 4** 1.718 4** 7.25 4** 7.25 4** 4.25 4** 4.25 8** 7.25
H 1
1
/2-8 40 5.520 40 4.850 40 11.75 40 11.00 40 9.83 40 9.16 40 21.00
H 1
1
/2-8 4** 2.815 4** 2.190 4** 7.75 4** 7.75 4** 7.12 4** 6.50 8** 7.75
BOLT ENGAGEMENT IN VALVE* STUDS & NUTS MACHINE BOLTS STUDS & NUTS
ASME Class 150 2" 24"
MSS SP-44 Class 150 30" 48"
LUG VALVES WAFER VALVES
VALVE
SERIES
THREAD
SIZE
24"
20"
A A B B C C D D F F G G E E
QTY LG QTY LG QTY LG QTY LG QTY LG QTY LG QTY LG
Every efort is made to provide accurate information, but no liability for claims arising from erroneous data will be accepted by Flowseal.
Length of machine bolts based on:
1. Gasket thickness of 0.06 inches.
2. Minimum fange thickness of weld neck fanges per ASME B16.5.
ITEM 0520
INSTALLATION RECOMONDATIONS
936/588-4447
FAX 936/588-4427
FLOWSEAL
9
* Bolt lengths A & B are from face of valve body to minimum depth in lug. Flange & gasket thickness must be added to calculate
minimum bolt length.
** Special length required for tapped blind holes on either side of the valve shaft at the top and bottom ends of the valve body.
2" J
5
/8-11 8 .940 8 .570 8 2.25 8 2.62 8 1.50 8 2.00 8 5.25
2
1
/2" J
5
/8-11 8 .970 8 .670 8 2.75 8 3.00 8 1.75 8 2.00 8 5.75
3" J
3
/4-10 8 1.034 8 .826 8 3.00 8 3.00 8 2.12 8 .75 8 6.00
4" J
3
/4-10 8 1.196 8 .870 8 3.50 8 3.25 8 2.50 8 2.00 8 6.50
5" J
3
/4-10 8 1.220 8 .790 8 5.25 8 3.62 8 2.25 8 2.75 8 7.00
6" J
3
/4-10 12 1.301 12 .929 12 3.75 12 3.50 12 2.75 12 2.25 12 7.00
8" J
7
/8-9 12 1.702 12 1.128 12 4.50 12 4.00 12 3.25 12 2.75 12 8.25
J 1-8 16 1.867 16 1.300 16 5.00 16 4.50 16 3.25 16 3.12 14 9.25
J 1-8 4** 5.00
J 1
1
/8-8 16 2.057 16 1.475 16 5.50 16 5.00 16 4.00 16 3.38 12 10.00
J 1
1
/8-8 8** 5.25
H 1
1
/8-8 16 2.442 16 2.118 16 6.00 16 5.75 16 4.62 16 4.25 16 11.50
H 1
1
/8-8 4** 1.608 4** 1.267 4** 5.25 4** 4.75 4** 3.75 4** 3.44 8** 5.25
H 1
1
/4-8 16 2.562 16 2.628 16 6.50 16 6.50 16 4.88 16 4.88 16 13.00
H 1
1
/4-8 4** 1.538 4** 1.588 4** 5.25 4** 5.25 4** 3.88 4** 4.25 8** 5.25
H 1
1
/4-8 20 2.870 20 2.890 20 7.00 20 7.00 20 5.25 20 5.25 20 14.00
H 1
1
/4-8 4** 1.657 4** 1.437 4** 5.50 4** 5.50 4** 4.00 4** 3.88 8** 5.50
H 1
1
/4-8 20 3.184 20 3.006 20 7.50 20 7.25 20 5.69 20 5.69 20 14.50
H 1
1
/4-8 4** 1.681 4** 1.750 4** 5.75 4** 5.50 4** 4.19 4** 4.00 8** 5.75
H 1
1
/2-8 20 3.560 20 3.510 20 8.25 20 8.25 20 6.31 20 6.25 20 16.50
H 1
1
/2-8 4** 1.800 4** 1.750 4** 6.25 4** 6.25 4** 4.56 4** 4.50 8** 6.25
H 1
3
/4-8 24 4.331 24 4.429 24 10.25 24 10.50 24 7.88 24 7.88 24 20.50
H 1
3
/4-8 4** 2.039 4** 2.071 4** 8.00 4** 8.00 4** 5.44 4** 5.47 8** 8.00
BOLTING DIMENSIONS
VALVE
SIZE
VALVE
SERIES
MSS SP-44 Class 300 30"
QTY LENGTH QTY LENGTH QTY LENGTH QTY LENGTH QTY LENGTH QTY LENGTH QTY LENGTH
14"
16"
18"
20"
24"
30"
12"
10"
THREAD
SIZE
3" J
3
/4-10 8 1.034 8 1.026 8 3.50 8 3.50 8 2.25 8 2.38 8 7.00
4" J
7
/8-9 8 1.274 8 1.165 8 3.50 8 3.25 8 2.75 8 2.75 8 7.75
6" J 1-8 12 1.274 12 1.306 12 4.75 12 4.75 12 3.25 12 3.25 12 9.50
8" J 1
1
/8-8 12 1.794 12 1.795 12 5.75 12 5.75 12 4.12 12 4.12 12 11.50
H 1
1
/4-8 12 2.495 12 2.000 12 6.75 12 6.25 12 5.00 12 4.50 12 13.00
H 1
1
/4-8 4** 1.375 4** 2.000 4** 5.50 4** 6.25 4** 3.88 4** 4.50 8** 6.25
H 1
1
/4-8 16 2.683 16 2.697 16 7.00 16 7.00 16 5.38 16 5.38 16 14.00
H 1
1
/4-8 4** 1.325 4** 1.765 4** 5.25 4** 6.00 4** 4.00 4** 4.38 8** 6.00
H 1
3
/8-8 16 2.994 16 2.996 16 7.50 16 7.50 16 CF 16 CF 16 15.00
H 1
3
/8-8 4** 1.506 4** 1.869 4** 6.00 4** 6.50 4** CF 4** CF 8** 6.50
10"
12"
14"
VALVE
SIZE
THREAD
SIZE
VALVE
SERIES
QTY LENGTH QTY LENGTH QTY LENGTH QTY LENGTH QTY LENGTH QTY LENGTH QTY LENGTH
ITEM 0520
FLOWSEAL
936/588-4447
FAX 936/588-4427
5 2 8 o t 2
5 3 2 1 o t 0 1
0 5 0 2 o t 4 1
5 7 0 3 o t 4 2
36 to 48 100
Remove the handle or actuator and the mounting hard-
ware from the valve.
Remove the gland flange nuts and lockwashers.
Remove the gland flange and gland.
Replace the old packing with new packing. Correct
packing selection is important. On larger valves it may
be necessary to compress each stem seal into the
stuffing box before adding the next one.
Reinstall gland, gland flange, lockwashers and nuts.
Tighten the gland flange nuts evenly to torque specified
in Table 1.
Operate the disc several times.
Reinstall the handle or actuator and mounting hard-
ware.
Set the actuator stops.
MAINTENANCE INSTRUCTIONS
10
Packing Replacement
SECTION 3
Table 1
Remove the end cap bolts and lockwashers.
Rotate the end cap to break the seal, then pull the cap out.
Remove the old seal.
Clean the body and end cap prior to installing the new seal.
Slide the new seal into place, then guide the end cap into
the body.
Align the bolt holes and reinstall the lockwashers and bolts.
Tighten the bolts evenly to the torque specified in Table 2.
End Cap Seal Replacement
(where applicable)
Valve Size (in.) Torque (in-lb)
Be sure the line is depressurized and drained.
Be sure of the pipeline media. Proper care should be
taken for protection against toxic and/or flammable
fluids.
Never install the valve without an Operator (Manual or
Automatic) already attached to the valve shaft.
Never remove the Operator from the valve while the
valve is in the pipeline under pressure. Flowseal's
eccentric valve design may allow line pressure to open
the valve if the handle/actuator is not in place while the
valve is under pressure.
Always be sure that the disc is in the full-closed position
before removing or installing the valve.
Take care in handling the valve. Personal injury or
property damage may result if the valve is damaged or
mishandled during maintenance operations.
Before removing the valve from the line or loosening any
bolts, it is important to verify the following conditions:
Safety Precautions
1.
2.
3.
4.
5.
6.
General Maintenance
Normal maintenance for a Flowseal HPBFV is limited to
adjustment of the shaft packing by tightening down evenly
on the gland flange using the gland flange studs and nuts.
Overtightening of the gland should be avoided since this will
shorten the life of the packing. During commissioning, it is
common for dirt and foreign objects to be left in the pipeline
during construction. This debris can damage the HPBV seat
or disc edge which will prevent the valve from providing tight
shut-off. In such cases seat replacement may be necessary.
1.
2.
3.
4.
5.
6.
7.
Standard Soft Seat Replacement
Place the valve on a bench with the seat retainer facing up.
Use blocks to elevate the valve above the work surface to
provide enough clearance to prevent the disc from being
damaged when the valve is opened.
(a) Cap Screw Retainer:
Remove the cap screws and lift the seat retainer
out of the valve.
(b) Wedge Ring Retainer:
Unlock the retainer by removing the set screws.
If difficulty is experienced in removing the retainer,
open the disc approximately 20 degrees and then
tap the retainer with a non-metallic hammer. Lift the
retainer from the body.
Remove the old seat from the seat retainer and discard.
Thoroughly clean the seat cavity in the body and the seat
retainer prior to installing a new seat.
Table 2
0 5 8 o t 2
0 8 2 1 o t 0 1
14 to 30 100
1.
2.
3.
4.
1.
2.
3.
4.
5.
6.
7.
8.
9.
ITEM 0520
FLOWSEAL
936/588-4447
FAX 936/588-4427
5.
6.
7.
8.
9.
10.
11.
12.
11
Standard Soft Seat Replacement (cont.)
Carefully clean and polish the disc sealing surface with a
soft cloth. The disc sealing surface should be free of all
grooves and scratches.
Place the seat retainer on a flat surface with the seat
locating area facing up.
Place the new preformed seat assembly (Seat and O-
ring) on the seat retainer with the marked (tape) side
facing down.
Using the balls of each thumb, press down on the seat
engaging the shoulder of the seat behind the lip in the seat
retainer. Stretch the seat into place by sliding each thumb
around the circumference of the seat maintaining down-
ward pressure and forcing the seat shoulder over the seat
retainer lip.
With the disc in the closed position place the seat retainer
with seat into the counterbore of the body.
Apply lubricant to the cap screw threads and tighten
them down uniformly.
Open the disc and relax the retainer pressure slightly to
permit the seat to expand fully inward against the seat
retaining lip machined in the retainer and body seat
cavities. A positive snap action will be observed.
Leaving the valve disc open, retighten the cap
screws to the torques specified in Table 3.
Operate the disc several times and inspect the seat for
damage before reinstalling the valve in the pipeline.
Table 3
0 5 2 1 o t 2
5 7 0 2 o t 4 1
24 to 48 100
Place the wedge ring in the groove on the outside
edge of the retainer taking care to position the
wedge ring gap away from any set screw. Using
opposing C-clamps, pull the retainer into a posi-
tion flush with body face. (The C-clamps should
not block access to the set screw holes.)
Inspect the position of the disc in the closed position to
determine whether the actuator stops are adjusted prop-
erly. The face of the disc should be parallel to the seat
retainer face when the valve is in the fully closed position.
Leaving the valve disc open, retighten the C-
clamps and install the set screws. Remove the C-
clamps after all screws have been tightened.
ITEM 0520
FLOWSEAL
936/588-4447
FAX 936/588-4427
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Remove any actuator and mounting bracket from top of
valve.
Remove all top and bottom packing and/or end seals as
required.
To prepare for removal of existing wedge pins, grind away
any disc material that has been peened over pin heads.
(a) For Through Shaft Design:
(b) For Split Shaft Design:
Support the valve body and disc on a flat surface in the
horizontal position. Slowly remove shaft(s).
Remove the disc from the body.
To remove bearings, cut or grind a slot lengthwise in each
bearing in order to be able to collapse bearing prior to
removal. Be careful not to damage bearing seating bore
within the body.
Clean all components thoroughly.
Inspect all parts for damage prior to reassembly. Dam-
aged parts should be repaired or replaced with new parts.
Carefully clean and polish the disc sealing surface with a
soft cloth. The disc sealing surface should be free of all
grooves and scratches.
Install the new bearings by gently tapping them into the
body with a soft rod and hammer. The bearings should be
installed into the shaft bore firmly against the counterbore
or bottom of shaft hole.
(a) Valves 2" thru 12":
(b) Valves 14" and larger:
The shaft keyway when viewed from the top of the valve
should be to the right, which is also the direction from
which the pins are installed.
Follow Steps 1 and 2 of Soft Seat Replacement instruc-
tions.
Remove old soft seat and graphite gaskets and discard.
Clean and inspect the metal seat.
If metal seat is scored, bent or otherwise damaged it will
require replacement.
Thoroughly clean the seat cavity in the body and the seat
retainer prior to installing the new seat.
Carefully clean and polish the disc edge sealing surface
with a soft cloth. The disc sealing surface should be free of
all grooves and scratches.
A graphite gasket is required on both sides of the metal
seat. Gaskets can be made from self-adhesive graphite
tape as follows:
(a) Suggested graphite tape size:
2" - 12" valves
1
/2" wide
14" - 48" valves 1" wide
(b) To install the tape, peel off 6" of backing paper at a
time. Apply the tape to the metal seat covering the
flat outer edge area on both sides. Overlap the two
ends of the tape a minimum of
1
/8 inch.
Note: It is important that both sides have gaskets.
(c)
(d) If cap screw retainer design, bolt holes in metal seat
should be opened by slitting an X in the hole. Do
not attempt to cut round holes.
For Fire-Flow valves, place the preformed seat assembly
in the body seat cavity with the marked (tape) side up. For
metal seated valves, place the 316 SS back-up ring in the
body seat cavity.
Place the metal seat with graphite gaskets on the TFE seat
or 316 SS back-up ring already in the body. The metal seat
should be installed with the rounded edge down against
the TFE seat or the 316 SS back-up ring.
Follow steps 9 thru 12 of Soft Seat Replacement instruc-
tions.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Smooth tape as much as possible by hand. Slight
roughness is acceptable and will be pressed flat
during final assembly. Avoid tearing tape. If a tear
occurs, tape should be overlapped a minimum of
1
/8 inch. Trim excess tape from outside diameter of
the seat.
Fire-Flow and Metal Seat Replacement
Disc, Shaft and Bearing Replacement
12
Flowseal uses a wedge pin method of disc/shaft pinning. This
method permits the replacement of either a disc or a shaft
since they are not required to be matched sets.
Using a punch approximately the same size as
the wedge pins, drive each pin out of the disc hub from
the non-peened side of the disc to the peened side of
the disc.
Pull the wedge pins out of the disc hub using
thethreaded holes on top of each pin and a jack screw.
With the valve body on edge on the bench, shaft
horizontal, and the body overtravel stop nearest to the
bench, position the disc in the open position with the flat
face upward. Present the disc to the valve body from
the side opposite the seat retainer cavity.
Support the disc on a bench, flat side down and
elevated above the bench top to a height of approxi-
mately 4 inches. Lower the valve body over the disc,
seatretainer side facing upward, until the bearing bore
and disc hole are aligned. Install the shaft into the body
and disc.
ITEM 0520
FLOWSEAL
936/588-4447
FAX 936/588-4427
Position the disc in the closed position.
Install the ratchet plate using socket head cap screws and
lockwashers, but do not tighten the fasteners.
Install the drive key in the shaft. Tap the key into place to
ensure it is fully seated in the keyway .
Install the handle so that it is parallel with the disc face.
The locking lever must be fully retracted before it will pass
through the ratchet plate. Tighten the set screw in the
handle against the key.
With the handle installed flush with the ratchet plate,
engage the locking lever with the ratchet plate. Using the
handle, adjust the position of the ratchet plate until the disc
face is parallel with the valve face, then tighten the
fasteners securely.
Remove the handle by disengaging the locking lever and
lifting up. The locking lever will slide thru the ratchet plate
only in the disengaged position.
Remove the ratchet plate fasteners and rotate the plate
180. Reinstall the fasteners but do not tighten them.
Reinstall the handle 180 from the standard position so
that it is parallel with the disc (Note: The locking lever must
be disengaged). Tighten the handle set screw against the
key.
Adjust the ratchet plate as described above.
Line up the shaft flat to permit the insertion of the wedge
pins. Install the first wedge pin in the disc hole closest to
the top of the valve. Finger tight installation is appropriate.
Move the shaft fully into the valve and against this first
installed pin. Insert the second pin. Tap both wedge pins
in equal amounts until all play between shaft and disc is
removed. Care should be taken not to attempt to over seat
the wedge pins. If the pin is flush or protruding after tapping
in, tack weld on the opposite side for security. Otherwise,
peening of the installing side is recommended.
Install a new end seal if applicable with the end cap as
described in Steps 4 through 7 of the End Cap Seal
Replacement procedure.
Install new packing box components as described in
Steps 4 through 10 of the Packing Replacement
procedure.
Install new seat as described in the Seat Replacement
procedure.
Cycle the valve several times to ensure the disc is pinned
tightly to the shaft and there is no shaft binding or seat
damage before reinstalling the valve in the pipeline.
Reinstall the actuator mounting hardware and actuator.
Set the actuator stops.
Manual Gear Mounting Procedure
1.
2.
3.
4.
5.
6.
Changing the Quadrant:
If it is necessary to relocate the manual gear handwheel
180 from its standard position, complete the following
steps:
Close the valve.
Remove the bolts and lockwashers holding the gearbox
to the mounting bracket. Lift the gearbox off the shaft.
Rotate the gearbox 180 around the shaft.
Align the key with the gearbox keyseat and slide the
gearbox onto the shaft.
Reinstall the bolts and lockwashers to fasten the gearbox
to the mounting bracket.
Adjust the gearbox stops as described previously.
1.
2.
3.
4.
5.
6.
Remote Actuator (Male Drive)
Mounting Procedure
1.
2.
3.
4.
5.
6.
13
Install the actuator mounting bracket on the valve body
with the actuator mounting holes facing up-ward. Fasten
the bracket securely in place with the appropriate ma-
chine bolts and lockwashers.
Install the drive key in the keyway of the shaft. Tap the key
in place to insure it is fully seated.
Install the drive coupling on the shaft by lining up the
proper keyway in the coupling with the key in the shaft.
Rotate the actuator shaft to the full clockwise position.
Align the drive coupling with the actuator shaft and install
the actuator on the mounting bracket.
Fasten the actuator to the mounting bracket with the
appropriate machine bolts and lockwashers. It may be
necessary to slightly rotate the actuator shaft to align the
mounting holes in the actuator with the mounting bracket.
14.
15.
16.
17.
18.
19.
20.
21.
Install the mounting bracket on the valve body. Fasten it
tightIy in place with the appropriate machine bolts and
lockwashers.
ensure it is fully seated.
Rotate the gear shaft to the full clockwise position. Align
the keyway in the gearbox bore with the key in the shaft
and slide the gearbox onto the shaft.
Fasten the gearbox to the mounting bracket with the
necessary to rotate the gear shaft slightly to align the
mounting holes in the gear with the plate.
Adjust the stops in the gearbox to position the face of the
disc parallel with the face of the valve in the closed
position and perpendicular to the face of the valve in the
open position.
Ratchet Handle Mounting Procedure
If it is necessary to relocate the handle 180 from its
standard position, complete the following steps:
1.
2.
3.
4.
5.
1.
2.
3.
4.
ITEM 0520
FLOWSEAL
936/588-4447
FAX 936/588-4427
Close the valve.
Remove the bolts and lockwashers holding the actuator
Lift the actuator off the mounting bracket.
Remove the key from the drive coupling and reinstall in
the adjacent keyway 90 away. Tap the key in place to
Align the keyway in the actuator bore with the key in the
drive coupling and slide the actuator onto the drive
coupling.
Reinstall the bolts and lockwashers to fasten the actuator
Adjust the actuator stops as described previously.
Close the valve.
Lift the actuator off the mounting bracket.
Remove the drive coupling from the valve shaft and
rotate it 90.
Reinstall the drive coupling on the valve shaft.
Remove they key from the drive coupling and reinstall
the key in the adjacent keyway 90 away. Tap the key in
place to ensure it is fully seated.
Align the keyway in the actuator bore with the key in the
drive coupling and slide the actuator onto the drive
coupling.
Close the valve.
Remove the bolts and lockwashers holding the actua-
tor to the mounting bracket. Lift the actuator off the
mounting bracket.
Remove the drive coupling from the valve shaft and
rotate it 90 to the adjacent keyway.
Reinstall the drive coupling on the valve shaft.
Align the drive coupling with the actuator shaft and
install the actuator on the mounting bracket.
Reinstall the bolts and lockwashers to fasten the actua-
tor to the mounting bracket.
Adjust the actuator stops as described above.
Mounting Procedure (cont.)
Adjust the stops in the actuator to position the face of the
disc parallel with the face of the valve body in the closed
position and perpendicular to the face of the valve body in
the open position.
Caution: The overtravel stop in the valve body is not to be
used as an actuator stop.
7.
If it is necessary to rotate the actuator 90 from standard
position, complete the following steps:
1.
2.
3.
4.
5.
6.
7.
position, complete the following steps.
1.
2.
3.
4.
5.
6.
Close the valve.
Lift the actuator off the mounting bracket. Rotate the
actuator 180.
Remote Actuator (Female Drive)
Mounting Procedure
with the actuator mounting holes facing up. Fasten the
bracket securely in place with the appropriate machine
bolts and lockwashers.
Install the drive key in the shaft. Tap the key in place to
insure it is fully seated.
proper coupling keyway with the key in the shaft.
Install the drive key in the drive coupling. Tap the key in
place to insure it is properly seated.
6.
7.
8.
position complete the following steps:
1.
2.
3.
4.
5.
6.
7.
If it is necessary to rotate the actuator 180 from its standard
position, complete the following steps:
1.
2.
3.
4.
5.
6.
7.
8.
9.
14
1.
2.
3.
4.
5.
Rotate the actuator to the full clockwise position. Align
the keyway in the actuator bore with the key in the drive
coupling and slide the actuator on the drive coupling.
necessary to rotate the actuator slightly to align the
actuator with the mounting bracket.
Adjust the stops in the actuator to position the face of !he
position and perpendicular to the face of the valve body
in the open position.
Caution: The overtravel stop in the valve body is not to
be used as an actuator stop.
ITEM 0520
FLOWSEAL
936/588-4447
FAX 936/588-4427
Item Description
15, 16
16, 17
15
14
1
5
2
3
6
12, 17 13,18
10
4
9
8
7
14
11
11
7
7
8
9
10
4
7
11, 19
14
13
1
12
6
5
3
2
Parts List
15
1 Body
2 Seat Retainer
3 Disc
4 Shaft
5 Seat
6 Seat O-ring
7 Bearing
8 Packing
9 Gland
10 Gland Follower
11 End Cap
12 End Cap Bolts
13 Set Screws
14 Wedge Pins
15 Gland Flange Stud
16 Gland Flange Nut
17 Lockwasher
18 Wedge Ring
19 End Cap Seal
Through Shaft Design
1 Body
2 Seat Retainer
3 Disc
4 Shaft
5 Seat
6 Seat O-ring
7 Bearing
8 Packing
9 Gland
10 Gland Follower
11 Disc Thrust Spacer (2"-5")
12 Set Screws
13 Wedge Pins
14 Gland Flange Stud
15 Gland Flange Nut
16 Lockwasher
17 Wedge Ring
Item Description
Split Shaft Design
ITEM 0520
FLOWSEAL
936/588-4447
FAX 936/588-4427
16
BODY RATING
The charts below refect the pressure/temperature ratings for carbon steel and stainless steel valves, in accordance with
ASME B16.34. The hydrostatic shell test is performed on the body at 150% of the cold working pressure (C.W.P. is defned
as the pressure rating between -20 to 100F and the hydrostatic seat test is performed on the disc and seat at 110% of the
cold working pressure.
F
Maximum Non-Shock
Working Pressure-PSI
Carbon Steel
(1)
Carbon Steel
(2)
316SS
ASME Class 150 300 600 150 300 600 150 300 600
HYDROSTATIC
SHELL TEST
450 1125 2225 450 1125 2225 425 1100 2175
HYDROSTATIC
SEAT TEST
315 815 1630 315 815 1630 305 800 1585
-20 - 32 285 740 1480 - - - 275 720 1440
32-100 285 740 1480 285 740 1480 275 720 1440
200 260 675 1350 260 675 1350 240 620 1240
300 230 655 1315 230 655 1315 215 560 1120
400 200 635 1270 200 635 1270 195 515 1030
500 170 600 1200 170 600 1200 170 480 955
600 140 550 1095 140 550 1095 140 450 905
650 125 535 1075 125 535 1075 125 445 890
700 110 535 1065 110 535 1065 110 430 865
750 95 505 1010 95 505 1010 95 425 845
800 80 410 825 80 410 825 80 415 830
850 65 405 810
900 50 395 790
1000 20 365 725
(1)
CE impact tested materials and standard non-impact tested materials.
(2)
CE non-impact tested materials.
C
Maximum Non-Shock
Working Pressure-Bars
Carbon Steel
(1)
Carbon Steel
(2)
316SS
ASME Class 150 300 600 150 300 600 150 300 600
HYDROSTATIC
SHELL TEST
30 77 153 30 77 153 29 75 150
HYDROSTATIC
SEAT TEST
22 56.9 112.4 22 56.9 112.4 20.9 54.6 109.3
-29 to 0 19.6 51.1 102.1 - - - 19.0 49.6 99.3
0 to 38 19.6 51.1 102.1 19.6 51.1 102.1 19.0 49.6 99.3
50 19.2 50.1 100.2 19.2 50.1 100.2 18.4 48.1 96.3
100 17.7 46.4 92.8 17.7 46.4 92.8 16.2 42.2 84.4
150 15.8 45.2 90.5 15.8 45.2 90.5 14.8 38.5 77.0
200 14.0 43.8 87.6 14.0 43.8 87.6 13.7 35.7 71.3
250 12.1 41.7 83.4 12.1 41.7 83.4 12.1 33.4 66.8
300 10.2 38.7 77.5 10.2 38.7 77.5 10.2 31.6 63.3
350 8.4 37.0 73.9 8.4 37.0 73.9 8.4 30.4 60.8
400 6.5 34.5 69.0 6.5 34.5 69.0 6.5 29.1 58.2
425 5.6 28.8 57.5 5.6 28.8 57.5 5.6 28.7 57.3
450 4.7 28.1 56.2
500 2.8 26.8 53.7
525 1.9 25.8 51.6
(1)
CE impact tested materials and standard non-impact tested materials.
(2)
CE non-impact tested materials.
COMPONENTS RATING
The chart at right refects the maximum temperature ratings
for individual components of the Flowseal HPBFV.
Special care should be taken when specifying component
materials for valves at elevated temperatures, especiallymetal
seat valves.
Consult factory if additional information is required re-garding
the suitability of components for specifc pressure/tempera-
ture applications.
Description & Material Temperature
F C
Seat Seal (Soft Seated)
TFE
RTFE
UHMWPE
-100 to 400
-100 to 500
-100 to 200
-73 to 204
-73 to 260
-73 to 93
Seat Seal (Fire-Flow)
TFE/Inconel
RTFE/Inconel
-100 to 400
-100 to 500
-73 to 204
-73 to 260
Seat Seal (Metal Seats)
Inconel 718
316 Stainless Steel
-100 to 1150
-100 to 1000
-73 to 621
-73 to 538
Seat O-Ring
Silicone (Standard with RTFE)
Viton (Standard with TFE)
-100 to 500
-50 to 400
-73 to 260
-46 to 204
Stem Packing
TFE
Graphite
-100 to 500
-100 to 1150
-73 to 260
-73 to 621
Shaft
17-4PH H1150
17-4PH H1150M
316 Stainless Steel
K-Monel 500
Inconel 718
-100 to 800
-100 to 800
-100 to 1150
-100 to 1150
-100 to 1150
-73 to 427
-73 to 427
-73 to 621
-73 to 621
-73 to 621
Bearings
TFE/Fiberglass Composite
RTFE/316 Stainless Steel
Bronze
Steel
316 Stainless Steel
-100 to 500
-100 to 500
-100 to 750
-100 to 1150
-100 to 1000
-73 to 260
-73 to 260
-73 to 339
-73 to 621
-73 to 538
Disc Treatment
Electroless Nickel Plating
Stellite
Malcomizing
-100 to 750
-100 to 1150
-100 to 900
-73 to 399
-73 to 621
-73 to 482
ITEM 0520
Example: 12 - 1WA - 171MTG - 3
Gear Operated
FLOWSEAL ACTUATOR OPTIONS:
Lever:
: l a n o i t p O : e l b a l i a v a s e p y t e v i F : s r o t a r e p O r a e G m r o W
l e e h w n i a h C e c i v r e s e r u t a r e p m e t h g i H
n o i s n e t x e t f a h s t u p t u O e c i v r e s d e i r u B
n o i s n e t x e t f a h s t u p n I e c i v r e s e l b i s r e m b u S
r o t a r e p o l a i c e p s y r a t i l i M e c i v r e s e n i r a M
r o t a r e p o l a i c e p s A W W A l e e h w d n a h m u n i m u l a d r a d n a t S
Hydraulic Actuator:
Pneumatic Actuators: Crane Revo spring return pneumatic actuator
r o t a u t c a c i t a m u e n p g n i t c a e l b u o d o v e R e n a r C
Electric Actuators: Series 44000 electric actuator
e d o C e z i S . 1
2 0 " 2
5 2 0 " 2 / 1 2
3 0 " 3
5 3 0 " 2 / 1 3
4 0 " 4
to
8 4 " 8 4
e d o C s s a l C y d o B . 2
150 PSI Max. Diff. Pressure 0
1 0 5 1 E M S A
3 0 0 3 E M S A
6 0 0 6 E M S A
e d o C e p y T y d o B . 3
W r e f a W
L d e g g u L
D S E D D d e g g u L
4. Shaft Design Code
A t h g i a r t S
Class 150 2" - 12"
Class 150 36" - 48"
Class 300 2" - 12" & 30"
Class 600 2" - 8"
C d e c n a l a B
Class 150 14" - 30"
Derated 36" - 48" (150 psig max.)
Class 300 14" - 24"
Class 600 10" - 16"
5. Body Material Code
1 l e e t S n o b r a C
2 S S 6 1 3
3 l e n o M
4 0 2 y o l l A
Alum Bronze MIL-B-24480 5
Alum Bronze B148 ASTM C958 8
ASTM A744 CN-3MN A
2205 Duplex ASTM A890 Gr 4A B
C O M S 4 5 2
H C y o l l e t s a H
X l a i c e p S
6. Disc Material Code
Alum Bronze/ENP B148 C958 0
2 S S 6 1 3
3 l e n o M
4 0 2 y o l l A
Alum Bronze MIL-B-24480 5
7 d e d i r t i N S S 6 1 3
Alum Bronze B148 ASTM C958 8
9 P N E / S S 6 1 3
ASTM A744 CN-3MN A
C O M S 4 5 2
Hastelloy C/ENP J
X l a i c e p S
7. Shaft Material Code
17-4PH SS (See Note 1) 1
2 S S 6 1 3
Monel (See Note 1) 3
4 0 2 y o l l A
Inconel 718/750 6
7 9 7 4 A m u i l a r r e F
0 0 5 c i n o r t i N
ASTM A744 CN-3MN A
C O M S 4 5 2
X l a i c e p S
8. Seat Material / O-Ring Code
T n o t i V / E F T
N e n e r p o e N / E F T
R * * / E F T R
O S A L F A / E F T R
Polyethylene (UHMWPE) / Viton L
Fire-Flow (TFE & Metal) / Viton F
Fire-Flow (RTFE & Metal)/Viton A
Fire-Flow (RTFE & Metal) / B
Silicone
M l e n o c n I
S S S 0 0 3
Fire-Flow (TFE & Monel) / Viton C
Fire-Flow (RTFE & Monel) / J
Silicone
Fire-Flow (TFE & Hastelloy C) / H
Viton
Fire-Flow (RTFE & Hastelloy C) / K
Silicone
X l a i c e p S
9. Packing Material Code
T E F T
G e t i h p a r G
F w o l F - e r i F
X l a i c e p S
Live-Load Packing/TFE A
Live-Load Packing/Graphite B
Live-Load Packing/Fire-Flow C
EF Seal (Viton O-Rings)/TFE D
10. Bearing Material Code
316 SS Backed TFE H
Stainless Steel Nitrided S
B e z n o r B
K l e n o M
Hastelloy C Backed TFE J
X l a i c e p S
11. Actuator Type Code
B t f a h S e r a B
H e l d n a H t e h c t a R
Ratchet Handle w/Lock L
T e l t t o r h T
3 r a e G m r o W
Worm Gear (4-Way keyed) 9
Pneumatic Double Acting 4
Pneumatic SR Fail Close 5
Pneumatic SR Fail Open 6
7 c i l u a r d y H
8 c i r t c e l E
X r e h t O
12. Special Feature Code
O e n o N
Level 2 Commercial Oxygen Cleaning A
B l a n o i t c e r i d - i B
Chlorine Service C
Dead-end Service (DDES) D
CE Marked (impact tested) PI
CE Marked (non-impact tested) PN
F e c a F t a l F
G e e r F e n o c i l i S
Epoxy Coated Body H
J l e e h w n i a h C
Stem Extension K
L r a e G e l b a k c o L
M 4 2 6 4 2 - V - l i M
NACE Construction N
60 to 125 AARH Facing S
Vacuum Service V
Further Description Required X
13. Series
*Factory Assigned J
Note 1: Shaft materials other than 17-4 PH or Monel will affect
working pressure ratings. Please consult factory.
Note 2: DDES = Double Dead End Service.
Note 3: For CE marked valves, see Body Rating chart on page
16, as temp ranges can vary per material.

** Original may be Silicone or Viton.
FLOWSEAL FIGURE NUMBER SYSTEM
ITEM 0520
0 1 1 W 1 2 1 R A T G B O J
MANUAL AND AUTOMATED
RESILIENT SEAT BUTTERFLY VALVES
INSTALLATION
and
MAINTENANCE
INSTRUCTIONS
CENTER LINE
ITEM 0530
CENTER LINE
936/588-4447
FAX 936/588-4427
CONTENTS
Introduction
Valve Description................................................................................................................................... 3
Valve Design Features .......................................................................................................................... 3
Flange and Pipe Schedule Compatibility ............................................................................................... 3
Gasket Compatibility.............................................................................................................................. 3
Operating Pressures.............................................................................................................................. 3
Product Identification ............................................................................................................................. 3
Installation Recommendations
Valve Ratings ........................................................................................................................................ 4
Valve Seat Position ............................................................................................................................... 4
Disc Clearances .................................................................................................................................... 4
Opening Rotation................................................................................................................................... 4
Installation Position................................................................................................................................ 4
Valve and Flange Preparation ............................................................................................................... 4
Installation Tools.................................................................................................................................... 4
Required Bolting .................................................................................................................................... 4
Unpacking and Storage Instructions...................................................................................................... 4
Pre-Installation Procedure ..................................................................................................................... 5
Valve Installation Procedure ............................................................................................................ 5 & 6
Flange Bolting Recommendations......................................................................................................... 7
Safety Precautions ................................................................................................................................ 8
General Maintenance ............................................................................................................................ 8
Butterfly Valve Disassembly .................................................................................................................. 8
Butterfly Valve Assembly ................................................................................................................. 8 & 9
Check Valve Disassembly ..................................................................................................................... 9
Check Valve Assembly ........................................................................................................................ 10
Ratchet Handle Mounting Procedure .................................................................................................. 10
Manual Gear Mounting Procedure ...................................................................................................... 10
Remote Actuator (Male Drive) Mounting Procedure............................................................................ 10
Remote Actuator (Female Drive) Mounting Procedure ....................................................................... 10
Parts List .............................................................................................................................................. 11
Centerline Figure Number System ................................................................................................. 12-16
2
ITEM 0530
CENTER LINE
936/588-4447
FAX 936/588-4427
SERIES
BODY
DISC
SEAT
RATING PSI
Valve Description
The Center Line Resilient Seat Butterfly Valve (RSBFV) is
designed for use in ASME Class 150 piping systems and is
available in both Wafer and Lug style body designs. The
standard valve size range available is as follows:
Series 200 200 psi Standard BFV 2" to 12"
150 psi Standard BFV 14" to 36"
Series 225 285 psi BFV 2" to 24"
Series 250 285 psi BFV (SS & CS) 2" to 24"
Series 300 Two-piece Stem 2" to 12"
Series 800 Check Valve 2" to 24"
Center Line Series 225 Butterfly Valve are also available
with an ASME Class 300 bolt pattern for Lug bodies of sizes
2" through 12".
Valve Design Features
The unique Center Line seat and disc design insures
positive valve sealing while maintaining low seating torque.
All Center Line Butterfly Valve discs are precision ma-
chined to a half ball profile, providing a precise disc to seat
relationship.
Center Line's cartridge style seat incorporates an elas-
tomer bonded to a phenolic stabilizing ring, eliminating
elastomer movement and reducing seat tearing or fatigu-
ing due to bunching.
Center Line's basic three bushing design completely
isolates the valve shaft from the body, resulting in in-
creased control of the valve disc, lower valve seating
torque, and longer valve life.
The Center Line cartridge seat has a much smaller mass
of elastomer than traditional boot seat designs, limiting
seat swell and the accompaning variations in seating
torque.
Flange and Pipe Schedule Compatibility
The Center Line RSBFV is designed to fit between standard
piping flanges as follows:
ASME 125 Cast Iron Flanges (All Sizes)
ASME 150 Steel Flanges, Schedule 40 (All Sizes)
ASME 150 Steel Flanges, Schedule 80 (2" to 10")
ASME 300 Steel Flanges, Schedule 40 (Series 225 Lug,
2" to 12" only).
When using Schedule 80 piping, special care must be taken
to make sure the valve is centered between the flanges to
prevent damage to the disc edge when opening or closing.
3
INTRODUCTION
SECTION 1
CENTER LINE

Gasket Compatibility
In the Center Line butterfly valve and check valve design, the
elastomer seat extends beyond the valve face and provides
a leakproof seal between the valve and the mating pipe
flange faces. Gaskets are not needed and should not be
used when the valve is installed between standard weld
neck or slip-on type flanges.
Operating Pressures
All Center Line Series 200 and 205 Butterfly Valves are rated
at 200 psi bubble tight shut-off for sizes 2" to 12" and 150 psi
bubble tight shut-off for sizes 14" and larger. Center Line
Series 225 Butterfly Valves are rated for bubble tight shut-
off at 285 psi, while Series 400 Damper Valves which are not
designed for bubble tight shut-off have a body working
pressure of 200 psi. Center Line Series 800 Check Valves
are rated at a minimum pressure differential of 25 psi and a
maximum pressure differential of 150 psi for bubble tight
shut-off.
Product Identification
Each Center Line valve has an identification tag attached to
the valve body. Information on this tag includes the valve
Series Number, materials of construction for the Body, Disc,
and Seat, and the valve Pressure Rating.
ITEM 0530
CENTER LINE
936/588-4447
FAX 936/588-4427
1.
2.
3.
4.
5.
6.
7.
8.
Check the packing list against the valve received to
verify that the size, material, and trim are correct.
Check to make sure that the valve and operator were not
damaged during shipment.
When lifting the valve, take care to avoid damage to the
flange faces, disc sealing edge, or operator.
If the valve is to be stored before being installed, it should
be protected from harsh environmental conditions.
Store the valve with the disc in the almost closed
position to protect the sealing edge and the seat.
Keep the valve in a clean location, away from dirt, debris
and corrosive materials.
Keep the valve in a dry area with the flanges protected
and on a suitable skid or pallet.
Keep the valve in a cool location if possible, out of direct
sunlight.
Opening Rotation
The Center Line valve disc can rotate 360 without damag-
ing the valve or elastomer seat. The valve is designed to
open with either clockwise or counterclockwise rotation of
the shaft.
Valve Ratings
Center Line valves are intended for use at the pressure
indicated on the nameplate attached to each individual
valve. Check the valve operating temperature and pressure
rating before proceeding with installation.
4
SECTION 2
Valve and Flange Preparation
If the valve and mating pipe are properly prepared for
installation, future problems can be avoided. All valve seat
and pipe flange faces should be free of dirt, grit, dents, or
surface irregularities which may disrupt flange sealing and
cause external leakage. The valve disc sealing surface
should also be inspected to eliminate any dirt or foreign
material that will adversely affect the operation of the valve.
Installation Position
To prevent damage to the disc and seat during installation,
the valve disc should be slightly open but not extending
beyond the valve liner face. Positioning the disc in this
almost closed position will reduce seat interference and
initial torque build-up during valve installation.
In general, it is preferable to install RSBFV's with the shaft
in a horizontal orientation. In this position, shaft and disc
weights are evenly distributed, minimizing seat wear.
Additionally, any foreign matter which may accumulate at
the bottom of the disc and shaft is effectively removed
each time the valve is opened.
Center Line butterfly valves are designed to operate be-
tween two flanges. If the valve installation calls for the use
of one pipe flange only, a Lug style valve with Dead End
Service feature must be used.
Disc Clearances
Prior to installing the valve, it is important to make sure the
ID of the pipe and the pipe flanges are large enough to allow
the disc edge to swing into the opening without interference.
Damage to the disc edge can severly affect the performance
of the valve. Flange and pipe schedule compatibility for
Center Line valves is shown in Section 1 of this manual.
Valve Seat Position
All Center Line butterfly valves are completely bi-directional,
so installation is not dependent on seat orientation. For Center
Line Series 800 Check Valves, every effort should be made for
installation with backflow protection (no flow) into the seat side
of the valve. Bubble-tight shutoff will be achieved in this
orientation with 25 to 150 psi P across the valve.
Unpacking and Storage Instructions
Installation Tools
The only tool required in the installation of a Center Line
RSBFV is a wrench suitable for tightening the flange bolts
and/or nuts required to secure the valve in-line. A hoist may
be required to help manipulate valves 10" and larger. Smaller
sized valves can usually be installed by hand. Temporary
pipe supports may be used to keep mating flange faces
parallel in order to aid in valve installation.
Required Bolting
The table outlined on Page 7 is furnished to provide informa-
tion regarding the size, type, and quantity of bolting recom-
mended for the installation of Center Line RSBFV's. This
table is intended for use as a planning and procurement
guide. All recommendations are based on pipe flanges in
accordance with ASME 125/150 specifications. Flange
bolting is not included with the valve shipment.
ITEM 0530
CENTER LINE
936/588-4447
FAX 936/588-4427
Remove any protective flange covers from the valve.
Inspect the valve to be certain the waterway is free from
dirt and foreign matter. Be certain the adjoining pipeline is
free from any foreign material such as rust and pipe scale
or welding slag that could damage the seat and disc
sealing surfaces.
Any actuator should be mounted on the valve prior to
installation to facilitate proper alignment of the disc in the
valve seat.
Check the valve identification tag for materials, and oper-
ating pressure to be sure they are correct for the applica-
tion.
Check the flange bolts or studs for proper size, threading,
and length.
5
Pre-Installation Procedure
1.
2.
3.
4.
5.
Personal injury or property damage
may result if the valve is installed
where service conditions could ex-
ceed the valve ratings.
WARNING!
Position the connecting pipe flanges in the line to insure
proper alignment prior to valve installation. Spread the pipe
flanges apart enough to allow the valve body to be located
between the flanges without actually contacting the flange
surfaces (See Figure 1.) Exercise particular care in handling
the valve so as to prevent possible damage to the disc or seat
faces.
Valve Installation Procedure
For Lug style valves:
a. Place the valve between the flanges.
b. Install all bolts between the valve and the mating
flanges. Hand tighten bolts as necessary.
For Check Valves:
a. Note the opening direction of the disc for proper
valve orientation.
b. Place the valve between the flanges using the four
(4) alignment holes provided.
c. Install the remaining flange bolts, shifting the valve
as necessary to permit the bolts to pass by the valve
body. Hand tighten bolts as necessary.
2.
3.
4.
5.
6.
Before completing the tightening of any bolts, the valve
should be centered between the flanges and then
carefully opened and closed to insure free, unob-
structed disc movement (See Figure 2.)
Using the sequence shown in Figure 3, tighten the
flange bolts evenly to assure uniform compression.
If an actuator is to be used, air hoses or electricity
should be connected to the unit as specified by the
actuator manufacturer.
Cycle the valve to the fully open position, then back to
the fully closed position, checking the actuator travel
stop settings for proper disc alignment. The valve
should be operated to assure that no binding is taking
place.
The valve is now ready for operation.
Remember: Install the valve with the disc in
the ALMOST CLOSED position.
Do not use any flange gaskets.
Correct
Disc positioned in the
almost closed position.
Pipe flange spread allows
sufficient room for valve.
Incorrect
Disc opened beyond valve
body face. Pipe flanges not
spread sufficiently.
Figure 1-Initial Installation of Valve
1. For Wafer style valves:
a. Place the valve between the flanges.
b. Loosely install the two upper and lower flange bolts
that pass through the body alignment holes.
c. Install the remaining flange bolts, shifting the valve as
necessary to permit the bolts to pass by the valve
body. Hand tighten all bolts as necessary.
ITEM 0530
CENTER LINE
936/588-4447
FAX 936/588-4427
Gasket
6
Incorrect
Pipe Flanges mis-aligned.
Uneven torque applied to
bolting.
Correct
Piping aligned.
Thread engagement even
on both sides of valve.
Incorrect
Disc in closed position.
Gaskets installed between
valve and mating flanges.
Correct
No flange gaskets used.
Disc in the almost closed
position.
Figure 2-Centering and Flanging of Valve
Figure 3-Flange Bolt Tightening Sequence
Figure 4-Final Valve Alignment and Tightening of Flange Bolts
1
15
8
12
4
10
6
14 2
16
7
11
3
9
5
13
1
8
4
6 2
7
3
5
1
8
4
6 2
11
7
3
9
5
10
12
1
2
3
4
ITEM 0530
CENTER LINE
936/588-4447
FAX 936/588-4427
7
Flange Bolting Recommendations
2" 5/8-11 4 4.750 5.125 1.250 15-60
2 1/2" 5/8-11 4 5.250 5.375 1.500 15-60
3" 5/8-11 4 5.250 5.375 1.500 15-60
4" 5/8-11 8 5.750 6.000 1.750 15-60
5" 3/4-10 8 6.000 6.375 1.750 25-100
6" 3/4-10 8 6.250 7.000 2.000 25-100
8" 3/4-10 8 6.750 8.000 2.250 25-100
10" 7/8-9 12 7.250 8.500 2.250 50-200
12" 7/8-9 12 7.750 9.750 2.500 50-200
14" 1-8 12 8.250 12.250 2.750 70-300
16" 1-8 16 8.750 11.750 2.750 70-300
18" 1 1/8-7 16 10.000 13.000 3.500 100-400
20" Series 200 1 1/8-7 20 11.250 14.500 4.250 100-400
0 0 4 - 0 0 1 0 5 2 . 4 0 5 2 . 1 1 6 1 7 - 8 / 1 1 5 2 2 s e i r e S " 0 2
0 0 4 - 0 0 1 0 5 2 . 3 0 0 0 . 5 . a e 4 +
24" Series 200 1 1/4-7 20 12.750 15.125 4.750 150-500
0 0 5 - 0 5 1 0 5 7 . 4 0 5 7 . 2 1 6 1 7 - 4 / 1 1 5 2 2 s e i r e S " 4 2
0 0 5 - 0 5 1 0 5 7 . 3 0 5 2 . 5 . a e 4 +
0 0 5 - 0 5 1 0 0 5 . 4 0 5 7 . 3 1 4 2 7 - 4 / 1 1 0 0 2 s e i r e S " 0 3
0 0 5 - 0 5 1 0 5 2 . 4 0 5 7 . 5 . a e 4 +
Center Line Wafer And Lug Valves, 2"-30", ASME 125/150 Bolt Pattern
Valve Thread Number Stud Length Stud Length Bolt Length Req. Torque
Size Size Required Wafer B'y (in.) Check Valve (in.) Lug B'y (in.) (Ft-lbs)
Bolting and torque recommendations are made without a warranty, and apply only to steel weld-neck or slip-on flanges.
The use of lock washers and/or lubrication with the bolting will affect stated torque values.
ITEM 0530
CENTER LINE
936/588-4447
FAX 936/588-4427
SECTION 3
Be sure the line is depressurized and drained.
Be sure of the pipeline media. Proper care should be
taken for protection against toxic and/or flammable
fluids.
Never remove the valve without an Operator (Manual or
Automatic) already attached to the valve shaft.
Never remove the Operator from the valve while the
valve is in the pipeline under pressure.
Always be sure that the disc is in the closed position
before removing the valve.
1.
2.
3.
4.
5.
Thoroughly clean all parts. Inspect components for any
defects.
Apply a small amount of silicone grease to the inside
surfaces of the body, including the upper and lower shaft
holes.
Insert the shaft bushings into the body being careful not to
allow intrusion into the body seat bore.
Install the seat into the center of the body, making sure the
shaft holes in the seat line up with the holes in the body.
1.
2.
3.
4.
8
Resilient Seat
Bushings
Completely coat the inside surfaces of the seat with
silicone grease. Carefully push the disc into the seat in the
open position (90 degrees to the body.) Line up the shaft
holes of the disc as close as possible with the shaft holes
in the seat body.
5.
Disc
1.
2.
3.
4.
5.
6.
Position valve flat with the disc in the closed position.
Loosen the taper pin(s) from the valve disc using a
hammer and punch.
Note: Punch should be of same size or larger
diameter as small end of taper pin to avoid mush-
rooming of taper pin.
Remove taper pin(s) from disc. Extract the valve shaft
from the body using a twisting motion.
Remove the valve disc from body making sure not to
damage the seat or disc sealing edge.
Cartridge seat removal can be accomplished from ei-
ther direction by applying pressure evenly on one face
to push the seat through the body. If the valve is of dead
end service design, remove set screws around periph-
ery of body extending into seat prior to seat removal.
Remove shaft bushings from body as required.
General Maintenance
The following periodic preventative maintenance practices
are recommended for all Center Line Butterfly Valves.
1.
2.
3.
4.
Operate the valve from full open to full closed to assure
operability.
Check flange bolting for evidence of loosening and
correct as needed.
Inspect the valve and surrounding area for previous or
existing leakage at flange faces or shaft connections.
Check piping and/or wiring to actuators and related
equipment for looseness and correct as needed.
Before removing the valve from the line or loosening any
bolts, it is important to verify the following conditions:
Butterfly Valve Assembly Safety Precautions
Butterfly Valve Disassembly
ITEM 0530
CENTER LINE
936/588-4447
FAX 936/588-4427
3
4
6
6
2
1
2
5
7
5
8
8
1
1.
2.
3.
4.
5.
Check Valve Disassembly
Remove set screw (7) from the alignment body (1).
Remove the valve insert (4) from the alignment body (1).
Remove shaft plugs (8) from the insert with a screwdriver.
Note: Plugs are sometimes difficult to loosen. When this
happens, apply heat with small torch directly to the plug for
30 seconds. Do not allow the flame to touch the elastomer
face on either side of the inset.
Remove the shaft (3) from the valve insert.
Note: When the stem is removed, the springs (5) behind
the check plates (2) will be released. On sizes 8" to 20",
these springs must be securely held to prevent recoil upon
loss of tension.
Remove the check valve plates (2) from the valve insert.
Note the location of the thrust washers (6). These must be
replaced in the same location upon reassembly.
Butterfly Valve Assembly
(continued from page 8)
6.
7.
8.
9
Insert the shaft through the body and disc, use a twisting
motion to align the keyway parallel with the disc.
Shaft
Insert taper pin(s) into the disc and set with two or three
sharp blows. Wipe dust shield o-ring with silicone grease
and place over the shaft into the top of the body.
If the valve is of dead end service design, insert set screws
through the body into the seat.
Key
Taper Pins
O-Ring
ITEM 0530
CENTER LINE
936/588-4447
FAX 936/588-4427
with the actuator mounting holes facing up-ward. Fasten
the bracket securely in place with the appropriate ma-
chine bolts, nuts, and lock washers.
Install the drive key in the keyway of the shaft. Tap the key
in place to insure it is fully seated.
proper keyway in the coupling with the key in the shaft.
Rotate the actuator shaft to the full clockwise position.
appropriate machine bolts and lock washers. It may be
necessary to slightly rotate the actuator shaft to align the
mounting holes in the actuator with the mounting bracket.
Adjust the stops in the actuator to position the face of the
position and perpendicular to the face of the valve body in
the open position.
Install the ratchet plate using machine bolts, nuts and lock
washers, but do not tighten the fasteners.
ensure it is fully seated in the keyway .
Install the handle so that it is parallel with the disc face.
The locking lever must be fully retracted before it will pass
through the ratchet plate. Tighten the set screw in the
handle against the key.
With the handle installed flush with the ratchet plate,
engage the locking lever with the ratchet plate. Using the
handle, adjust the position of the ratchet plate until the disc
face is parallel with the valve face, then tighten the
fasteners securely.
Rotate the gear shaft to the full clockwise position. Align
the keyway in the gearbox bore with the key in the shaft
and slide the gearbox onto the shaft.
Fasten the gearbox to the mounting bracket with the
necessary to rotate the gear shaft slightly to align the
mounting holes in the gear with the plate.
Adjust the stops in the gearbox to position the face of the
disc parallel with the face of the valve in the closed position
and perpendicular to the face of the valve in the open
position.
Check Valve Assembly
Place valve plates (2) into the insert (4).
Replace thrust washers (6) in original location.
Install shaft (3) half way into the insert.
Pre-load first spring (5) with 1/2 turn windup. Do not
unwind spring. Legs of spring should be horizontal, 180
apart.
Place spring (5) on shaft (3) and release.
Install shaft (3) just far enough to allow installation of
second spring (5).
Push shaft (3) completely into insert (4).
Replace shaft plugs (8) in insert (4) with pipe thread
sealant and tighten firmly.
Place insert (4) in body (1) with tapped hole in body aligned
with drill point in insert.
Replace set screw (7) and tighten.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Mounting Procedure
1.
2.
3.
4.
5.
6.
7.
10
Ratchet Handle Mounting Procedure
1.
2.
3.
4.
5.
1.
2.
3.
4.
5.
Manual Gear Mounting Procedure
Remote Actuator (Female Drive)
Mounting Procedure
1.
2.
3.
4.
5.
6.
7.
8.
with the actuator mounting holes facing up. Fasten the
bracket securely in place with the appropriate machine
bolts, nuts, and lock washers.
Install the drive key in the shaft. Tap the key in place to
insure it is fully seated.
proper coupling keyway with the key in the shaft.
Install the drive key in the drive coupling. Tap the key
in place to insure it is properly seated.
Rotate the actuator to the full clockwise position. Align
the keyway in the actuator bore with the key in the drive
coupling and slide the actuator on the drive coupling.
necessary to rotate the actuator slightly to align the
actuator with the mounting bracket.
Adjust the stops in the actuator to position the face of
!he disc parallel with the face of the valve body in the
closed position and perpendicular to the face of the
valve body in the open position.
ITEM 0530
CENTER LINE
936/588-4447
FAX 936/588-4427
6
4
7
8
9
3
5
2
10
1
1
4
4
6
5
6
9
8
10
7
7
3
2
1 * Valve Body
2 * Liner (Molded to Item 1)
3 Shaft
4 Shaft Plug (Qty. 2)
5 Plate (Qty. 2)
6 Thrust Washer (Qty. 4)
7 Spring (Qty. 2)
8 Alignment Body
9 Set Screw
10 Plate Travel Stop (14" &
larger only)
1 Body
2 Disc
3* Seat
4 Shaft
5* Taper Pin
6 Key
7* O-Ring
8 Bushing
9 Bushing
10 Bushing
Parts List
Item Description
Item Description
*Recommended Spare Parts
Series 200, 225, 250
Butterfly Valve
Series 800
Check Valve
11
* Items 1 and 2 Must Be
Ordered Together.
6
11
8
Detail A
ITEM 0530
PED Certification: Series 200 valve can be supplied with PED Certification from 2" - 24" only
1 2 3 4 5 6 7 8 9
EXAMPLE: 02 AV02135X-D
2" 200 Wafer Series, Epoxy Coated Ductile Iron Body, 200 PSI, DI-ENP Disc, 416 SS Stem, PTFE
Bushings, EPDM liner, No Operator (Bare Stem), Custom
Center Line Series 200
Custom Product
2. Series/Style Code
200 Wafer - 2" - 30" (
200 Lug - 2" - 30" (Standard)
200 Lug - 2" - 30" DES*
200 Flanged (36" - 42")
* DES = Double Dead End Service
A
B
C
D
3. Body Material Code
Epoxy Coated CI (2" - 12" Standard)
Epoxy Coated DI - A536 (2"-12")
Cast Iron (14" - 30")
Ductile Iron - A536 (14" - 42" Standard)
Ductile Iron - A395 (2" - 30")
S
V
1
2
G
5. Disc Code
DI - ENP (2" - 12")
316 SS
DI - (14" - 42")
Al Brnz. (2" - 42")
Monel 400
2
4
5
6
7
4. Pressure Code
200 PSI (2" - 12")
75 PSI Undercut (8 - 30" )
150 PSI (14" - 42")
125 PSI (2" - 12") PTFE liner
0
3
6
8
9. Actuator Code
Handle
Gear Operator
No Operator
Lockable/Infinite (2" - 6")
Infinite (8")
Pneumatic Double Acting
Pnue. Spring Return - Fail Close
Pneu. Spring Return - Fail Open
Electric
Gear Operator/Memory Stop
Buried Gear w/2" Sq. Nut
2" Nut Direct to Valve Stem
Chain Wheel
2
5
X
3
4
6
7
8
9
G
C
D
U
8. Seat /Liner Code
Buna-N
Abrasion Res. Buna-N
Neoprene (Black)
EPDM
Viton (275 F) std. phenolic backing
Hypalon
Perx. Crd. Buna-N
PTFE/Buna-N**
Viton (400 F)
EPDM (FDA)
White Buna-N (FDA)
Potable Water EPDM
White Buna-N
** 2 & 5" not available
1
2
3
5
6
7
8
L
P
V
W
D
B
7. Bushings Code
Bronze
PTFE
0
3
6. Stem/Shaft Code
416 SS
316 SS *
Monel 400
17-4 PH
* Standard with 316 SS disc only
1
4
7
9
1. Size Code
2"
2"
3"
4"
5"
6"
8"
10"
12"
14"
16"
18"
20"
24"
30"
36"
42"
02
25
03
04
05
06
08
10
12
14
16
18
20
24
30
36
42
10. Custom Code
Special Features
CE Marked - Non Impact Tested
D
P
12
30 A 2 6 5 1 3 P X
ITEM 0530
Electric multi-turn actuators

Operation instructions
SA 07.1 SA 30.1
SAR 07.1 SAR 30.1
with actuator controls
AUMA MATIC AM 01.1 / AM 02.1
for flange type FA
Item: 0520 = SAR07.5-54B/GS63.3

Item 0530 = SA10.1-26B/GS100.3
ITEM 0520,
0530
2
Multi-turn actuators SA 07.1 SA 30.1/ SAR 07.1 SAR 30.1
with actuator controls AUMA MATIC AM 01.1 / AM 02.1 Operation instructions
Table of contents Page
1. Safety instructions 4
1.1 Range of application 4
1.2 Electrical connection 4
1.3 Maintenance 4
1.4 Warnings and notes 4
2. Short description 5
3. Technical data 6
4. Additional information to the wiring diagram legend 9
5. Transport, storage and packaging 10
5.1 Transport 10
5.2 Storage 10
5.3 Packaging 11
6. Mounting to valve/ gearbox 12
7. Mounting positions of the local controls 14
8. Electrical connection 15
8.1 Connection with AUMA plug/ socket connector (S, SH, SE) 17
9. Manual operation 19
10. Operation and indications of the local controls 20
11. Opening the switch compartment 22
11.1 Removing the cover from the switch compartment 22
11.2 Pulling off the indicator disc (option) 22
12. Setting the limit switching 23
12.1 Setting end position CLOSED (black section) 23
12.2 Setting end position OPEN (white section) 23
12.3 Checking the limit switches 23
13. Setting the DUO limit switching (option) 24
13.1 Setting direction CLOSE (black section) 24
13.2 Setting direction OPEN (white section) 24
13.3 Checking the DUO limit switches 24
14. Setting the torque switching 25
14.1 Setting 25
14.2 Checking the torque switches 25
15. Test run 26
15.1 Checking the direction of rotation 26
15.2 Checking the setting of the limit switching 27
15.3 Checking the type of seating 27
15.4 Checking the PTC tripping device (option) 27
16. Setting the potentiometer (option) 29
Scope of these instructions: These instructions valid for multi-turn actuators of the type range
SA 07.1 SA 30.1/ SAR 07.1 SAR 30.1 with
the actuator controls AM 01.1 / AM 02.1.
These operation instructions are only valid for clockwise closing,
i.e. driven shaft turns clockwise to close the valve.
ITEM 0520,
0530
3
Operation instructions with actuator controls AUMA MATIC AM 01.1 / AM 02.1
Page
17. Setting the electronic position transmitter RWG (option) 30
17.1 Setting 2-wire system 4 20 mA and 3- /4-wire system 0 20 mA 31
17.2 Setting 3- / 4- wire system 4 20 mA 32
18. Setting the mechanical position indicator (option) 33
19. Closing the switch compartment 33
20. Actuator controls AUMA MATIC 34
20.1 Functions of the diagnosis LEDs on the interface board (standard version) 34
20.2 Programming the logic board 35
20.3 EMERGENCY - OPEN and EMERGENCY - CLOSE signal (option) 36
21. Electronic positioner (option) 37
21.1 Technical data 37
21.2 Setting 37
21.2.1 Setting type of signal 39
21.2.2 Setting actuator behavior on loss of signal 40
21.3 Positioner adjustment for end position CLOSED (standard version) 41
21.4 Positioner adjustment for end position OPEN (standard version) 43
21.5 Setting the sensitivity 43
21.6 Positioner adjustment for end position OPEN (inverse operation) 45
21.7 Positioner adjustment end position CLOSED (inverse operation) 46
21.8 Positioner in Split Range version (option) 47
21.8.1 Split Range: description of functions 47
21.8.2 Programming 47
21.8.3 Positioner adjustment for Split Range 47
22. Timer (option) 49
22.1 Functions of the diagnosis LEDs (timer) 49
22.2 Setting start and end of stepping mode via DUO limit switching (option) 50
22.3 Setting ON and OFF times 51
23. Fuses 52
23.1 Fuses within the actuator controls 52
23.2 Motor protection 54
24. Enclosure protection IP 68 (option) 55
25. Maintenance 56
26. Lubrication 56
27. Disposal and recycling 56
28. Service 57
29. Spare parts list Multi-turn actuator SA(R) 07.1 SA(R) 16.1 60
30. Spare parts list controls AUMA MATIC 62
Index 63
Addresses of AUMA offices and representatives 64
ITEM 0520,
0530
1. Safety instructions
1.1 Range of application
AUMA actuators are designed for the operation of industrial valves, e.g.
globe valves, gate valves, butterfly valves and ball valves.
For other applications, please consult us. The manufacturer is not liable for any
possible damage resulting from use in other than the designated applications.
Such risk lies entirely with the user.
Observance of these operation instructions is considered as part of the con-
trols/ actuators designated use.
1.2 Electrical connection
During electrical operation, certain parts inevitably carry lethal voltages. Work
on the electrical system or equipment must only be carried out by a skilled elec-
trician themselves or by specially instructed personnel under the control and
supervision of such an electrician and in accordance with the applicable electri-
cal engineering rules.
1.3 Maintenance
The maintenance instructions (refer to page 56) must be observed, otherwise a
safe operation of the actuator is no longer guaranteed.
1.4 Warnings and notes
Failure to observe the warnings and notes may lead to serious injuries or dam-
age. Qualified personnel must be thoroughly familiar with all warnings and notes
in these operation instructions.
Correct transport, proper storage, mounting and installation, as well as careful
commissioning are essential to ensure a trouble-free and safe operation.
During operation, the multi-turn actuator warms up and surface temperatures
> 140 F may occur. Check the surface temperature prior to contact in order to
avoid burns.
The following references draw special attention to safety-relevant procedures in
these operation instructions. Each is marked by the appropriate pictograph.
This pictograph means: Note!
Note marks activities or procedures which have major influence on the correct
operation. Non-observance of these notes may lead to consequential damage.
This pictograph means: Electrostatically endangered parts!
If this pictograph is attached to a printed circuit board, it contains parts which
may be damaged or destroyed by electrostatic discharges. If the boards need to
be touched during setting, measurement, or for exchange, it must be assured
that immediately before a discharge through contact with a grounded metallic
surface (e.g. the housing) has taken place.
This pictograph means: Warning!
Warning marks activities or procedures which, if not carried out correctly, can
affect the safety of persons or material.
4
ITEM 0520,
0530
2. Short description
AUMA multi-turn actuators of the type range SA 07.1 SA 30.1/SAR 07.1
SAR 30.1 are driven by an electric motor and controlled by the actuator con-
trols AUMA MATIC AM 01.1/ AM 02.1, which is included in the scope of delivery.
A handwheel is provided for manual operation.
The limitation of travel is realized via limit switches in both end positions. Torque
seating is also possible in both end positions. The type of seating is determined
by the valve manufacturer.
Both the multi-turn actuator and the controls have a modular design, i.e. they
are designed in accordance with the principle of a modular construction system.
This means that each actuator or each controls are individually manufactured
and combined for a specific valve automation task. An order-specific commis-
sion number, printed on the name plate, is assigned to each actuator/ controls.
Commissioning
Please note that for low temperature versions ( 58 F), the controls requires a
heat-up time.
This heat-up time is applicable in case the actuator and the controls are not live
and have cooled down to ambient temperature. In case commissioning has to
be performed under these conditions, the following heat-up times have to be
observed:
60 min. at 58 F
80 min. at 76 F
5
0
10
20
30
40
50
0 14 4 22 40 76
60
70
80
58
t [min.]
[F]
Figure A: Heat-up time chart
ITEM 0520,
0530
3. Technical data
Features and functions
Type of duty
1)
Standard: SA Short time duty S2 - 15 min
SAR Intermittent duty S4 - 25 %
Option: SA Short time duty S2 - 30 min
SAR Intermittent duty S4 - 50 %
Intermittent duty S5 25 %
Motors Standard: 3-ph AC asynchronous motor, type IM B9 according to IEC 34
Option: Special motors
Insulation class Standard: F, tropicalized
Option: H, tropicalized
Motor protection Standard: Thermoswitches (NC)
Option: PTC thermistors (according to DIN 44082)
Self-locking Yes, for output speeds from 5.6 to 108 rpm
Limit switching Counter gear mechanismfor end positions CLOSEDand OPEN
for 1 to 500 turns per stroke (optional for 1 to 5,000 turns per stroke)
Standard: Tandemswitch (2 NCand 2 NO) for each end position
Options: Single switch (1 NCand 1 NO) for each end position,
switches galvanically isolated
Triple switch (3 NC and 3 NO) for each end position,
switches galvanically isolated
Intermediate position switch (DUO limit switching),
adjustable for any intermediate position
Torque switching Infinitely adjustable torque switching for direction OPEN and CLOSE
Standard: Single switch (1 NC and 1 NO) for each direction
Options: Tandem switch (2 NC and 2 NO) for each direction, switches galvanically isolated
Position feedback signal,
analogue (options)
Potentiometer or 0/4 20 mA (RWG)
For further details, see separate data sheet
Mechanical position indicator
(option)
Continuous indication, adjustable indicator disc with symbols OPEN and CLOSED
Running indication (option) Blinker transmitter
Heater in switch compartment Standard: Resistance type heater with 5 W, 24 V DC
Options: Self-regulating PTC heater, 5 20 W
24 48 V AC/DC, 110 250 V AC/DC or 380 400 V AC
Motor heater (option) SA(R) 07.1 10.1: 12.5 W
SA(R) 14.1 16.1: 25 W
SA(R) 25.1 30.1: 50 W
Manual operation Manual drive for setting and emergency operation, handwheel does not rotate during electrical operation.
Option: Handwheel lockable
Connection to controls AUMA plug/ socket connector with screw type connection
Output drive types A, B1, B2, B3, B4 according to EN ISO 5210
A, B, D, E according to DIN 3210
C according to DIN 3338
Special output drives: AF, AK, AG, IB1, IB3
Power supply, mains frequency
and current consumption
For mains voltage and mains frequency, refer to name plates at the controls and the motor
Permissible variation of the nominal voltage: 10 %
Permissible variation of the mains frequency: 5 %
Motor current consumption: Refer to motor name plate
Current consumption of the controls depending on the mains voltage:
100 to 120 V AC = max. 600 mA
208 to 240 V AC = max. 300 mA
380 to 500 V AC = max. 150 mA
External supply of the
electronics (option)
24 V DC + 20 % / 15 %,
Observe current consumption of the controls
Rated power Refer to motor name plate
Note: The controls is designed for the rated power of the actuator
Overvoltage category Category III
1) Based on 68 F ambient temperature and at an average load with running torque according to Technical data SA or SAR
6
ITEM 0520,
0530
Switchgear Standard: Reversing contactors
2)
(mechanically and electrically interlocked)
for motor power up to 1.5 kW
Options: Reversing contactors
2)
(mechanically and electrically interlocked)
for nominal motor current up to 18 A (OPEN - CLOSE- duty)
or 16 A (modulating duty)
Thyristor unit
3)
(recommended for modulating actuators)
for motor power up to 1.5 kW, 500 V AC with internal fuses
for motor power up to 5.5 kW, 500 V AC, external fuses required
Control Standard: Control inputs 115 V AC, OPEN - STOP - CLOSE (via opto-isolator,
with one common), current consumption: approx. 10 mA per input
Observe min. duration of impulse for modulating actuators
Option: Control inputs 24 V DC, OPEN - STOP - CLOSE (via opto-isolator,
with one common), current consumption: approx. 15 mA per input
Output signals Standard: 5 output relays with gold-plated contacts:
4 potential-free NO contacts with one common:
max. 250 V AC, 0.5 A (resistive load)
Standard configuration:
End position OPEN, end position CLOSED, selector switch REMOTE,
selector switch LOCAL
1 potential-free change-over contact, max. 250 V AC, 0.5A (resistive load)
for collective fault signal
Standard configuration:
Torque fault, phase failure, motor protection tripped
Option: Signals in connection with positioner:
End position OPEN, end position CLOSED
(requires tandem switch within actuator)
Selector switch REMOTE, selector switch LOCAL via 2
nd
level
selector switch
1 potential-free change-over contact, max. 250 V AC, 0.5A (resistive load)
for collective fault signal:
Torque fault, phase failure, motor protection tripped
Voltage output Standard: Auxiliary voltage 115 V AC, max. 30 mA for supply of the control inputs,
3)
,
galvanically isolated from internal voltage supply
Option: Auxiliary voltage 24 V DC, max. 50 mA for supply of the control inputs,
galvanically isolated from internal voltage supply
Local controls Standard: Selector switch LOCAL - OFF - REMOTE(lockable in all three positions)
Push buttons OPEN- STOP- CLOSE
3 indication lights:
End position CLOSED(red), collective fault signal (yellow), end position OPEN(green)
Option: Protection cover, lockable
Functions Standard: Switch-off mode adjustable
Limit or torque seating for end position OPEN and end position CLOSED
Overload protection against excessive torques over the whole travel
Excessive torque (torque fault) can be excluded from collective fault signal
Phase failure monitoring with automatic phase correction
Push-to-run operation or self-retaining in REMOTE
Push-to-run operation or self-retaining in LOCAL
Blinker transmitter signal of actuator can be switched on or off (option)
Options: Positioner
4)
:
Nominal position value via analogue input E1 = 0/4 20 mA
Adjustable behavior on loss of signal
Adjustable sensitivity (dead band) and pause time
Split Range operation
Motor protection evaluation Standard: Monitoring of the motor temperature in combination with thermoswitches
in the actuator motor
Options: Additional thermal overload relay in the controls in combination with thermoswitches
within the actuator
PTC tripping device in combination with PTC thermistors in the actuator motor
Electrical connection Standard: AUMA plug/ socket connector with screw type connection
Options: Parking frame for wall mounting of the disconnected plug
Protection cover for plug compartment (when plug is removed)
2) The lifetime guaranteed by the manufacturer amounts to min. 2 million cycles. If a higher number of switching cycles is to be expected, thyristor units with virtually
unlimited lifetime should be used
3) Not possible in combination with PTC tripping device
4) Requires position transmitter (potentiometer or RWG) in actuator
7
ITEM 0520,
0530
Threads for cable glands Standard: NPT-threads
Options: Pg-threads, G-threads
Wiring diagram Wiring diagram according to commission number included in delivery
Further options for version with RWG in the actuator
Position feedback (option) Analogue output E2 = 0/4 20 mA (load max. 500 )
Service conditions
Enclosure protection according
to EN 60 529
5)
Standard: IP 67
Options: IP 68
IP 67-DS (Double Sealed)
IP 68-DS (Double Sealed)
(Double Sealed = additional protection of the interior of the housing
against ingress of dust and dirt when removing the plug)
Corrosion protection Standard: KN Suitable for installation in industrial units, in water or power plants
with a low pollutant concentration
Options: KS Suitable for installation in occasionally or permanently aggressive
atmosphere with a moderate pollutant concentration
(e.g. in wastewater treatment plants, chemical industry)
KX Suitable for installation in extremely aggressive atmosphere
with high humidity and high pollutant concentration
KX-G Same as KX, however aluminium-free version (outer parts)
Finish coating Standard: Two-component iron-mica combination
Standard color Standard: AUMA silver-grey (similar to RAL 7037)
Option: Other colors are possible on request
Ambient temperature Standard: SA: 25 C to + 70 C
SAR: 25 C to + 60 C
Options: 40 C to + 60 C/ 40 to 140 F, low temperature version
50 C to + 60 C/ 75 to 140 F, extreme low temperature version
incl. heating system
60 C to + 60 C/ 75 to 140 F, extreme low temperature version
incl. heating system
Vibration resistance
according to IEC 60 068-2-6
1 g, from 10 Hz to 200 Hz
Resistant to vibrations during start-up or for failures of the plant. However, a fatigue strength may
not be derived from this.
Applies to actuator with actuator controls, not valid in combination with gearboxes
Lifetime SA 07.1 10.1: 20,000 operations (OPEN - CLOSE - OPEN) with 30 turns per stroke
SA 14.1 16.1: 15,000 operations (OPEN - CLOSE - OPEN) with 30 turns per stroke
SA 25.1 30.1: 10,000 operations (OPEN - CLOSE - OPEN) with 30 turns per stroke
SAR 07.1 10.1: 5 million operations/ starts
6)
SAR 14.1 16.1: 3.5 million operations/ starts
6)
SAR 25.1 30.1: 2.5 million operations/ starts
6)
Weight Multi-turn actuator: Refer to Technical data SA/ SAR
Actuator controls: Approx. 7 kg (including AUMA plug/ socket connector)
Accessories
Wall bracket
7)
AUMA MATIC mounted separately from the actuator, including plug/ socket connector.
Connecting cables on request.
Recommended for high ambient temperatures, difficult access, or in case of heavy vibrations
during service.
Further information
Reference documents Product description Electric multi-turn actuators SA/ SAR
Product description Actuator controls AUMA MATIC
Dimension sheets SA/ SAR ...with integral controls AUMA MATIC
Technical data sheets AM 01.1/AM 02.1
Technical data sheets SA/ SAR
Electrical data sheets SA/ SAR
5) For 3-phase asynchronous motors in enclosure protection IP 68, higher corrosion protection KS or KX is strongly recommended. Additionally, for enclosure protection
IP 68, we recommend to use the double sealed terminal compartment DS. For special motors, the enclosure protection according to the name plate applies
6) The lifetime of modulating actuators depends on the load and the number of starts. A high starting frequency will rarely improve the modulating accuracy. To reach the
longest possible maintenance and fault-free operation time, the number of starts per hour chosen should be as low as permissible for the process
7) Cable length between actuator and AUMA MATIC max. 100 m. Not suitable for version with potentiometer in the actuator. Instead of the potentiometer, an RWG has
to be used in the actuator
8
ITEM 0520,
0530
4. Additional information to the wiring diagram legend
Information A:
A running indication is possible if blinker transmitter (S5) is installed
(opening and closing of contacts).
Direction CLOSE: Connections X
K
6 - X
K
7
Direction OPEN: Connections X
K
6 - X
K
8
Contacts remain closed in end position.
When connected to an external PLC, the blinking signal can be switched off via
the DIP-switches (table 4, page 35).
Information B:
The type of seating in the end positions is determined by the valve manufac-
turer. The setting is done at the programming switches S1-2 and S3-2
(see page 35). The tripping of a torque switch in an intermediate position
switches off the actuator and causes a fault signal.
The limit switches serve for signalization when switching off by torque seating.
They need to be set so that the appropriate switch is tripped shortly before
reaching the end position. If the torque switch trips before the limit switch, the
actuator is switched off and a fault signal is generated.
For further programming possibilities, e.g. self-retaining in operation mode
REMOTE, see table 4, page 35.
Information D:
The following faults are registered and can be transmitted to the control room as
a potential-free collective fault signal:
- Power failure
- Phase failure
- Motor protection tripped
- Torque switch tripped in mid-travel.
This signal can be switched off on the logic board, see table 4, page 35.
Information E:
Input signals according to DIN 19 240.
The nominal operation current of inputs X
K
2, X
K
3, and X
K
4 amounts to
10 15 mA. If the internal voltage 24 V DC is used for remote control, it must
only be connected via potential-free contacts.
Information F:
In case of wrong phase sequence, the running direction is automatically
adjusted. In case of a phase failure, the actuator stops. The fault is indicated at
LED V14 on the interface board (see page 34). For collective fault signal, see
information D.
Information G:
Potential-free contacts are available for signals. The internal control voltage
(X
K
11 / + 24 V and X
K
5 / 24V) must not be used for external lamps, relays,
etc.
Please note that this information only pertains to point to point
drawings.
9
ITEM 0520,
0530
5. Transport, storage and packaging
5.1 Transport
.
For transport to place of installation, use sturdy packaging.
.
Do not attach ropes or hooks to the handwheel for the purpose of lifting by
hoist.
.
If multi-turn actuator is mounted on valve, attach ropes or hooks for the pur-
pose of lifting by hoist to valve and not to multi-turn actuator.
Fitting the handwheel:
For transport purposes, handwheels from a diameter of 400 mm are supplied
separately.
Engage manual operation prior to mounting the handwheel! If
the manual operation is not engaged, damage can occur at the
change-over mechanism.
.
Engage manual operation (figure B-1):
Manually lift the red change-over lever while slightly turning the shaft back and
forth until manual operation engages. The manual operation is correctly
engaged if the change-over lever can be lifted by approx. 85.
Manual force is sufficient for operating the change-over lever. It
is not necessary to use an extension. Excessive force may
damage the change-over mechanism.
.
Install handwheel over the red change-over lever on to the shaft (figure B-1).
.
Release change-over lever (should snap back into initial position by spring
action, figure B), if necessary, push it back manually.
.
Secure handwheel using the snapring supplied.
5.2 Storage
.
Store in well-ventilated, dry room.
.
Protect against floor dampness by storage on a shelf or on a wooden pallet.
.
Cover to protect against dust and dirt.
.
Apply suitable corrosion protection agent to uncoated surfaces.
If multi-turn actuators are to be stored for a long time (more than 6 months), the
following points must be observed additionally:
.
Prior to storage: Protect uncoated surfaces, in particular the output drive parts
and mounting surface, with long-term corrosion protection agent.
.
Check for corrosion approximately every 6 months. If first signs of corrosion
show, apply new corrosion protection.
After mounting, connect actuator immediately to electrical
system, so that the heater prevents condensation.
10
85
Figure B-1 Figure B-2
ITEM 0520,
0530
5.3 Packaging
Our products are protected by special packaging for the transport ex works. The
packaging consists of environmentally friendly materials which can easily be
separated and recycled.
We use the following packaging materials: wood, cardboard, paper, and Poly-
urethane foam. For the disposal of the packaging material, we recommend recy-
cling and collection centers.
11
ITEM 0520,
0530
6. Mounting to valve/ gearbox
.
Prior to mounting the multi-turn actuator must be checked for
damage. Damaged parts must be replaced by original spare
parts.
.
After mounting to valve/ gearbox, touch up any possible dam-
age to paint finish.
The multi-turn actuator leaves the factory in position CLOSED (limit switch
CLOSED tripped).
.
Check if mounting flange fits the valve/ gearbox.
Spigot at flanges should be loose fit!
The output drive types B1, B2, B3, or B4 (figure B-3) are delivered with bore
and keyway (usually according to ISO 5210).
For output drive type A (figure C-1), the internal thread of the stem nut must
match the thread of the valve stem. If not ordered explicitly with thread, the stem
nut is unbored or with pilot bore when delivered. For finish machining of stem
nut, refer to next page.
.
Check whether bore and keyway match the input shaft of valve/ gearbox.
.
Thoroughly degrease mounting faces at multi-turn actuator and valve/ gear-
box.
.
Apply a small quantity of grease to input shaft of valve/gearbox.
.
Place actuator on valve/gearbox and fasten. Fasten bolts
(quality min. grade 5, refer to table 1) evenly crosswise.
12
Figure B-3
Output drive type B1/B2
Plug sleeve
Output drive type B3/B4
Bore with keyway
UNC bolts grade 5 T
A
(ft lbs.)
5
16
- 18 19
3
8
- 16 33
1
2
- 13 78
5
8
- 11 155
3
4
- 10 255
Conversion factor: 1 Nm corresponds to 1.3529 ft lbs.
Table 1: Standard dry fastening torque for bolts
ITEM 0520,
0530
Finish machining of stem nut (output drive type A):
The output drive flange does not have to be removed from the actuator.
.
Remove spigot ring (80.2, figure C-1) from mounting flange.
.
Take off stem nut (80.3) together with thrust bearing (80.01) and thrust bear-
ing races (80.02).
.
Remove thrust bearing and thrust bearing races from stem nut.
.
Drill and bore stem nut and cut thread.
When fixing in the chuck, make sure stem nut runs true!
.
Clean the machined stem nut.
.
Apply Lithium soap EP multi-purpose grease to thrust bearing and races, then
place them on stem nut.
.
Re-insert stem nut with thrust bearings into the mounting flange. Ensure that
dogs are placed correctly in the slots of the hollow shaft.
.
Screw in spigot ring until it is firm against the shoulder.
.
Press Lithium soap EP multi-purpose grease on mineral oil base into the
grease nipple with a grease gun (for quantities, please refer to table):
Protection tube for rising valve stem
.
Seal thread with hemp, Teflon tape, or thread sealing material.
.
Screw protection tube (1) into thread (figure C-2) and tighten it firmly.
.
Push down the sealing (2) to the housing.
.
Check whether cap (3) is available and without damage.
13
Output
drive
A 07.2 A 10.2 A 14.2 A 16.2 A 25.2 A 30.2 A 35.2 A 40.2 A 48.2
Qty
1)
1.5 g 2 g 3 g 5 g 10 g 14 g 20 g 25 g 30 g
1) For greases with a density = 0.9 kg/dm
3
; conversion factor: 1 oz corresponds to 28.35 g
Table 2: Grease quantities for output drive type A
3
1
2
Figure C-1
80.3
80.2
Output drive type A
Stem nut
80.01/80.02
Figure C-2: Protection tube for rising valve stem
ITEM 0520,
0530
7. Mounting positions of the local controls
The mounting position of the local controls is designed according to the order. If,
after mounting the actuator to the valve or the gearbox on site, the local controls
is in an unfavorable position, the mounting position can easily be changed at a
later date.
Four mounting positions are possible:
Changing the mounting position
.
Disconnect actuator from the mains before opening.
.
Turn local controls by a maximum of 180, rotate circuit board
accordingly!
.
Ensure that the wires are neither twisted nor jammed.
.
Loosen 4 bolts and remove the local controls.
.
Turn local controls in one of the four positions and re-place on the actuator,
rotate circuit board accordingly.
.
Clean sealing faces of housing and cover.
.
Check whether O-ring is in good condition.
.
Replace cover on switch compartment and fasten bolts evenly crosswise.
14
Figure D-1: Mounting position A
Actuator
Figure D-2: Mounting position B
Actuator
Figure D-3: Mounting position C
Actuator
Figure D-4: Mounting position D
Actuator
ITEM 0520,
0530
8. Electrical connection
Work on the electrical system or equipment must only be
carried out by a skilled electrician themselves or by specially
instructed personnel under the control and supervision of such
an electrician and in accordance with the applicable electrical
engineering rules.
Wiring diagram
The terminal plan applicable to the actuator is placed inside the terminal com-
partment, the operation instructions are attached to the handwheel in a
weather-proof bag.
External fuse
For short-circuit protection and for protecting the actuator, fuses and disconnect
switches have to be provided by the customer.
The current values for sizing the switch can be derived from the current con-
sumption of the motor plus the current consumption of the controls.
Motor current consumption:
Refer to name plate on motor (nominal current).
Current consumption of the controls depending on the mains voltage:
100 to 120 V AC = max. 650 mA
208 to 240 V AC = max. 325 mA
380 to 500 V AC = max. 190 mA
The maximum permissible fuse for controls with a rated power of 1.5 kW is 16 A
(gL/ gG), and for controls with a rated power of 7.5 kW, the value amounts to 32
A (gL/ gG).
Cable installation in accordance with EMC
Signal and bus cables are susceptible to interference.
Motor cables are interference sources.
.
Lay cables being susceptible to interference or sources of interference at the
highest possible distance from each other.
.
The interference immunity of signal and bus cables increases if the cables are
laid close to the ground potential.
.
If possible, avoid laying long cables and make sure that they are installed in
areas being subject to low interference.
.
Avoid long parallel paths with cables being either susceptible to interference
or interference sources.
.
For the connection of remote position transmitters (potentiometer, RWG),
screened cables must be used.
Heater
As standard, the control unit of the actuator is equipped with a heater to prevent
condensation within the actuator. Unless ordered otherwise, the heater is inter-
nally supplied. For external supply (option), the heater always has to be
connected.
Some actuators are optionally equipped with an additional motor heater. The
motor heater is always externally supplied and has to be connected according
to the wiring diagram.
15
ITEM 0520,
0530
Actuator controls on wall bracket (accessory)
For version on wall bracket, please observe the following:
.
Versions with potentiometer in the actuator are not suitable. Instead of the
potentiometer, an RWG has to be used in the actuator
.
Permissible cable distance between actuator and AUMA MATIC amounts to a
maximum of 100 m.
.
Factory supplied cables for the connection between actuator and AUMA
MATIC on wall bracket can be obtained from AUMA on request.
In case non factory supplied cables are used, the following additionally has to
be observed:
.
Use suitable flexible and screened connecting cables.
.
Connect the wires in correct phase sequence.
Check the direction of rotation before switching on (see page 26)
Subsequent mounting of the actuator controls on the actuator
In case the actuator and the actuator controls have different commission num-
bers (refer to name plates), the designations of the terminal plan and the wiring
diagram (KMS . . .) have to match for both devices.
16
Figure E: AUMA MATIC on wall bracket
Connecting cables
to actuator
ITEM 0520,
0530
8.1 Connection with AUMA plug/ socket connector (S, SH, SE)
Before mains connection
Check whether type of current, supply voltage, and frequency comply with
motor data (refer to name plate at motor):
Opening the terminal compartment
.
Loosen bolts (1) and remove cover (figure G).
.
Loosen screws (2) and remove socket carrier from cover.
.
Insert cable glands suitable for connecting cables
(The enclosure protection stated on the name plate is only ensured if suitable
cable glands are used.).
.
Seal cable entries which are not used with suitable plugs.
17
VD00 63-4/45
Art. No.: Z006.413
3 ~ 480V 60Hz
0.09 kW
Y 0.60A
Current type/mains voltage/mains frequency
NEMA 4X
Thermal protection: Th
Insulation class: F
Enclosure protection
Figure F-1: Version SH (standard) Figure F-2: Version S Figure F-3: Version SE
Figure G: Opening the terminal compartment
Cover
(1)
Socket carrier
(2)
Cable gland and
screw plug
in enclosure protection
according to name plate
ITEM 0520,
0530
Connecting the cables
.
Connect cables according to order-related wiring diagram.
Cross sections:
- Power terminals (U1, V1, W1, U2, V2, W2) and
protective earth (symbol: )
max. 6 mm flexible, max. 10 mm solid
- Control contacts (1 to 50) = max. 2.5 mm
.
All PE conductors have to be tightened firmly to the PE connection
(symbol: ) using either ring lugs (flexible cables), or lugs (solid cables) (fig-
ure H).
Each time the PE connection has been disconnected, it has to
be ensured that the PE conductors are firmly connected.
Screw
Washer
Circlip
Protective earth with ring lugs/lugs
PE connection
Socket carrier
Closing the terminal compartment
.
Insert socket carrier into the cover and fasten with screws (2) (figure G).
.
Clean sealing faces at the cover and the housing.
.
.
Apply a thin film of non-acidic grease (e.g. Vaseline) to the sealing faces.
.
Replace cover and fasten bolts (1) evenly crosswise.
.
Fasten cable glands with the specified torque to ensure the required enclo-
sure protection.
Parking frame, protection cover (accessories)
A special parking frame (figure J) for protection against touching the exposed
contacts and against environmental influences is available.
The open terminal compartment can be closed using a protective cover
(not illustrated).
18
Figure J: Parking frame (accessory)
Parking frame
Figure H: PE connection
ITEM 0520,
0530
9. Manual operation
The actuator may be operated manually for purposes of setting and commis-
sioning and in case of motor failure or power failure.
Manual operation is engaged by an internal change-over mechanism.
Engaging manual operation
.
Lift up change-over lever in the center of the handwheel to approx. 85, while
slightly turning the handwheel back and forth until manual operation engages
(figure K-1).
Manual force is sufficient for operating the change-over lever. It
is not necessary to use an extension. Excessive force may
damage the change-over mechanism.
.
Release change-over lever (should snap back into initial position by spring
action, figure K), if necessary, push it back manually.
Operating the change-over lever while the motor is running
(figure L-1) can lead to increased wear at the change-over
mechanism.
.
Turn handwheel into desired direction (figure 13-2).
Disengaging manual operation
Manual operation is automatically disengaged when motor is started again.
The handwheel does not rotate during motor operation.
19
Figure K-1 Figure K-2
Figure L-1 Figure 13-2
ITEM 0520,
0530
10. Operation and indications of the local controls
Selector switch
Position OFF (0):
- No remote control possible
- No local control possible
- Actuator remains ready for signalization
signalization (the controls power supply is maintained)
Position Local control (I):
The actuator can be operated locally via the push buttons
OPEN - STOP - CLOSE.
Position Remote control (II):
The actuator can be controlled from remote, e.g. via the con-
trol room.
Position Test (III):
Test PTC tripping device (refer to page 27)
Only available in combination with motor protection
(PTC thermistor).
Yellow indication light (fault) is illuminated.
Position Reset (III):
Reset fault signal (yellow indication light) after the motor pro-
tection has tripped (refer to page 54).
Only available in combination with motor protection
(PTC thermistor).
20
Figure M: Local controls
Selector switch
Push buttons Indication lights
I I
0
I I
0
I I
0
Reset
III
Test
III
I II
0
Test
III
Reset
I II
III
0
ITEM 0520,
0530
Push buttons
If the selector switch is in position local control (I), use the push buttons OPEN -
STOP - CLOSE to operate the actuator locally.
OPEN: Actuator runs in direction OPEN
STOP: Actuator stops
CLOSE: Actuator runs in direction CLOSE
The operation commands OPEN - CLOSE can be used for control during
push-to-run operation or in the self-retaining mode.
In the push-to-run operation, the actuator runs as long as the push button is
pressed.
In the self-retaining mode, the actuator runs to the defined end position, unless
another command has been received beforehand.
For further information on the programming, refer to page 35.
Indication lights
The 3 indication lights give the following signals (standard indication).
Illuminated (red): Actuator is in end position OPEN
Collective fault signal (yellow)
Illuminated (green): Actuator is in end position CLOSED
Collective fault signal:
The collective fault signal (yellow indication light) will be activated if one of the
following events occurs:
.
Torque fault, i.e. the set torque (page 25) was exceeded before reaching an
end position.
.
Motor protection has tripped (refer to page 54), i.e. the motor is overheated.
.
A phase failure (for 3-phase AC motors) has occurred.
.
Test PTC tripping device
Indication lights are blinking:
If the actuator is equipped with a blinker, the indication lights can be used as
running indication.
If the blinker transmitter is active (page 35), the respective indication light blinks
during operation.
21
ITEM 0520,
0530
11. Opening the switch compartment
To be able to carry out the following settings (up to and including clause 18.),
the switch compartment must be opened and, if installed, the indicator disc
must be removed.
These settings are only valid for clockwise closing, i.e. driven shaft turns clock-
wise to close the valve.
Work on the electrical system or equipment must only be
carried out by a skilled electrician themselves or by specially
instructed personnel under the control and supervision of such
an electrician and in accordance with the applicable electrical
engineering rules.
11.1 Removing the cover from the switch compartment
.
Loosen 4 bolts and take off the cover at the switch compartment
(figure N-1 or figure N-2).
11.2 Pulling off the indicator disc (option)
.
If installed, pull off indicator disc (figure O). Open end wrench
may be used as lever.
22
Figure N-1: Cover with
indicator glass
Figure N-2: Cover without
indicator glass
D S R
W D R
Figure O: Pulling off the indicator disc
Indicator disc
ITEM 0520,
0530
12. Setting the limit switching
12.1 Setting end position CLOSED (black section)
.
Turn handwheel clockwise until valve is closed.
.
Turn handwheel back by approximately half a turn (overrun). During test run check
overrun and, if necessary, correct setting of the limit switching.
.
Press down and turn setting spindle A(figure P-1) with a flat blade screwdriver
in direction of arrow, thereby observe pointer B.
While a ratchet is felt and heard, the pointer Bmoves 90 every time.
When pointer Bis 90 frommark C, continue turning slowly. When pointer Bhas
reached the mark C, stop turning and release setting spindle. If you override the trip-
ping point inadvertently (ratchet is heard after the pointer has rotated), continue turn-
ing the setting spindle in the same direction and repeat setting process.
12.2 Setting end position OPEN (white section)
.
Turn handwheel counterclockwise until valve is open.
.
Turn handwheel back by approximately a turn (overrun). During test run check
overrun and, if necessary, correct setting of the limit switching.
.
Press down and turn setting spindle D(figure P-1) with a flat blade screwdriver
in direction of arrow, thereby observe pointer E.
While a ratchet is felt and heard, the pointer Emoves 90 every time.
When pointer Eis 90 frommark F, continue turning slowly.
When pointer Ehas reached the mark F, stop turning and release setting spindle. If
you override the tripping point inadvertently (ratchet is heard after the pointer has
rotated), continue turning the setting spindle in the same direction and repeat setting
process.
12.3 Checking the limit switches
The red test buttons T and P(figure P-1) are used for manual operation of the limit
switches.
.
Turning T in direction of the arrowLSC(WSR) triggers limit switch CLOSED.
The green indication light on the local controls is illuminated as long as the test button
is pushed down.
.
Turning Pin direction of the arrowLSO(WL) triggers limit switch OPEN.
The yellowindication light (fault) on the local controls is illuminated.
.
The red indication light on the local controls is illuminated as long as the test button is
pushed down.
23
Figure P-1: Control unit
A
T
B
C
D
P
E
F
ITEM 0520,
0530
13. Setting the DUO limit switching (option)
Any application can be switched on or off via the two intermediate position switches.
For setting, the switching point (intermediate position) must be
approached fromthe same direction as later during
electrical operation.
13.1 Setting direction CLOSE (black section)
.
Move valve to desired intermediate position.
.
Press down and turn setting spindle G(figure P-2) with a flat blade screwdriver
in direction of arrow, while observing pointer H.
While a ratchet is felt and heard, the pointer Hmoves 90 every time.
When pointer His 90 frommark C, continue turning slowly. When pointer Hhas
reached the mark C, stop turning and release setting spindle. If you override the trip-
13.2 Setting direction OPEN (white section)
.
Move valve to desired intermediate position.
.
Press down and turn setting spindle K(figure P-2) with a flat blade screwdriver
in direction of arrow, while observing pointer L.
While a ratchet is felt and heard, the pointer L moves 90 every time.
When pointer L is 90 frommark F, continue turning slowly. When pointer L has
reached the mark F, stop turning and release setting spindle. If you override the trip-
13.3 Checking the DUO limit switches
The red test buttons T and P (figure P-2) are used for manual operation of the
DUO limit switches.
.
Turning T in direction of the arrowTSC(DSR) triggers DUOlimit switch CLOSED.
The torque switch CLOSEDis actuated at the same time.
.
Turning Pin direction of the arrowTSO(DL) triggers DUOlimit switch OPEN.
The torque switch OPENis actuated at the same time.
.
After checking the switches, the fault (red indication light) has to be reset using the
OPENor CLOSEpush buttons of the local controls for operation in the opposite direc-
tion.
24
Figure P-2: Control unit
G
T
H
C
K
P
L
F
ITEM 0520,
0530
14. Setting the torque switching
14.1 Setting
.
The set torque must suit the valve!
.
This setting must only be changed with the consent of the
valve manufacturer!
.
Loosen both lock screws O at the torque dial (figure Q).
.
Turn torque dial P to set it to the required torque.
Example:
Figure Q shows the following setting:
35 ft lbs for direction CLOSE
25 ft lbs for direction OPEN
.
Tighten lock screws O again
.
The torque switches can also be operated in manual
operation.
.
The torque switching acts as overload protection over full
travel, also when stopping in the end positions by limit switch-
ing.
14.2 Checking the torque switches
The red test buttons T and P (figure P-1) are used for manual operation of the
torque switches:
.
Turning T in direction of the arrow TSC (DSR) triggers torque switch
CLOSED.
The yellow indication light (fault) on the local controls is illuminated.
.
Turning P in direction of the arrow TSO (DL) triggers torque switch OPEN.
The yellow indication light (fault) on the local controls is illuminated.
.
If a DUO limit switching (optional) is installed in the actuator, the intermediate
position switches will be operated at the same time.
.
After checking the switches, the fault (yellow indication light) has to be reset
using the OPEN or CLOSE push buttons of the local controls for operation in
the opposite direction.
25
Ft. Lbs
Ft. Lbs
15
3
5
4
5
25
45
2
5
1
5
35
Figure Q: Torque switching heads
Setting CLOSED Setting OPEN
O
P
ITEM 0520,
0530
15. Test run
15.1 Checking the direction of rotation
.
If provided, place indicator disc on shaft.
The direction of rotation of the indicator disc (figure R-1) indicates the direc-
tion of rotation of the output drive.
.
If there is no indicator disc, the direction of rotation can also be observed on
the hollow shaft. For this purpose, remove screw plug (no. 27)
(figure R-2).
.
Move actuator manually to intermediate position or to sufficient distance from
end position.
.
Set selector switch to local control (I) (figure S).
.
Switch on the voltage supply.
.
Press push button CLOSE (figure T-1) and observe the direction
of rotation:
If the indicator disc turns counterclockwise, the direction of rotation
is correct.
If the direction of rotation is wrong, switch off immediately.
Afterwards, correct phase sequence in the connecting cable from the
wall bracket to the actuator and repeat test run.
26
Figure R-1: Indicator disc
CLOSED OPEN
Figure R-2: Opening the hollow shaft
27
S1/S2
Figure S: Selector switch LOCAL
Figure T-1: Push button CLOSE Figure T-2: Push button STOP
ITEM 0520,
0530
15.2 Checking the setting of the limit switching
.
Set selector switch to position OFF (0) (figure U-1).
The controls power supply is maintained in position OFF.
.
Move actuator manually into both end positions of the valve.
.
Check if limit switching is set correctly for both end positions. Hereby observe
that the appropriate switch is tripped in each end position and released again
after the direction of rotation is changed. If this is not the case, the limit
switching must be set again.
When limit switching is set correctly:
.
Set selector switch to local control (I) (figure S).
.
Perform test run at the local controls via push buttons OPEN - STOP -
CLOSE.
15.3 Checking the type of seating
The valve manufacturer states whether switching off in the end positions should
be by limit switch (limit seating) or torque switch (torque seating).
.
For checking the setting, refer to page 35, subclause 20.2.
15.4 Checking the PTC tripping device (option)
.
Turn selector switch to position TEST (wiping) (figure U-2).
If the PTC tripping device is working properly, the tripping of the motor protec-
tion is signaled via the collective fault signal (refer to wiring diagram) and via
the fault indication light on the local controls.
.
Turn selector switch to position RESET (wiping) (figure U-3):
The fault signal is reset if the device is working properly.
27
Figure U-1: Selector switch OFF
Figure U-2: Selector switch TEST
Figure U-3: Selector switch RESET
ITEM 0520,
0530
In case the selector switch position TEST does not initiate a fault signal, the wir-
ing and the selector switch have to be checked by the AUMA service.
If no other options (clauses 16. to 18.) require setting:
.
Close switch compartment (see page 33, clause 19.).
28
ITEM 0520,
0530
16. Setting the potentiometer (option)
For remote indication
.
Move valve to end position CLOSED.
.
Turn potentiometer (E2) clockwise to the stop.
End position CLOSED corresponds to 0 %, end position OPEN to 100 %.
.
Turn potentiometer (E2) slightly back.
Due to the ratio of the reduction gearings for the position trans-
mitter, the complete resistance range is not always utilized for
the whole travel. Therefore, an external possibility for adjust-
ment (setting potentiometer) must be provided.
.
Perform fine-tuning of the zero point at external setting potentiometer
(for remote indication).
29
Figure V: Control unit
E2
ITEM 0520,
0530
17. Setting the electronic position transmitter RWG (option)
For remote indication or external control
After mounting the actuator on the valve, check setting and adjust, if necessary
(refer to subclauses 17.1 or 17.2).
The position transmitter board (figure W) is located under the cover plate
(figure Y).
30
Terminal plans KMS TP_ _ 4 / _ _ _
3- or 4- wire system
KMS TP _ 4 _ / _ _ _
KMS TP _ 5 _ / _ _ _
2-wire system
Output current I
a
0 20 mA, 4 20 mA 4 20 mA
Power
supply
U
v
24 V DC, 15 %
smoothed
14 V DC + (I x R
B
),
max. 30 V
Max. input
current
I 24 mA at 20 mA
output current
20 mA
Max. load R
B
600 (Uv - 14 V) / 20 mA
Table 3: Technical data RWG 4020
Figure W: Position transmitter board
S1
ITEM 0520,
0530
17.1 Setting 2-wire system 4 20 mA and 3- /4-wire system 0 20 mA
.
Connect voltage to electronic position transmitter via AM.
.
.
Connect ammeter for 0 20 mA to measuring points (figure Y-1).
The circuit (external load) must be connected
(observe max. load R
B
), or the appropriate poles at the terminals
(refer to wiring diagram) must be linked, otherwise no value can
be measured.
.
.
Turn potentiometer (E2) back a little.
.
Turn potentiometer 0 clockwise until output current starts to increase.
.
Turn potentiometer 0 back until the following value is reached:
for 3- or 4-wire system: approx. 0.1 mA
for 2-wire system: approx. 4.1 mA.
This ensures that the signal remains above the dead and live zero point.
.
Move valve to end position OPEN.
.
Set potentiometer max. to end value 20 mA.
.
Approach end position CLOSED again and check minimum value
(0.1 mA or 4.1 mA). If necessary, correct the setting.
If the maximum value cannot be reached, the selection of the
reduction gearing must be checked.
31
Figure Y-1
0 (0/4 mA) max. (20 mA)
Meas.point (+)
0/4 20 mA
Meas.point ()
0/4 20 mA
Cover plate E2
ITEM 0520,
0530
17.2 Setting 3- / 4- wire system 4 20 mA
.
Connect voltage to electronic position transmitter via AM.
.
.
Connect ammeter for 0 20 mA to measuring points (figure Y-2).
The circuit (external load) must be connected
(observe max. load R
B
), or the appropriate poles at the terminals
(refer to wiring diagram) must be linked, otherwise no value can
be measured.
.
.
Turn potentiometer (E2) back a little.
.
Turn potentiometer 0 clockwise until output current starts to increase.
.
Turn back potentiometer 0 until a residual current of approx. 0.1 mA is
reached.
.
Move valve to end position OPEN.
.
Set potentiometer max. to end value 16 mA.
.
.
Set potentiometer 0 from 0.1 mA to initial value 4 mA.
This results in a simultaneous shift of the end value by 4 mA, so that the range
is now 4 20 mA.
.
Approach both end positions again and check setting. If necessary, correct the
setting.
If the maximum value cannot be reached, the selection of the
reduction gearing must be checked.
32
Figure Y-2
0 (0/4 mA) max. (20 mA)
Meas. point (+)
0/4 20 mA
Meas. point ()
0/4 20 mA
Cover plate E2
ITEM 0520,
0530
33
18. Setting the mechanical position indicator (option)
.
Place indicator disc on shaft.
.
.
Turn lower indicator disc (figure Z-1) until symbol CLOSED is in alignment
with the mark on the cover (figure Z-2).
.
Move actuator to end position OPEN.
.
Hold lower indicator disc CLOSED in position and turn upper disc with sym-
bol OPEN until it is in alignment with the mark on the cover.
Indicator disc rotates approximately 180 to 230 at full travel from OPEN to
CLOSED or vice versa. For this purpose, a suitable reduction gearing was
installed in our factory.
If the turns per stroke of the actuator are changed at a later date, the reduction
gearing may have to be exchanged.
19. Closing the switch compartment
.
Clean sealing faces of housing and cover
.
.
Apply a thin film of non-acidic grease to the sealing faces.
.
Replace cover on switch compartment and fasten bolts evenly crosswise.
Check the multi-turn actuator for damage to paint finish. If
damage to paint-finish has occurred after mounting, it has to be
touched up to avoid corrosion.
Figure Z-1
Indicator disc
Figure Z-2
Mark
ITEM 0520,
0530
20. Actuator controls AUMA MATIC
20.1 Functions of the diagnosis LEDs on the interface board (standard version)
V14 is illuminated: Phase failure and/ or motor protection tripped.
In combination with motor protection (PTC thermistor)
(option):
Reset by selector switch position III at local controls
V15 is illuminated: Torque fault: Torque switch operated in mid-travel
The LEDs STOP, CLOSE, OPEN indicate the available control commands
(only in selector switch position REMOTE).
34
Figure AA: Positions of the boards within the controls
Timer board
(option)
Cover plate
Interface board
Logic boards
Cover
Positioner board
(option)
Figure AB: Cover plate on interface board
ITEM 0520,
0530
20.2 Programming the logic board
The type of seating limit or torque seating (switch S1-2 and switch S3-2, fig-
ure AC) must be determined by the valve manufacturer.
.
Set desired programming according to table 4 at the switch S2-2.
35
Position 1:
Limit
seating
in end position OPEN
Position 2:
Torque
seating
in end position OPEN
Position 1:
Limit
seating
in end position CLOSED
Position 2:
Torque
seating
in end position CLOSED
S3-2
S1-2
S2-2
Figure AC: Logic board A2
DIP switch S2-2 Programming
(ON = pressed)
Direction CLOSE Direction OPEN
Self-retaining REMOTE
Push-to-run operation REMOTE
Self-retaining LOCAL
Push-to-run operation LOCAL
Blinker transmitter (option)
activated deactivated
Torque fault: Torque switch trip-
ping (in mid-travel) contained in
collective fault signal
included not included
Table 4
ITEM 0520,
0530
20.3 EMERGENCY - OPEN and EMERGENCY - CLOSE signal (option)
(5
th
digit in wiring diagram MSP C, D, or P)
When an EMERGENCY run command is given, the actuator operates the valve
to the predetermined end position (effective in all three selector switch positions:
LOCAL, OFF, REMOTE).
.
The input at terminal X
K
1 (refer to wiring diagram) must be connected to an
NC contact (closed circuit principle).
.
If EMERGENCY - OPEN or EMERGENCY - CLOSE signal is generally not
desired:
Take off cover plate and disconnect links B1 (for EMERGENCY - CLOSE) and
B2 (for EMERGENCY - OPEN).
36
Figure AD: Cover plate for EMERGENCY - OPEN or EMERGENCY - CLOSE option
Links:B1 (EMERGENCY-CLOSE)
B2 (EMERGENCY-OPEN)
LED for
EMERGENCY run command
B2
B1
ITEM 0520,
0530
21. Electronic positioner (option)
21.1 Technical data
21.2 Setting
The positioner in the actuator controls AUMA MATIC is programmed
according to the purchase order details and is set together with the actuator prior to
delivery.
Due to peculiarities of the regulating systemnot known beforehand, a readjustment
may become necessary. Before adjusting the positioner, the programming of the
positioner should be checked.
.
Check programming of the logic board according to subclause 20.2.
The self-retaining REMOTE function (see table 4) must be switched
off in conjunction with the positioner.
.
Take off cover plate (figure AE) and carry out required programming at positioner
board (figure AF) according to tables 6 and 7.
37
Command signal (input signal E1, set value) 0/4 20 mA (option: 0 5 V)
Feedback (input signal E2, actual value) 0 5 V (option: 0/4 20 mA)
Sensitivity (dead band) E (P9) 0.5 % 2.5 %
Fine tuning Sens (P7)
(useful for output speeds < 16 rpm only;
not possible with 1-phase AC motors)
min. 0.25 %
Pause time t-off (P10) 0.5 10 s
Input resistance 250 Ohm
Modulating duty with stepping mode (not required for modulating setting):
Running time t-on (P8)
effective until error is 25 %; then set value is
automatically reduced by 3.
0.5 15 s
Table 5: Technical data for positioner
ITEM 0520,
0530
Prior to setting, it must be ensured that the circuit for the position
feedback E2 (see wiring diagram) is closed (measuring device or
link). In case of missing signal E2, the LED (V10) E1/E2 < 4 mA
(figure AE) is illuminated and the positioner shows no reaction.
21.2.1 Setting type of signal
The signal type (current/ voltage signal) of nominal value E1 and actual value
E2 is set in the factory and marked with a label on the cover plate of the
positioner (refer to figure AE).
For split range version (page 38) and for versions with a setpoint
E1 0/4 20 mA, it is possible to change the type of signalling. For these ver-
sions, the positioner board is equipped with an additional switch S1-7.
38
Figure AE: Cover plate positioner
V10 (red)
P10
P8
Label with signal indication
(in our example: E1 = 4 20 mA, E2 = 4 20 mA)
Figure AF: Positioner board A7
V28
V27
V18
V10
P10
MP2(+)
MP1()
S1-7
P9 (E)
P7 (Sens)
P3 (0)
P4 (max)
S2-7
S3-7
E2{
Meas.
points:
Measuring points: MP3(+)/MP4() for E1
ITEM 0520,
0530
If the setting is subject to subsequent change, the marking also has to be
changed. Furthermore, the wiring diagram indicated on the name plate of the
actuator controls also changes (see page 61).
39
Programming
Command signal
Setpoint E1
Feedback
Actual value E2
1)
via DIP switch S1-7
(see figure AF)
4 20 mA
0 20 mA
4 20 mA
0 20 mA
4 20 mA
0 20 mA
0 5 V
0 5 V
4 20 mA
0 20 mA
0 5 V 0 5 V
0 10 V
4 20 mA
0 20 mA
0 10 V 0 5 V
1) Signals for internal feedback:
0/4 20 mA from electronic position transmitter
or 0 5 V from precision potentiometer 5 k
Table 6: Possible settings
ITEM 0520,
0530
21.2.2 Setting actuator behavior on loss of signal
In case of a loss of signal of nominal value E1 or actual value E2, the reaction of
the actuator can be programmed via the switch S2-7. The complete range of
choices, however, is only available with signals 4 20 mA.
The following reactions are possible:
Fail as is:
Actuator stops immediately and remains in this position.
Fail close
Actuator moves the valve to the end position CLOSED.
Fail open:
Actuator moves the valve to the end position OPEN.
40
Behavior on loss of signal of Prerequisite
1)
Programming
E1 E2
Command signal
Setpoint E1
Feedback
Actual value E2
2)
via DIP switch S2-7
(see figure AF)
fail as is 4 20 mA 4 20 mA
fail close
4 20 mA 4 20 mA
0 20 mA
0 5 V
4 20 mA
fail open
4 20 mA 4 20 mA
4 20 mA
0 20 mA
0 5 V
fail as is fail open 4 20 mA 0 5 V
fail close fail open
4 20 mA
0 20 mA
0 5 V
0 20 mA 4 20 mA
0 20 mA
0 5 V
0 10 V
0 20 mA
0 5 V
fail close fail as is
0 20 mA 4 20 mA
0 10 V 4 20 mA
1) During loss of signal, signals from 0 20 mA and 0 5 V may be misinterpreted since E1 or E2 (without any fault) can also
be < 4 mA (end position CLOSED = 0 mA or 0 V) when working properly.
0/4 20 mA from electronic position transmitter or 0 5 V from precision potentiometer 5 k
Table 7: Possible settings
ITEM 0520,
0530
21.3 Positioner adjustment for end position CLOSED (standard version)
Before beginning the setting of the positioner, it has to be
ensured that the limit and torque switching of the actuator as
well as the feedback have been set (clauses 16. and 17.).
.
Set selector switch (local controls) to position LOCAL.
.
Move multi-turn actuator by pressing push button to
end position CLOSED.
.
Supply nominal value E1 of 0 or 4 mA (see wiring diagram).
.
Turn potentiometer t-off (P10) counterclockwise to the stop
(figure AG).
Missing signals E1/ E2 or wrong polarity are indicated by LED
(V10) E1/E2 < 4 mA" (figures AE or AG)
.
Connect voltmeter to measuring points MP3 and MP4 (figure AG) for measur-
ing the nominal value (0 5 V).
For a nominal value E1 of 0 mA, the voltmeter shows 0 V.
In case nominal value (0 V or 1 V) is not correct:
Correct nominal value signal from control room.
.
Connect voltmeter to measuring points MP2 and MP1 for measuring the
actual value signal.
For an actual value E2 of 0 V, the voltmeter shows 0 V.
If measured value is not correct:
Adjust position feedback according to clause 16. and 17. and repeat
positioner adjustment.
41
I
f
Possible LED display:
(refer to figures AG and AH)
T
h
e
n
Required setting in end position CLOSED:
the LEDs are not illuminated
Turn potentiometer 0 (P3) slowly clockwise until
LED (V27 yellow) is illuminated
LED (V28 green) is
illuminated
LED (V28 green) is no longer illuminated and
LED (V27 yellow)
is illuminated
Turn potentiometer 0 (P3) counterclockwise until
LED (V27 yellow) is no longer illuminated.
Then turn potentiometer 0 (P3) slightly clockwise until
Table 8
ITEM 0520,
0530
42
Figure AG: Positioner board A7
V28
V27
V18
V10
P10
MP4()
MP3(+)
MP2(+)
MP1()
S1-7
P9 (E)
P7 (Sens)
P3 (0)
P4 (max)
S2-7
S3-7
E2{
Meas.
points:
ITEM 0520,
0530
21.4 Positioner adjustment for end position OPEN (standard version)
.
Run multi-turn actuator by pressing push button (local controls) to end posi-
tion OPEN.
.
actual value E2:
When position feedback is set correctly, the voltmeter shows approx. 5 V.
.
Connect max. command signal (nominal value E1) = 20 mA.
.
Connect voltmeter to measuring points MP4 and MP3 for measuring the nom-
inal value E1:
For a nominal value of 20 mA, the voltmeter shows 5 V.
If measured value is not 5 V:
Check the externally supplied command signal E1.
21.5 Setting the sensitivity
.
Set selector switch at the local controls to position REMOTE.
.
Set command signal E1 according to label on cover plate (see figure AH).
The sensitivity (E / dead band) is set to maximum value (2.5 %) in the fac-
tory.
.
The deadband can be increased by turning the potentiometer E (P9) clock-
wise. Left stop = small dead band (= high sensitivity). For a precise setting of
the dead band, a set point device with setting options in the 0.1 mA range is
required.
.
A better sensitivity (E
min
= 0.25 %) can be achieved by turning the potentiom-
eter P7 (sens) clockwise.
When setting E, the following must be observed:
If the number of starts is too high, this will lead to unnecessary
wear at the valve and actuator. Therefore the maximum possible
dead band acceptable for the process must be set.
To prevent exceeding the max. permissible number of starts (refer to Technical
data sheets for modulating actuators) in extreme cases, a pause time between
0.5 s (left stop) and 10s (right stop) may be set with the potentio-
meter t-off (P10).
43
I
f
LED display:
T
h
e
n
Required setting in end position OPEN:
Turn potentiometer max. (P4) slowly counterclockwise until
LED (V28 green) is illuminated
LED (V28 green)
is illuminated
Turn potentiometer max (P4) clockwise until LED (V28 green)
is no longer illuminated.
Then turn potentiometer max (P4) slowly counterclockwise until
LED (V27 yellow)
is illuminated
Turn potentiometer max (P4) slowly counterclockwise until
LED (V27 yellow) is no longer illuminated and
Table 9
ITEM 0520,
0530
44
Figure AH: Cover plate for positioner
Label with signal indication
(in our example: E1 = 4 20 mA, E2 = 4 20 mA)
V28 (green)
V27 (yellow)
V18 (red)
V10 (red)
P10
Figure AI: Cover plate for positioner A7
V28
V27
V18
V10
P10
MP2(+)
MP1()
S1-7
P9 (E)
P7 (Sens)
P3 (0)
P4 (max)
S2-7
S3-7
E2{
Meas.
points:
ITEM 0520,
0530
21.6 Positioner adjustment for end position OPEN (inverse operation)
In standard version the maximum input signal (E1 = 20 mA) results in operation
to end position OPEN.
.
By switching the code switch S3-7 (figure AJ) to position 1, an inversion of
this signal definition (inverse operation) can be achieved.
.
In case an RWG (option) is installed, the connections 7 (red) and 5 (black) on
the positioner board (figure W) of the actuator have to be exchanged.
.
In case a potentiometer is installed, (option) the connections 21 (red) and 22
(black) at XA (connection for actuator) must be interchanged.
Before beginning the setting of the positioner, it has to be
ensured that the limit and torque switching of the actuator as
well as the feedback have been set (clauses 16. and 17.).
.
Set selector switch (local controls) to position LOCAL.
.
Run actuator with push button to end position OPEN .
.
Supply nominal value E1 of 0 or 4 mA (see wiring diagram).
.
Turn potentiometer t-off (P10) counterclockwise to the stop
(figure AJ).
Missing signals E1/ E2 or wrong polarity are indicated by LED
(V10) E1/E2 < 4 mA" (figures AH or AJ)
.
Connect voltmeter to measuring points MP3 and MP4 (figure AJ) for measur-
ing the nominal value (0 5 V).
In case nominal value (0 V or 1 V) is not correct:
Correct nominal value signal in control room.
.
actual value signal.
45
I
f
Possible LED display:
(refer to figures AH and AJ)
T
h
e
n
Required setting in end position OPEN:
LED (V27 yellow)
is illuminated
LED (V27 yellow) is no longer illuminated and
LED (V28 green)
is illuminated
Turn potentiometer 0 (P3) counterclockwise until
LED (V28 green) is no longer illuminated.
Then turn potentiometer 0 (P3) slowly clockwise until
Table 10
ITEM 0520,
0530
21.7 Positioner adjustment end position CLOSED (inverse operation)
.
Run actuator with push button (local controls) to end position CLOSED.
.
actual value E2:
When position feedback is set correctly, the voltmeter shows 5 V.
Adjust position feedback according to clauses 16. and 17. and repeat
.
Connect max. command signal (nominal value E1) = 20 mA.
.
Connect voltmeter to measuring points MP4 and MP3 for measuring the nomi-
nal value E1:
For a nominal value of 20 mA, the voltmeter shows 5 V.
If measured value is not 5 V:
Check the externally supplied command signal E1.
46
I
f
LED display:
T
h
e
n
Required setting in end position CLOSED:
Turn potentiometer max (P4) slowly counterclockwise until
LED (V27 yellow)
is illuminated
Turn potentiometer max (P4) clockwise until LED (V27 yellow)
is no longer illuminated.
Then turn potentiometer max (P4) slowly counterclockwise until
LED (V27 yellow) is illuminated.
LED (V28 green)
is illuminated
Turn potentiometer max (P4) slowly counterclockwise until the
LED (V28 green) is no longer illuminated and
LED (V27 yellow) is illuminated.
Table 11
Figure AJ: Positioner board A7
V28
V27
V18
V10
P10
MP2(+)
MP1()
S1-7
P9 (E)
P7 (Sens)
P3 (0)
P4 (max)
S2-7
S3-7
Meas.
points:
ITEM 0520,
0530
21.8 Positioner in Split Range version (option)
For Split Range, a modified version of the positioner is used. The standard ver-
sion is not suitable for Split Range operation.
Split Range operation is only possible with the position transmitter RWG.
21.8.1 Split Range: description of functions
In Split Range operation, a setpoint is shared by up to four positioners. A typical
example is a pipeline with a bypass. The actuator mounted on the bypass reacts
in the lower range (0 10 mA), the actuator on the main valve in the upper
range (10 20 mA). Other values such as 4 12 mA and 12 20 mA can also
be set.
21.8.2 Programming
DIP 5 at code switch S1-7 must always be in position ON for Split Range ver-
sion.
The further programming of the positioner via the code switch S2-7 can be
made in the same way as during normal operation.
21.8.3 Positioner adjustment for Split Range (see also example further down the page)
.
Supply the specified minimum command signal (nominal value E1) for the
positioner and check by measuring with voltmeter at the measuring points MP3
and MP4 (figure AK).
.
Connect voltmeter between measuring point M3 and measuring point MP1.
Calculate setting value:
Initial value = E 1
min
[in Ampere] x 250 Ohm
Set initial value with potentiometer P5.
.
Supply specified maximum command signal (nominal value E1) and check by
measuring at the measuring points MP3 and MP4.
.
Connect voltmeter between measuring point M9 and measuring point MP1.
Set potentiometer P6 to 5 V.
.
Supply input signal E1 from minimum to maximum value and check the set
range 0 5 V at measuring point M9. If necessary, readjust with P5 or P6.
.
Apply the same procedure to the second actuators positioner and set accord-
ing to the specified nominal values E1.
.
After setting the Split Range operation, perform further readjustment as
described on page 41.
47
Programming
Command signal
Setpoint E1
Feedback
1)
Actual value E2
via DIP switch S1-7
(see figure AK)
4 12/12 20 mA
0 10/10 20 mA
4 20 mA
0 20 mA
4 12/12 20 mA
0 10/10 20 mA
0 5 V
0/4 20 mA from electronic position transmitter
Table 12: Possible settings for Split Range operation
ITEM 0520,
0530
Example:
Two actuators are to be operated in Split Range version. Actuator 1 must be in
position CLOSED with a nominal value signal E1 of 0 mA and in position OPEN
with a signal of 10 mA.
Actuator 2 must be in position CLOSED with a nominal value signal of 10 mA
and in position OPEN with a signal of 20 mA.
.
Positioner actuator 1:
Supply E1 = 0 mA, set with P5 = 0 V at M3 (measured against MP1),
supply E1 = 10 mA, set with P6 = 5V at M9 (measured against MP1).
.
Positioner actuator 2:
Supply E1 = 10 mA, set with P5 = 0 V at M3 (measured against MP1),
supply E1 = 20 mA, set with P6 = 5V at M9 (measured against MP1).
.
Perform adjustments and settings for E2, etc. Afterwards the nominal value E1
can be transmitted through both actuators (connected in series). When oper-
ating within range E1 = 0 10 mA, actuator 1 moves, actuator 2 remains in
end position CLOSED. When operating within range
E1 = 10 20 mA, actuator 2 moves, actuator 1 remains in end position OPEN.
48
Figure AK: Positioner board A7, Split Range version
Meas.points
Meas.points
E1{
E2{
P9 (E)
P7 (Sens)
P3 (0)
P4 (max)
P6
P5
S3-7
S2-7
S1-7
V10 (red)
P10
V18 (red)
V27 (yellow)
V28 (green)
M3
M9
ITEM 0520,
0530
22. Timer (option)
The timer board is used to increase the operating time for the entire or any por-
tion of the valve travel.
Example:
In order to avoid water hammer in long pipelines, stepping mode can be chosen
for any part of the travel.
.
The timer is installed in the actuator controls AUMA MATIC instead of the
interface board.
.
Electronic timer is not possible in combination with positioner.
22.1 Functions of the diagnosis LEDs (timer)
V14 is illuminated: Phase failure and/ or motor protection tripped.
For version with PTC thermistor: reset by
selector switch position III at local controls.
V15 is illuminated: Torque fault: Tripping torque was exceeded before
reaching the end position.
V21 is illuminated: Stepping mode in direction CLOSE is switched on.
V22 is illuminated: Stepping mode in direction OPEN is switched on.
49
Figure AL: Cover plate for timer A1.6
ITEM 0520,
0530
22.2 Setting start and end of stepping mode via DUO limit switching (option)
Start and end of stepping mode can also be set via external switches
(use potential-free contacts).
Direction OPEN, first normal operation then stepping mode
.
Run valve in direction OPEN to the desired start of stepping mode.
.
Press down and turn setting spindle K (figure AM) with screw driver
in direction of arrow, thereby observe LED V22 (figure AL).
Start of stepping mode in direction OPEN is set correctly if the LED changes
from off to on (see sketch on the left).
Direction CLOSE, first normal operation then stepping mode
.
Run valve in direction CLOSE to the desired start of stepping mode.
.
Press down and turn setting spindle G (figure AM) with screw driver
Start of stepping mode in direction CLOSE is set correctly if the LED changes
from off to on (see sketch on the left).
Direction OPEN, first stepping mode then normal operation
.
Run valve in direction OPEN to the desired end of stepping mode.
.
Press down and turn setting spindle K (figure AM) with screw driver
End of stepping mode is correctly set if the LED changes from on to off (see
sketch on the left).
Direction CLOSE, first stepping mode then normal operation
.
Run valve in direction CLOSE to the desired end of stepping mode.
.
Press down and turn setting spindle G (figure AM) with screw driver
End of stepping mode is correctly set if the LED changes from on to off (see
sketch on the left).
50
V 22 off V22 on
normal operation stepping
Start stepping mode OPEN
V 21 on V21 off
stepping normal operation
Start stepping mode CLOSED
Figure AM: Control unit
G K
V 22 on V22 off
stepping normal operation
End stepping mode OPEN
V 21 off V21 on
normal operation stepping
End stepping mode CLOSED
ITEM 0520,
0530
22.3 Setting ON and OFF times
ON and OFF times can be set independently of each other between 1 30 sec-
onds at the 4 potentiometers R10 to R13.
Clockwise rotation: Time extension
Counterclockwise rotation: Time reduction
R10 (t-off) : OFF time in direction OPEN
R11 (t-on) : Running time in direction OPEN
R12 (t-off) : OFF time in direction CLOSE
R13 (t-on) : Running time in direction CLOSE
51
Figure AN: Cover plate for timer A1.6
R 10
R 11
R 12
R 13
ITEM 0520,
0530
23. Fuses
.
Switch off the mains before changing the fuses.
.
When replacing fuses, only fuses according to table 13 may
be used.
23.1 Fuses within the actuator controls
Fuses (figures AP and AO) are accessible after removal of the local controls.
F1/ F2: Primary fuses on power supply unit
F3: Internal 24 V DC supply, RWG, logic board
F4: Internal 115 V AC supply (optional: 24 V AC);
Heater, tripping device for PTC thermistors,
control of reversing contactors, remote operation
.
After replacing the fuses, screw local controls back on again.
52
Figure AO: Fuses on power supply board
F3 F4
Switchgear Voltage supply
(mains voltage)
Voltage output
(power supply unit)
G fuses: (figures AP and AO)
F 1/F 2
(Board A20, refer to
wiring diagram)
F 3*
)
(Boards A2, refer to
wiring diagram)
F 4*
)
(Boards A8, refer to
wiring diagram)
Reversing
contactors
500 V
24 V 1 A T; 500 V
AUMA article no.:
K002.277
500 mA T; 250 V
1.6 A T; 250 V
115 V 0.4 A T; 250 V
> 500 V
24 V 2 A FF; 660 V
AUMA article no.:
K002.665
1.6 A T; 250 V
115 V 0.4 A T; 250 V
Thyristors 500 V
24 V 16 A FF; 500 V
AUMA article no.:
K001.189
1.6 A T; 250 V
115 V 0.4 A T; 250 V
Size 6.3 x 32 mm 5 x 20 mm 5 x 20 mm
*) according to IEC 60127-2/III
Table 13
Figure AP: Fuses on signal and control board
1F2 1F1
ITEM 0520,
0530
Carefully lead cables back into the housing to prevent them
from pinching.
53
ITEM 0520,
0530
23.2 Motor protection
In order to protect against overheating and impermissibly high temperatures at
the actuator, PTC thermistors or thermoswitches are embedded in the motor
winding. The thermoswitch is tripped as soon as the max. permissible winding
temperature has been reached.
The actuator is stopped and the yellow indication light on the local controls is
illuminated.
The motor has to cool down before the operation can be resumed.
Version with thermoswitch (standard)
The actuator can be controlled again after the motor has cooled down.
As soon as the actuator receives a run command (OPEN - CLOSE), the fault
signal (yellow indication light) is no longer illuminated.
Version with thermoswitch and additional thermal overload relay within
the controls (option):
The operation can only be continued after the fault signal (yellow indication
light) has been reset. The fault signal is reset automatically via an overload relay
integrated in the actuator controls after the motor has cooled down.
Version with PTC thermistor (option)
The operation can only be continued after the fault signal (yellow indication
light) has been reset. The fault signal is reset via selector switch position
RESET (figure AQ) of the local controls.
54
Figure AQ: Selector switch RESET
ITEM 0520,
0530
24. Enclosure protection IP 68 (option)
Definition
According to EN 60 529, the conditions for meeting the requirements of enclo-
sure protection IP 68 are to be agreed between manufacturer and user.
AUMA actuators and controls in enclosure protection IP 68 meet the following
requirements according to AUMA:
.
Duration of submersion in water max. 72 hours
.
Head of water max. 6 m
.
Up to 10 operations during submersion
.
Modulating duty is not possible during submersion
Enclosure protection IP 68 refers to the interior of the actuators (motor, gearing,
switch compartment, controls, and terminal compartment).
Inspection
AUMA actuators and controls in enclosure protection IP 68 undergo a routine
testing for tightness in the factory.
Cable glands
.
For the entries of the motor and control cables, appropriate cable glands in
enclosure protection IP 68 must be used. The size of the cable glands must
be suitable for the outside diameter of the cables, refer to recommendations
of the cable gland manufacturers.
.
As standard, actuators and controls are delivered without cable glands. For
delivery, the threads are sealed with plugs in the factory.
.
When ordered, cable glands can also be supplied by AUMA at an additional
charge. For this, it is necessary to state the outside diameter of the cables.
.
The cable glands must be sealed against the housing at the thread with an
O-ring.
.
It is recommended to additionally apply a liquid sealing material
(Loctite or similar).
Commissioning
When commissioning, the following should be observed:
.
Sealing faces of housing and covers must be clean.
.
O-rings of the covers must not be damaged.
.
A thin film of non-acidic grease should be applied to sealing faces.
.
Covers should be tightened evenly and firmly.
After submersion
.
Check actuator.
.
In case of ingress of water, dry actuator correctly and check for proper func-
tion.
Further notes
When using output drive types A and AF (stem nut), it cannot be prevented that
water enters the hollow shaft along the valve stem during submersion. This
leads to corrosion. The water also enters the thrust bearings of output drive type
A, causing corrosion and damage to the bearings. The output drive types A and
AF should therefore not be used during submersion for this application.
55
ITEM 0520,
0530
25. Maintenance
After commissioning, check multi-turn actuator for damage to paint finish. Do a
thorough touch-up to prevent corrosion. Original paint in small quantities can be
supplied by AUMA.
AUMA multi-turn actuators require very little maintenance.
Precondition for reliable service is correct commissioning.
Seals made of elastomers are subject to ageing and must therefore regularly be
checked and, if necessary, be exchanged.
It is also very important that the O-rings at the covers are placed correctly and
cable glands fastened firmly to prevent ingress of dirt or water.
We recommend additionally:
.
If rarely operated, perform a test run about every 6 months. This ensures that
the actuator is always ready to operate.
.
Approximately six months after commissioning and then every year check
bolts between multi-turn actuator and valve/ gearbox for tightness. If required,
tighten applying the torques given in table 1, page 12.
.
For multi-turn actuators with output drive type A: At intervals of approx. 6
months from commissioning, press in Lithium soap EP multi-purpose grease
on mineral oil base at the grease nipple with grease gun (quantity see table 2,
page 13).
26. Lubrication
.
The gear housing is filled with lubricant in the factory.
.
A grease change is recommended after the following operation time:
.
If rarely operated, after 10 12 years.
.
If operated frequently, after 6 8 years.
Lubrication of the valve stem must be done separately.
27. Disposal and recycling
AUMA actuators have an extremely long lifetime. However, they have to be
replaced at one point in time.
The actuators have a modular design and may therefore easily be disassem-
bled, separated, and sorted according to materials, i.e.:
.
electronic scrap
.
various metals
.
plastics
.
greases and oils
The following generally applies:
.
Collect greases and oils during disassembly. As a rule, these substances are
hazardous to water and must not be released into the environment.
.
Arrange for controlled waste disposal of the disassembled material or for sep-
arate recycling according to materials.
.
Observe the regional regulations for waste disposal.
56
ITEM 0520,
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28. Service
AUMA offers extensive services such as maintenance and inspection for actua-
tors as well as various training courses. Addresses of AUMA offices and repre-
sentatives can be found on page 64 and on the Internet (www.auma.com).
57
ITEM 0520,
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Notes
58
ITEM 0520,
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29. Spare parts list Multi-turn actuator SA 07.1 SA 16.1/SAR 07.1 SAR 16.1
59
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ITEM 0520,
0530
Note:
Please state type and commission no. of the device (see name plate) when ordering spare parts. Only original AUMA
spare parts should be used. Failure to use original spare parts voids the warranty and exempts AUMA from any liability.
Delivered spare parts may slightly vary from the representation.
60
001.0 Housing Sub-assembly
002.0 Bearing flange Sub-assembly
003.0 Hollow shaft without worm wheel Sub-assembly
005.0 Worm shaft Sub-assembly
005.1 Motor coupling
005.2 Coupling pin
005.3 Manual drive coupling
005.4 Pull rod
006.0 Worm wheeel
009.0 Planetary gear for manual drive Sub-assembly
010.0 Retaining flange Sub-assembly
017.0 Troque lever Sub-assembly
018.0 Gear segment
019.0 Crown wheel Sub-assembly
020.0 Swing lever Sub-assembly
022.0 Drive pinion II for torque switching Sub-assembly
023.0 Output drive wheel for limit switching Sub-assembly
024.0 Intermediate wheel for limit switching Sub-assembly
025.0 Locking plate Sub-assembly
058.0 Wire for protective earth (pin) Sub-assembly
061.0 Torque switching head Sub-assembly
070.0 Motor (VD motor incl. no. 079.0) Sub-assembly
079.0
Planetary gear for motor drive
(SA/SAR) 07.1 14.1 for VD motor)
Sub-assembly
080.0
Planetary gear for motor drive
(SA/SAR 16.1 for AD90 motor)
Sub-assembly
155.0 Reduction gearing Sub-assembly
500.0 Cover for switch compartment Sub-assembly
501.0 Socket carrier (complete with sockets) Sub-assembly
502.0 Pin carrier without pins Sub-assembly
503.0 Socket for controls Sub-assembly
504.0 Socket for motor Sub-assembly
505.0 Pin for controls Sub-assembly
506.0 Pin for motor Sub-assembly
507.0 Plug cover Sub-assembly
511.0 Screw plug Sub-assembly
514.0 Output drive form A (without stem nut) Sub-assembly
514.1 Axial needle roller bearing Sub-assembly
516.1 Output drive shaft D
535.1 Snap ring
539.0 Screw plug
542.0 Handwheel with ball handle Sub-assembly
549.1 Output socket B3/B4/E
551.1 Parallel key
553.0 Mechanical position indicator Sub-assembly
554.0 Socket carrier with motor cable harness Sub-assembly
556.0 Potentiometer for position transmitter Sub-assembly
556.1 Potentiometer without slip clutch Sub-assembly
557.0 Heater Sub-assembly
558.0
Blinker transmitter including pins at wires
(without impulse disc and insulation plate)
Sub-assembly
559.0-1
Control unit without torque heads swit-
ching and switches
Sub-assembly
559.0-2
control unit with magnetic limit and torque
transmitter (MWG) for Non-intrusive versi-
on in combination with AUMATIC integral
controls
Sub-assembly
560.0-1 Switch stack for direction OPEN
560.0-2 Switch stack for direction CLOSE Sub-assembly
560.1 Switch for limit/torque switching
560.2 Switch case
566.0 Positioner transmitter RWG Sub-assembly
566.1 Potentiometer for RWG without slip clutch Sub-assembly
566.2 Electronic board RWG Sub-assembly
566.3 Wire harness for RWG Sub-assembly
567.1 Slip clutch for potentiometer/RWG Sub-assembly
568.1 Stem protection tube (without cap)
568.2 Cap for stem protection tube
568.3 V-seal
569.0 Change-over lever assy
569.1 Change-over lever
569.2 Notched pin
574.1 Radial seal output drive A for ISO flange
575.1 Stem nut type A
S1 Seal kit, small Set
S2 Seal kit, large Set
No. Designation Type No. Designation Type
ITEM 0520,
0530
30. Spare parts list controls AUMA MATIC
61
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ITEM 0520,
0530
Note:
spare parts should be used. Failure to use original spare parts voids the warranty and exempts AUMA from any liability.
Delivered spare parts may slightly vary from the representation.
62
No. Designation Type
001.0 Housing
002.0 Local controls Sub-assembly
002.5 Selector switch Sub-assembly
003.0 Local controls board Sub-assembly
003.1 Primary fuse
003.2 Fuse cover
004.0 Carrier for contactors
006.0 Power supply including mounting plate Sub-assembly
006.1 Mounting plate for power supply Sub-assembly
006.2 Power supply
006.2-1 Secondary fuse F3
006.2-2 Secondary fuse F4
008.0 Interface board Sub-assembly
008.1 Interface board
008.2 Cover plate for interface board
009.0 Logic board Sub-assembly
013.0 Adapter board Sub-assembly
500.0 Cover Sub-assembly
501.0 Socket carrier (complete with sockets) Sub-assembly
502.0 Pin carrier without pins Sub-assembly
503.0 Socket for controls Sub-assembly
504.0 Socket for motor Sub-assembly
505.0 Pin for controls Sub-assembly
506.0 Pin for motor Sub-assembly
507.0 Plug cover Sub-assembly
508.0 Motor power board Sub-assembly
509.0 Padlock
S1 Seal kit Set
ITEM 0520,
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63
Index
A
Ambient temperature 8
B
Blinker transmitter 35
C
Collective fault signal 34,35
Command signal 37,39,40
Corrosion protection 10,56
Cross sections 18
Current consumption 6,15
D
Direction of rotation 26
Disconnect switches 15
Disposal and recycling 56
DUO limit switching 24
E
Electrical connection 15
Electronic position transmitter RWG
30
2-wire system 31
3-/ 4-wire system 32
EMERGENCY signal 36
Enclosure protection IP 68 55
F
Finish machining of the stem nut 13
Fuses 52
H
Handwheel 19
Heater 15
I
Indicator disc 22,33
Interface board 34
Internet 5
Inverse operation 45,46
L
Limit switching 23,24,27
Local controls 27
Logic board 35
Loss of signal 40
Lubrication 56
M
Mains frequency 6
Maintenance 4
Manual operation 19
Mechanical position indicator 33
Motor protection 54
Mounting positions of the local
controls 14
Mounting to valve/ gearbox 12
N
Name plate 61
O
Output drive types 12
Overvoltage category 6
P
Packaging 10
Pause time 37,51
Position indicator 33
Position transmitter RWG 15,30
Positioner 37
Potentiometer 29
Power supply 6
Protection tube 13
Protective earth 18
PTC thermistors 54
PTC tripping device 27
Push-to-run operation 21,35
R
Rate power 6
Remote indication 29,30
RESET (Selector switch position)
27
Running time 37,51
S
Safety instructions 4
Selector switch 27
Self-retaining 21,35
Sensitivity 43
Service 57
Short description 5
Short-circuit protection 15
Signals 9
Spare parts list 59
Multi-turn actuator 59
Controls 61
Split Range Version 47
Stepping mode
Operating time 49
Pause time 51
Storage 10
T
Technical data 6
TEST (Selector switch position) 27
Test run 26
Thermoswitches 54
Timer 49
Torque setting 25
Transport 10
Tripping torque 25
Type of duty 6
Type of seating 35
W
Wall bracket 16
ITEM 0520,
0530
North American Sales and Service:
US Headquarters and Factory:
AUMA Actuators, Inc.
100 Southpointe Blvd.
Canonsburg PA 15317
Tel: 724-743-AUMA (2862)
Fax: 724-743-4711
email: mailbox@auma-usa.com
www.auma-usa.com
Regional Offices:
Northeast (Maryland and New York)
Southeast (South Carolina)
Midwest (Illinois)
Midwest (Kansas)
Houston (Texas)
West Coast (Northern and Southern California)
Representatives and Distributors
Anchorage
Atlanta
Baltimore
Baton Rouge
Birmingham
Boston
Charlotte
Chicago
Cincinnati
Corpus Christi
Dallas
Denver
Detroit
Hawaii
Houston
Indianapolis
Kansas City
Los Angeles
Mexicali (Mexico)
Mexico City
Milwaukee
Minneapolis
Montana
Monterrey (Mexico)
New York
Omaha
Orlando
Philadelphia
Phoenix
Pittsburgh
Rochester
Salt Lake City
San Diego
San Francisco
San Juan
Seattle
St. Louis
Toronto
Tulsa
International Headquarters:
AUMA Riester GmbH & Co. KG
Muellheim/ Germany
www.auma.com
International Sales and Service:
South America:
Argentina
Brazil
Chile
Colombia
Peru
Venezuela
Europe:
Austria
Benelux
Czech Republic
Denmark
Finland
France
Greece
Hungary
Italy
Norway
Poland
Portugal
Russia
Spain
Sweden
Switzerland
Turkey
Ukraine
United Kingdom
Africa
Egypt
South Africa
Asia, Australia
Australia
China
Hong Kong
India
Japan
Korea
Kuwait
Oman
Qatar
Singapore
Taiwan
Thailand
UAE
For the name and phone number of the office
nearest you, call us at 724-743-2862 or visit our
website at www.auma-usa.com/saleserv.htm
2005-06-27
Y000.176/047/us/1.08
ITEM 0520,
0530
ITEM 0520,
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ITEM 0520,
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ITEM 0520,
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10" Blow Off Valve
ITEM 0520,
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30" Discharge Valve
Part-turn gearboxes
Operation instructions
Worm gearboxes
GS 50.3 GS 250.3
for flange types FA
ITEM 0520,
0530
2
Worm gearboxes GS 50.3 GS 250.3 Operation instructions
Table of contents Page
1. Safety instructions 3
1.1 Range of application 3
1.2 Maintenance 3
1.3 Warnings and notes 3
2. Technical data 4
3. Transport, storage and packaging 7
3.1 Transport 7
3.2 Storage 7
3.3 Packaging 7
4. Fitting the handwheel 7
5. Mounting positions of the different versions 8
6. Mounting multi-turn actuators SA/SAR 9
7. Mounting to valve 11
8. Setting the end stops for manual operation 12
8.1 Worm gearboxes on butterfly valves 12
8.2 Worm gearboxes on ball valves 13
9. Setting the end stops with mounted multi-turn electric actuator 13
9.1 Worm gearboxes on butterfly valves 13
9.2 Worm gearboxes on ball valves 14
10. Changing the swing angle 16
10.1 Changing the swing angle for sizes GS 50.3 GS 125.3 (option) 16
10.2 Changing the swing angle for sizes GS 160.3 GS 250.3 17
11. Enclosure protection IP 68 18
12. Maintenance 19
12.1 General notes 19
12.2 Grease change for worm gearboxes GS 50.3 GS 125.3 and primary reduction gearing
VZ 2.3 VZ 4.3 20
12.2.1 Worm gearboxes 20
12.2.2 Primary reduction gearing 20
GZ 160.3 GZ 250.3 21
12.3.1 Worm gearboxes 21
12.3.2 Single-stage reductions gearings GZ 160.3 GZ 250.3 (reduction ratios 4:1 and 8:1) 21
12.3.3 Double-stage primary reduction gearing GZ 200.3 GZ 250.3 (reduction ratio 16:1) 22
12.4 After maintenance 22
13. Disposal and recycling 23
14. Service 23
15. Spare parts list worm gearboxes GS 50.3 GS 125.3 and reduction gearing
VZ 2.3 VZ 4.3 24
16. Spare parts list worm gearboxes GS 160.3 GS 250.3 26
17. Spare parts list reduction gearings GZ 160.3 GZ 250.3 (reduction ratios 4:1, 8:1 and 16:1) 28
Index 31
Addresses of AUMA offices and representatives 32
Scope of these instructions: These operation instructions are valid for worm gearboxes of the type range
GS 50.3 GS 125.3 with primary reduction gearings VZ 2.3 VZ 4.3. and GS
160.3 GS 250.3 with primary reduction gearings GZ 160.3 GZ 250.3.
ITEM 0520,
0530
1. Safety instructions
1.1 Range of application AUMA worm gearboxes GS 50.3 GS 250.3 are used for the operation of valves
(e.g. butterfly valves and ball valves).
They are designed for manual operation as well as motor operation in conjunction
with electric actuators.
For other applications, please consult us. The manufacturer is not liable for any
possible damage resulting from use in other than the designated applications.
Such risk lies entirely with the user.
Observance of these operation instructions is considered as part of the gearboxes
designated use.
1.2 Maintenance The maintenance instructions (refer to page 19) must be observed, otherwise a
safe operation of the worm gearbox is no longer guaranteed.
1.3 Warnings and notes Non-observance of the warnings and notes may lead to serious injuries or
damage. Qualified personnel must be thoroughly familiar with all warnings and
notes in these operation instructions.
Correct transport, proper storage, mounting and installation, as well as careful
commissioning are essential to ensure a trouble-free and safe operation.
The following references draw special attention to safety-relevant procedures in
these operation instructions. Each is marked by the appropriate pictograph.
This pictograph means: Note!
Note marks activities or procedures which have major influence on the correct
operation. Non-observance of these notes may lead to consequential damage.
This pictograph means: Warning!
Warning marks activities or procedures which, if not carried out correctly, can
affect the safety of persons or material.
3
Operation instructions Worm gearboxes GS 50.3 GS 250.3
ITEM 0520,
0530
4
2. Technical data
Features and functions
Version Standard: clockwise rotation RR, counterclockwise rotation LL, option: RL or LR
Housing material Standard: cast iron (GJL-250), Option: spheroidal cast iron (GJS-400-15)
Self-locking The gearboxes are self-locking when at stand-still under normal service conditions; strong
vibrations may cancel the self-locking effect. While in motion, safe breaking is not guaranteed. If
this is required, a separate brake must be used.
Output torques
End stops Positive for both end positions by traveling nut, sensitive adjustment
Strength of end stop Guaranteed strength of end stop (in ft lbs.) for input side operation
Swing angle
GS 50.3 GS 125.3
Standard: Fixed swing angle up to max. 100; set in the factory to 92 unless ordered otherwise.
Options: Adjustable in steps of:
10 35, 35 60, 60 80, 80 100, 100 125, 125 150,
150 170, 170 190
For version with worm wheel made of bronze: swing angle > 190,
Multi-turn version without end stops, version GSD
3)
Swing angle
GS 160.3 GS 250.3
Standard: Adjustable 80 100; set in the factory to 92 unless ordered otherwise.
Options: Adjustable in steps of: 20 40, 40 60, 60 80,
For version with worm wheel made of bronze: swing angle > 100,
Multi-turn version without end stops, version GSD
3)
Mechanical position indicator Standard: Pointer cover for continuous position indication
Options: Sealed pointer cover for horizontal outdoor installation
4)
Protection cover for buried service instead of pointer cover
Input shaft Cylindrical with parallel key according to DIN 6885.1
Operation
Motor operation With electric multi-turn actuator, directly or through primary reduction gearing VZ/GZ
Flanges for mounting of actuator, refer also to separate technical data sheets.
Type of duty According to actuator
Manual operation
5)
Via handwheel, directly or through primary reduction gearing VZ/GZ
Available handwheel diameters, selection according to the max. output torque:
25.4 mm correspond to 1 inch
1) With worm wheel made of spheroidal cast iron
2) Requires worm wheel made of bronze
3) Special sizing is required
4) For gas applications with sealed pointer cover, an air vent in the pointer cover or venting grooves in the valve mounting flange must be provided
5) Handwheel sizes shown reflect general industrial selection criteria. For information on gearbox/handwheel selection in accordance with AWWA Standard C504, please
refer to separate selection list/chart.
Type Output torques
100 % 140 % 175 %
1)
200 %
1)
Modulating torque
2)
max. ft lbs. max. ft lbs. max. ft lbs. max. ft lbs. max. ft lbs.
GS 50.3 184 258 369 92
GS 63.3 369 516 738 184
GS 80.3 738 1,033 1,475 369
GS 100.3 1,475 2,065 2,950 738
GS 125.3 2,950 4,130 5,900 1,475
GS 160.3 5,900 8,298 10,326 2,950
GS 200.3 11,801 16,595 20,652 5,900
GS 250.3 23,602 32,822 41,303 16,000
Type
GS 50.3 GS 63.3 GS 80.3 GS 100.3 GS 125.3
Reduction gearing VZ 2.3 VZ 3.3 VZ 4.3 VZ 2.3 VZ 3.3 VZ 4.3
Handwheel
mm
160
200
250
250
315
315
400
400
500
315
400
315
400
250
315
500
630
800
400
500
400
500
315
400
Type
GS 160.3 GS 200.3 GS 250.3
Reduction gearing GZ 160.3 GZ 200.3 GZ 250.3
Handwheel
mm
630
800
400 315 500
630
400 315 800
500
630
400
Type
GS 50.3 GS 63.3 GS 80.3 GS 100.3 GS 125.3
Reduction gearing VZ 2.3 VZ 3.3 VZ 4.3 VZ 2.3 VZ 3.3 VZ 4.3
ft lbs. 185 330 330 370 185 370 185
Type
GS 160.3 GS 200.3 GS 250.3
Reduction gearing GZ 160.3 GZ 200.3 GZ 250.3
Reduction ratio 4:1 8:1 4:1 8:1 16:1 4:1 8:1 16:1
ft lbs. 370 330 370 370
ITEM: 0520
ITEM: 0530
ITEM 0520,
0530
Primary reduction gearing
Primary reduction gearing Planetary gear with various reduction ratios for reducing the input torques
Valve attachment
Valve attachment Dimensions according to SP 101
Standard: GS 50.3 GS 125.3: without spigot
GS 160.3 GS 250.3: without spigot
Options: GS 50.3 GS 125.3: with spigot
GS 160.3 GS 250.3: with spigot
Splined coupling for connection
to the valve shaft
Standard: without bore or pilot bore from GS 160.3
Worm gearbox can be repositioned 4 x 90 on coupling
Options: Machined with bore and keyway, square bore or bore with two-flats
Service conditions
Enclosure protection according
to EN 60 529
6)
Standard: IP 68-3, dust and water tight up to max. 3 m head of water
Options
7)
: IP 68-6, dust and water tight up to max. 6 m head of water
IP 68-10, dust and water tight up to max. 10 m head of water
IP 68-20, dust and water tight up to max. 20 m head of water
Corrosion protection Standard: KN Suitable for installation in industrial units, in water or power plants
with a low pollutant concentration
Options: KS Suitable for installation in occasionally or permanently aggressive
atmosphere with a moderate pollutant concentration
(e.g. in wastewater treatment plants, chemical industry)
KX Suitable for installation in extremely aggressive atmosphere
with high humidity and high pollutant concentration
Paint Standard: GS 50.3 GS 125.3: Two-component iron-mica combination
GS 160.3 GS 250.3: Two-component iron-mica combination
Color Standard: Grey (DB 702, similar to RAL 9007)
Option: Other colors on request
Ambient temperature Standard: 20 F to + 175 F/ 25 C to + 80 C
Options: 40 F to + 140 F/ 40 C to + 60 C (low temperature), version L
75 F to + 140 F/ 60 C to + 60 C (extreme low temperature), version EL
+ 32 F to + 250 F/ 0 C to + 120 C (high temperature), version H
Lifetime Open-close duty: The lifetime is based on a load profile typical for part-turn valves
Modulating duty: min. 2.5 million operations
8)
6) Refer to section enclosure protection IP 68
7) Not available for GS 50.3
8) With worm wheel made of spheroidal cast iron
9) The lifetime for modulating duty depends on the load and the number of starts. A high starting frequency will rarely improve the modulating accuracy. To reach the
longest possible maintenance and fault-free operation time, the number of starts per hour chosen should be as low as permissible for the process
5
Type Operating cycles (OPEN - CLOSE - OPEN)
for swivel movements of 90 (max. 100)
and a maximum output torque of
100 % 140 % 175 %
8)
200 %
9)
GS 50.3 15,000 5,000 1,000
GS 63.3 15,000 5,000 1,000
GS 80.3 15,000 5,000 1,000
GS 100.3 15,000 5,000 1,000
GS 125.3 15,000 5,000 1,000
GS 160.3 15,000 5,000 1,000
GS 200.3 15,000 5,000 1,000
GS 250.3 10,000 3000 750
ITEM 0520,
0530
6
Accessories
Valve position indicators Valve position indicator WSG for the signalization of intermediate and end positions for precise
and low-backlash feedback for swing angles ranging from 82 98
(refer to separate data sheet)
Valve position indicator WGD for signalization of intermediate and end positions for swing
angles > 180 (refer to separate data sheet)
Limit switching Limit switching WSH for manually operated valves. For the signalization of intermediate and
end positions (refer to separate data sheet)
Further information
Reference documents Product description Worm gearboxes GS 50.3 GS 250.3 /GS 315 GS 500
Dimension sheets GS 50.3 GS 125.3, GS 160.3 GS 250.3
Technical data GS 50.3 GS 125.3, GS 160.3 GS 250.3
Technical data SA, SAR, WSG, WGD, WSH
Lever gearboxes See separate documents
ITEM 0520,
0530
3. Transport, storage and packaging
3.1 Transport
.
Transport to place of installation in sturdy packing.
.
If mounted together with actuator:
Attach ropes or hooks for the purpose of lifting by hoist only to the gearbox and
not to the actuator.
.
If eyebolts are supplied with the gearbox, they should be used to lift the gearbox
only and not the valve
3.2 Storage
.
Store in well-ventilated, dry room.
.
Protect against floor dampness by storage on a shelf or on a
wooden pallet.
.
Cover to protect against dust and dirt.
.
Apply suitable corrosion protection agent to bare surfaces.
In case worm gearboxes are to be stored for a long period
(more than 6 months), the following points must be observed additionally:
.
Prior to storage: Protect bare surfaces, in particular the output drive parts and
mounting surface, with long-term corrosion protection agent.
.
Check for corrosion approximately every 6 months. If first signs of corrosion
show, apply new corrosion protection.
3.3 Packaging Our products are protected by special packaging for the transport ex works. The
packaging consists of environmentally friendly materials which can easily be
separated and recycled.
For the disposal of the packaging material, we recommend recycling and collection
centers.
4. Fitting the handwheel For worm gearboxes designed for manual operation the handwheel may be
supplied separately. Fitting is done on site according to figure A.
7
Figure A: Handwheel
Ball handle
(option)
Spacer
(may be required)
Circlip
Handwheel
Worm shaft
gearbox
Circlip
Spacer
(may be required)
ITEM 0520,
0530
5. Mounting positions of the different versions
8
C
RR
RL
B
RR
RL
D
RR
RL
B C
LL
LR
D
LL
LR
A
LL
LR
A
RR
RL
GS versions LL / LR
Description of the 4 versions (viewed at the pointer cover):
LL
LR
RR LL RL LR
Mounting positions of AUMA multi-turn actuator with AUMA worm gearbox (please indicate when ordering)
GS versions RR / RL
Mounting positions can easily be changed at a later date.
Limitation: For SA/SAR 14.1/14.5 with GS 125.3, mounting position C in version RR/RL and A in version LL/LR is
only possible for a handwheel diameter up to 12.4 .
Up to size GS 125.3, the actuator-gearbox combination is delivered in the ordered mounting position. For packing
reasons, actuator and gearbox is delivered separately from size GS 160.3.
Code Direction of rotation at input shaft Position of worm shaft Direction of rotation at output drive
RR clockwise Right side clockwise
LL clockwise Left side counterclockwise
RL clockwise Right side counterclockwise
LR clockwise Left side clockwise
ITEM 0520,
0530
6. Mounting multi-turn actuators SA/SAR
When gearboxes and multi-turn actuators are supplied together, the mounting has
been done in the factory up to gearbox size GS 125.3. For sizes GS 160.3 and
larger, the mounting of gearboxes is performed as follows.
In case flange for actuator is not attached to gearbox or
reduction gearing:
.
Thoroughly degrease the mounting faces of the gearbox or reduction gearing as
well as the flange for actuator.
.
For GS 100.3 GS 250.3:
Insert pin in the corresponding groove of the bearing cover.
.
Fit flange for actuator and fasten with bolts and lock washers.
.
Fasten bolts crosswise with a torque according to table 2.
Mounting the multi-turn actuator:
.
Thoroughly degrease the faces of the flange for actuator at the gearbox or
reduction gearing as well as the actuators bearing flange.
.
Place the multi-turn actuator on the worm gearbox or reduction gearing. The
multi-turn actuator can be mounted on the valve at every 90
(see page 8, mounting positions).
.
Ensure that the spigot mates uniformly in the recess and that the mounting faces
are in complete contact.
.
Fasten actuator with bolts and lock washers (see table 1) at the flange of the
worm gearbox.
.
Do not attach ropes or hooks for the purpose of lifting the actuator
by hoist to the handwheel. If multi-turn actuator is mounted on
gearbox, attach ropes or hooks for the purpose of lifting by hoist
to gearbox and not to multi-turn actuator.
9
Figure B: Mounting multi-turn actuator to worm gearbox
Flange for actuator
Flange for actuator
Primary
reduction
gearing
Bearing flange
Bearing flange
ITEM 0520,
0530
10
Worm gearbox/
primary
reduction gearing
SA(R) 07.1-FA10 SA(R) 07.5-FA10
Bolt
(UNC)
Lock
washer
Qty.
Bolt
(UNC)
Lock
washer
Qty.
GS 50.3 3/8-16x1 3/8 4
GS 63.3 3/8-16x1 3/8 4 3/8-16x1 3/8 4
GS 80.3
3/8-16x1 3/8 4
GS 100.3
GS 100.3/VZ 3/8-16x1 3/8 4 3/8-16x1 3/8 4
GS 125.3
GS 125.3/VZ
3/8-16x1 3/8 4
GS 160.3
GS 160.3/GZ 3/8-16x1 3/8 4 3/8-16x1 3/8 4
GS 200.3
GS 200.3/GZ 3/8-16x1 3/8 4 3/8-16x1 3/8 4
Worm gearbox/
primary
reduction gearing
SA(R) 10.1-FA10 SA(R) 14.1-FA14 SA(R) 14.5-FA14 SA(R) 16.1-FA16
Bolt
(UNC)
Lock
washer
Qty.
Bolt
(UNC)
Lock
washer
Qty.
Bolt
(UNC)
Lock
washer
Qty.
Bolt
(UNC)
Lock
washer
Qty.
GS 63.3 3/8-16x1 3/8 4
GS 80.3 3/8-16x1 3/8 4
GS 100.3 3/8-16x1 3/8 4 5/8-11x1
1
2
5/8 4
GS 100.3/VZ 3/8-16x1 3/8 4
GS 125.3 5/8-11x1
1
2
5/8 4 5/8-11x1
1
2
5/8 4
GS 125.3/VZ 3/8-16x1 3/8 4 5/8-11x1
1
2
5/8 4
GS 160.3 5/8-11x1
1
2
5/8 4
3
4
-10x2 3/4 4
GS 160.3/GZ 3/8-16x1 3/8 4 5/8-11x1
1
2
5/8 4
GS 200.3
3
4
-10x2 3/4 4
GS 200.3/GZ 3/8-16x1 3/8 4 5/8-11x1
1
2
5/8 4 5/8-11x1
1
2
5/8 4
GS 250.3
GS 250.3/GZ 3/8-16x1 3/8 4 5/8-11x1
1
2
5/8 4 5/8-11x1
1
2
5/8 4
3
4
-10x2 3/4 4
Worm gearbox/
primary
reduction gearing
SA(R) 25.1-FA25 SA(R) 30.1-FA30
Bolt
(UNC)
Lock
washer
Qty.
Bolt
(UNC)
Lock
washer
Qty.
GS 160.3
GS 160.3/GZ
GS 200.3 5/8-11x2 5/8 8
GS 200.3/GZ
GS 250.3 5/8-11x2 5/8 8
3
4
-10x2 3/4 8
GS 250.3/GZ
Table 1: Bolts for mounting AUMA actuators to worm gearboxes/ primary reduction gearing
(strength class min. 8.8)
ITEM 0520,
0530
7. Mounting to valve AUMA worm gearboxes GS and primary reduction gearings VZ/GZ can be
operated in any mounting position.
.
For butterfly valves, the recommended mounting position is end position
CLOSED
(Prior to mounting, bring the gearbox to the mechanical end stop CLOSED by
turning the handwheel clockwise).
.
For ball valves, the recommended mounting position is end position OPEN
(Prior to mounting, bring the gearbox to the mechanical end stop OPEN by
turning the handwheel counterclockwise).
.
Alternatively, the limit stop housing can be turned up to the end position of the
respective valve.
.
Thoroughly degrease mounting faces of gearbox and valve.
.
Place coupling sleeve onto valve shaft and secure (refer to figure C, detail A or B),
ensure that dimensions X, Y, and Z are observed (refer to table 2).
.
Apply non-acidic grease at splines of coupling.
.
Mount gearbox on valve. Ensure that the spigot (if provided) mates uniformly in the
recess and that the mounting faces are in complete contact.
.
Fasten gearbox with bolts (quality min. 8.8) and lock washers.
.
Note:
Experience showed that it is very difficult to fasten bolts or nuts of 1-8 UNC or
larger with the defined torques. The worm gearbox may be moved radially against
the valve flange by accident.
To improve adhesion between valve and gearbox, we recommend to apply
Loctite 243 (or similar products) on mounting faces.
11
A
X
B
Z
Y
Figure C
Coupling
Valve
Grub screw
Gearbox Dimensions Bolts Strength class
Grade 5
Flange type X
max
Y max Z max Qty. x threads
(UNC)
Fastening torque T
A
[Ft lbs.]
GS 50.3-FA10 14 5 61 4 x
3
8
- 16 33
GS 63.3-FA10 7 18 73 4 x
3
8
- 16 33
GS 63.3-FA12 10 13 76 4 x
1
2
- 13 78
GS 80.3-FA14 23 5 88 4 x
5
8
- 11 155
GS 100.3-FA14 22 13 123 4 x
5
8
- 11 155
GS 100.3-FA16 22 8 123 4 x
3
4
- 10 257
GS 125.3-FA16 17 35 126 4 x
3
4
- 10 257
GS 125.3-FA25 17 27 126 8 x
5
8
- 11 155
GS 160.3-FA25 15 11 130 8 x
5
8
- 11 155
GS 160.3-FA30 30 0 140 8 x
3
4
- 10 255
GS 200.3-FA30 19 19 160 8 x
3
4
- 10 255
GS 200.3-FA35 44 0 190 8 x 1 - 8 590
GS 250.3-FA35 8 8 220 8 x 1 - 8 590
GS 250.3-FA40 13 0 230 8 x 1
1
4
- 7 1,200
Table 2: Standard dry fastening torques for bolts
ITEM 0520,
0530
8. Setting the end stops for manual operation
If worm gearboxes GS are supplied on a valve the end stops are
already set by the valve manufacturer.
8.1 Worm gearboxes on butterfly valves
Setting end position CLOSED
.
Remove all bolts (03) at limit stop housing (figures D, E).
.
Turn valve manually to end position CLOSED.
.
In case limit stop housing (10) has not yet rotated, turn it clockwise up to the
stop.
.
If the holes of limit stop housing (10) do not align with the threads of the housing
(1), take off the limit stop housing (10) and replace it in the required position.
.
Fasten bolts (03) with lock washers (04).
.
.
If the position of the pointer cover does not correspond to the symbol CLOSED,
slightly loosen the screws of the pointer cover. Turn the pointer cover to the
CLOSED symbol and fasten the screws again.
Setting end position OPEN The end stop need not be set since the required swing angle has been set in the
factory.
If the swing angle does not match, refer to section 10.
12
Gearbox End stops fas-
tened with
bolts (03)
Material Protective cap
fastened with
bolts (054)
Material Fastening torque
T
A
[Nm]
GS 50.3 M 8 A2-80 24
GS 63.3 M 8 A2-80 24
GS 80.3 M 8 A2-80 24
GS 100.3 M 12 A2-80 82
GS 125.3 M 12 A2-80 82
GS 160.3 M 10 A2-80 M 6 A2-80 48
GS 200.3 M 12 A2-80 M 6 A2-80 82
GS 250.3 M 16 A2-80 M 6 A2-80 200
Conversion factor: 1 Nm corresponds to 0.74 ft lbs.
Table 3
03/04
10 1
Figure D: End stop up to GS 125.3
03/04
10 1
Figure E: End stop from GS 160.3
ITEM 0520,
0530
8.2 Worm gearboxes on ball valves
In case end stops require adjustment, set end position OPEN first.
If the exact end position of the valve cannot be seen through a
position marking at the valve shaft, the setting may have to be
done with the valve removed.
Setting end position OPEN
.
Remove all bolts (03) at limit stop housing (10) (figures D, E).
.
Turn valve manually to end position OPEN.
.
In case limit stop housing (10) has not yet rotated, turn it counterclockwise up to
the stop.
.
If the holes of limit stop housing (10) do not align with the threads of the housing
(1), take off the limit stop housing (10) and replace it in the required position.
.
.
If the position of the pointer cover does not correspond to the symbol OPEN,
OPEN symbol and fasten the screws again.
Setting end position
CLOSED
The end stop need not be set since the required swing angle has been set in the
factory.
9. Setting the end stops with mounted multi-turn electric actuator
.
If worm gearboxes GS and multi-turn actuators are supplied on a
valve, the end stops as well as limit and torque switching should
already have been set by the valve manufacturer.
.
If the limit and torque switching have not yet been set, they have
to be set according to the operation instructions SA/SAR and the
specifications of the valve manufacturer.
.
The valve manufacturer states whether the valve should be limit
or torque seated.
9.1 Worm gearboxes on butterfly valves
.
Determine the overrun of the multi-turn actuator for both directions, i. e. how much
does the valve move after the motor has been switched off?
Setting end position CLOSED
.
Remove all bolts (03) at limit stop housing (figures D, E).
.
Change actuator to manual drive and move the valve manually to end position
CLOSED.
.
In case limit stop housing (10) has not yet rotated, turn it clockwise up to the
stop.
.
Turn limit stop housing (10) back counterclockwise by turn. This ensures that
the mechanical end stop is not reached in electric operation and thus the valve
can close tightly, provided that torque seating has been specified.
.
If the fixing holes of limit stop housing (10) do not align with the threads of the
housing (1), take off the limit stop housing (10) and replace it in required
position.
.
.
.
If the position of the pointer cover does not correspond to the symbol CLOSED,
CLOSED symbol and fasten the screws again.
13
ITEM 0520,
0530
Limit seating in end position CLOSED
.
Turn back the valve from the end position by an amount equal to the overrun.
.
Set limit switching according to the operation instructions SA/SAR.
.
Check torque switching for end position CLOSED according to the operation
instructions SA/SAR, and, if necessary, set to the required value.
Torque seating in end position CLOSED
.
Turn handwheel counterclockwise by approx. 4 6 turns.
.
Set limit switching for the end position CLOSED according to the operation
instructions SA/SAR (for actuator indication).
.
Check torque switching for end position CLOSED or set to the required value.
Setting end position OPEN The end stop need not be set since the required swing angle has been set in the
factory.
.
Move gearbox to the end stop in position OPEN.
The last part of the travel has to be made manually.
.
To turn the valve back manually from the end position by an amount equal to the
overrun, proceed as follows:
For actuators mounted directly:
by approx. 4 to 6 turns at the handwheel.
With mounted primary reduction gearing VZ/GZ:
by approx. 10 to 15 turns at the handwheel, according to the reduction ratio of
the primary reduction gearing.
.
Set limit switching in actuator for the end position OPEN according to the
operation instructions SA/SAR.
9.2 Worm gearboxes on ball valves
In case end stops require adjustment, set end position OPEN first.
If the exact end position of the valve cannot be seen through a
position marking at the valve shaft, the setting may have to be
done with the valve removed.
.
Determine overrun of the actuator for both directions, i. e. how much does the valve
move after the motor has been switched off?
14
03/04
10 1
Figure F: End stop up to GS 125.3
03/04
10 1
Figure G: End stop from GS 160.3
ITEM 0520,
0530
Setting end position OPEN
.
Remove all bolts (03) at limit stop housing (10) (figures F, G).
.
Change to manual drive and move the valve manually to end position OPEN.
.
In case limit stop housing (10) has not yet rotated, turn it counterclockwise up to
the stop.
.
Turn limit stop housing (10) back by turn clockwise. This ensures that the
mechanical end stop is not reached in electric operation.
.
If the holes of limit stop housing (10) do not correspond to the threads of the
housing (1), take off the limit stop housing (10) and replace it in the required
position.
.
.
.
If the position of the pointer cover does not align with the symbol OPEN, slightly
loosen the screws of the pointer cover. Turn the pointer cover to the OPEN
symbol and fasten the screws again.
Switching off in end position
OPEN
.
Turn back the valve from the end position by an amount equal to the overrun.
.
Set limit switching according to the operation instructions SA/SAR.
Setting end position
CLOSED
The end stop need not be set since the required swing angle has been set in the
factory.
.
Move gearbox to the end stop in position CLOSED.
The last part of the travel has to be made manually.
.
To turn the valve back manually from the end position by an amount equal to the
overrun, proceed as follows:
For actuators mounted directly:
by approx. 4 to 6 turns at the handwheel.
With mounted primary reduction gearing VZ/GZ:
by approx. 10 to 15 turns at the handwheel, according to the reduction ratio of
the primary reduction gearing.
.
Set limit switching in actuator for the end position CLOSED according to the
operation instructions SA/SAR.
15
ITEM 0520,
0530
10. Changing the swing
angle
The adjustment is made in end position OPEN.
Optional for size GS 50.3 GS 125.3
Standard for size GS 160.3 GS 250.3
Accuracy:
GS 50.3 GS 125.3: 0.6
GS 160.3 GS 250.3: 0.11 to 0.14
10.1 Changing the swing angle for sizes GS 50.3 GS 125.3 (option)
.
Unscrew protective cap (16) at limit stop housing (10) (figure H).
.
Remove roll pin (020) with appropriate tool (available from AUMA).
Increasing the swing angle
.
Turn end stop nut (15) back counterclockwise.
When turning back the end stop nut (015), make sure the roll pin
(020) can still be tapped in within the oblong hole.
.
Move valve into the desired end position.
.
Turn end stop nut (15) clockwise until it is tight up to the stop nut (7).
Reducing the swing angle
.
.
The end stop nut (15) must entirely cover the roll pin (020).
.
Tap in roll pin (020) with tool. If slot in end stop nut (15) does not align with the
hole in the worm shaft, turn end stop nut (15) slightly counterclockwise until it is
in alignment, then tap in roll pin.
.
Check O-ring (08) and replace, if damaged.
.
Replace protective cap (16).
.
If gearbox is mounted to a multi-turn actuator, set limit switching again for the
end position OPEN according to the operation instructions SA/SAR. Allow for
overrun.
16
020 15 10 7 16 08
Figure H: End stop up to GS 125.3
03/04 082/083
058
10 7 056 054
055
34 15 16
Figure J: End stop from GS 160.3
ITEM 0520,
0530
10.2 Changing the swing angle for sizes GS 160.3 GS 250.3
.
Remove all bolts (054) and pull off protective cap (16)
(figure J).
.
Remove screw (082) with washer (058) and setting ring (34).
Increasing the swing angle
.
Turn end stop nut (15) back counterclockwise.
.
.
Reducing the swing angle
.
.
.
Place setting ring (34), secure with washer (058) and screw (082).
.
Check O-ring (056) and replace, if damaged.
.
Place protective cap (16), fasten bolts (054) with lock washers (055).
.
.
If gearbox is mounted to a multi-turn actuator, set limit switching again for the
end position OPEN according to the operation instructions SA/SAR. Allow for
overrun.
17
ITEM 0520,
0530
11. Enclosure protection IP 68
Definition According to EN 60 529, the conditions for meeting the requirements of enclosure
protection IP 68 (requirements exceed those of IP 67) are to be agreed between
manufacturer and user. AUMA worm gearboxes and primary reduction gearings in
enclosure protection IP 68 meet the following requirements according to AUMA:
.
IP 68-3, submersible in water up to 3 m head of water
.
.
.
For size GS 50.3, only enclosure protection IP 68-3 is available.
If submersed in other media, additional measures for corrosion protection may be
necessary; please consult AUMA. Submersion in aggressive media, e.g. acids or
alkaline solutions, is not permitted.
Review Gearboxes in enclosure protection IP 68-3 were type tested in the factory.
Gearboxes in enclosure protection IP 68-6, IP 68-10 and IP 68-20 undergo a
routine testing for tightness in the factory.
Note:
.
The enclosure protection IP 68 refers to the interior of the gearboxes, but not to
the coupling compartment.
.
If the gearboxes are likely to be repeatedly submersed, a higher corrosion
protection KS or KX is required.
.
For gearboxes intended for buried service we strongly recommend to use the
higher corrosion protection KS or KX.
.
For horizontal outdoor installation of the gearboxes, a sealed pointer cover
should be used.
For gas applications with sealed pointer cover, an air vent in the pointer cover or
venting grooves in the valve mounting flange must be provided.
.
In case of permanent submersion of the gearboxes or for buried service, a
protection cover must be fitted instead of a pointer cover. This will be taken into
account in the factory if indicated on the purchase order. Subsequent exchange
of the pointer cover for the protection cover is possible.
.
Use suitable sealing material between valve flange and gearbox.
.
Water can enter into the coupling compartment along the valve shaft. This would
lead to corrosion of hub and coupling. Therefore a suitable anticorrosive (or
sticky grease) must be applied to the hub and coupling of the gearbox before
mounting.
.
With corrosion protection KX, the hub and coupling are provided with a high
quality corrosion protection as standard.
18
ITEM 0520,
0530
12. Maintenance
12.1 General notes After commissioning, check worm gearbox for damage to paint finish.
Do a thorough touch-up to prevent corrosion.
Original paint in small quantities can be supplied by AUMA.
AUMA worm gearboxes require only very little maintenance.
To ensure that the worm gearbox is always ready to operate, we recommend for
gearboxes operated less than 10 times per year, the following measures:
.
Approximately six months after commissioning and every year after check bolts
between multi-turn actuator, worm gearbox, and valve for tightness. If required,
tighten applying the torques given in table 2 (page 11).
.
Perform a test run every six months.
.
Perform a visual inspection for grease leakage on each gearbox every
2 years.
.
Carry out a detailed functional test for each gearbox every 5 years. Record the
results for future reference.
.
For gearboxes permanently exposed to ambient temperatures above
104 F, maintenance must be performed at shorter intervals.
Seals:
Seals made of elastomeric materials are subject to ageing. The theoretical usable
lifetime of the seals made of NBR is 13.5 years from the date of manufacture.
These figures are based on an average ambient temperature of 104 F. Seal kits
may be obtained from AUMA.
Grease:
A grease and seal change is recommended after the following operation time:
.
if operated seldom after 10 12 years
.
if operated frequently, after 6 8 years
.
in modulating duty after 4 6 years
.
Only original AUMA grease must be used.
.
For the grease type, refer to the name plate.
.
Lubricants should not be mixed.
The removed lubricant and the cleaning agent used must be
disposed of according to the relevant regulations.
19
GS 50.3 63.3 80.3 100.3 125.3 160.3 200.3 250.3
Qty dm 0.1 0.3 0.4 1.0 1.3 3.3 6.6 12.2
Weight
1)
g 90 270 360 900 1,170 3,000 6,000 11,000
Primary
reduction
gearing
VZ GZ
2.3 3.3 4.3 160.3 200.3 250.3
4:1/8:1 16:1 4:1/8:1 16:1
Quantity dm 0.35 0.35 0.35 1.0 1.5 2.0 2.2 2.8
Weight
1)
g 320 320 320 900 1,400 1,800 2,000 2,250
1) for = approx. 900 g/dm
3
; conversion factor: 1 oz corresponds to 28.35 g
Table 4: Grease quantities for wormgearboxes and primary reduction gearings
ITEM 0520,
0530
12.2 Grease change for worm gearboxes GS 50.3 GS 125.3 and primary reduction gearing VZ 2.3 VZ 4.3
.
For gearboxes with multi-turn actuator: Remove multi-turn actuator.
.
Remove gearbox from the valve:
During this time, the valve/pipeline must not be under pressure!
12.2.1 Worm gearboxes Refer to spare parts list GS 50.3 GS 125.3, page 24.
Grease type, see name plate; grease quantities, see page 19, table 4.
.
Mark position of the gearbox on the valve, loosen connecting bolts to the valve
and remove the worm gearbox.
.
Remove fastening bolts with lock washers from the housing cover (518.0) and
take off housing cover.
.
Remove bolts with lock washers from the bearing cover (522.0). Lift worm wheel
carefully from the housing. For this, the worm shaft must be pulled from the
bearings and tilted slightly in the worm channel.
.
Remove old grease completely from the housing and the individual parts and
clean gear housing. For this purpose, a suitable cleaning agent should be used.
.
Clean mounting faces at housing and housing cover (518.0). Replace O-rings at
the worm wheel (010, 011) by new ones.
.
Re-insert worm wheel carefully and bring worm shaft into correct position, fasten
bearing cover (522.0) at housing with bolts and lock washers.
.
Fill with new grease.
.
Place housing cover (518.0) on housing, while ensuring the proper position of
the O-rings (010, 011) at the worm wheel. Place bolts with lock washers and
fasten them evenly crosswise.
Thoroughly degrease mounting faces at mounting flange.
Apply non-acidic grease at splines of coupling
Mount worm gearbox to valve, ensure correct position,
observe mark made in previous step
Fasten with bolts of minimum quality 8.8 using lock washers, fasten bolts
crosswise to the appropriate torque according to table 2, page 11.
.
Gearbox without primary reduction gearing: Continue with section After
maintenance.
.
Gearbox with reduction gearings VZ 2.3 VZ 4.3: Perform grease change at the
reduction gearing according to the following subsection.
12.2.2 Primary reduction gearing Refer to spare parts list VZ 2.3 VZ 4.3., page 24.
.
Remove bolts with lock washers from housing cover (020.0) and pull off housing
cover (020.0) with the complete input drive shaft (021.0).
.
Take off plate with internal teeth (045.0) and planet carrier (022.0) with the
planet wheels.
.
clean them. For this purpose, a suitable cleaning agent should be used.
.
Clean mounting faces at housing (019.0), housing cover (020.0) and plate with
internal teeth (045.0). Replace O-rings by new ones.
.
Insert planet carrier (022.0) with planet wheels.
.
.
Place plate with internal teeth (045.0) and insert the input drive shaft (021.0)
completely. Screw in bolts with lock washers and fasten them evenly crosswise to
the appropriate torque according to table 2, page 11.
.
Continue with section After maintenance, page 22.
20
ITEM 0520,
0530
GZ 160.3 GZ 250.3
.
For gearboxes with multi-turn actuator: Remove multi-turn actuator.
.
Remove gearbox from the valve:
During this time, the valve/pipeline must not be under pressure!
12.3.1 Worm gearboxes Refer to spare parts list GS 160.3 GS 250.3, page 26.
Tools: Lock nut tool, can be obtained from AUMA.
.
Mark position of the gearbox on the valve, loosen connecting bolts to the valve
and remove the worm gearbox.
.
Remove bolts with lock washers from the housing cover (518.0) and take off
housing cover.
.
Remove bolts with lock washers from the bearing cover (522.0). Take off bearing
lock nut (537.0) by loosening the grub screw. Remove protective cap (536.0), pull
off snap ring from end nut (526.0). Remove end stop (523.0). Lift worm wheel
carefully from the housing. For this, the worm shaft must be pulled from the
bearings and tilted slightly in the worm channel.
Pull out worm shaft from housing in direction of the input shaft.
.
clean gear-housing. For this purpose, a suitable cleaning agent should be used.
.
Clean mounting faces at housing and housing cover (518.0). Replace O-rings at
the worm wheel (010, 011) by new ones.
.
Re-insert worm wheel carefully and bring worm shaft into correct position. Screw
in bearing lock nut (537.0) and secure with grub screw. Fasten bearing cover
(522.0) at the housing with bolts and lock nuts.
.
.
Place housing cover (518.0) on housing, while ensuring the proper position of
the O-rings (010, 011) at the worm wheel. Place bolts with lock washers and
fasten them evenly crosswise.
Thoroughly degrease mounting faces at mounting flange and valve.
Apply non-acidic grease at splines of coupling.
Mount worm gearbox to valve, ensure correct position, observe mark.
Fasten with bolts of minimum quality 8.8 using lock washers, fasten bolts
crosswise to the appropriate torque according to table 2, page 11.
.
Gearbox without primary reduction gearing: Continue with section After
maintenance.
.
Gearbox with reduction gearings GZ 160.3 GZ 250.3: Perform grease change
at the reduction gearing according to the following sections.
12.3.2 Single-stage reductions gearings GZ 160.3 GZ 250.3 (reduction ratios 4:1 and 8:1)
Refer to spare parts list GZ 160.3 GZ 250.3, page 28.
.
Remove bolts with lock washers at housing cover (002.0) and pull off housing
cover (002.0) with the input drive shaft (003.0) and the plate with internal teeth).
.
Remove screws from the plate with internal teeth and separate the plate with
internal teeth from the input drive shaft.
.
clean them.
.
For this purpose, a suitable cleaning agent should be used.
.
Clean mounting faces at housing (001.0), housing cover (002.0) and plate with
internal teeth. Replace O-rings by new ones.
.
Fill housing cover (002) with new grease.
.
Fix plate with internal teeth (006.0) with screws at housing cover.
21
ITEM 0520,
0530
.
Fill housing (001.0) with remaining grease and fit the complete housing cover
with input drive shaft (003.0). Screw in bolts with lock washers and fasten them
evenly crosswise to the appropriate torque according to table 2, page 11.
.
Continue with section After maintenance, page 22.
12.3.3 Double-stage primary reduction gearing GZ 200.3 GZ 250.3 (reduction ratio 16:1)
Refer to spare parts list GZ 160.3 GZ 250.3, page 28.
.
Remove bolts with lock washers from housing cover (002.0) and pull off housing
cover with the complete input drive shaft (003.0).
.
Take off screws with lock washers from housing frame (010.0) and remove
housing frame with planet carrier and hollow wheel.
.
Remove screws from the plate with internal teeth and separate the plate with
internal teeth from the input drive shaft (003.0).
.
Remove screws (021) from the second stage of the plate with internal teeth and
separate it from the pinion (011.1).
.
clean them. For this purpose, a suitable cleaning agent should be used.
.
Clean mounting faces at housing (001.0), housing frame, housing cover (002.0)
and hollow wheels. Replace O-rings by new ones.
.
Fill housing (001.0) with new grease.
.
Fix second stage of the plate with internal teeth on housing frame (010.0).
.
Replace complete housing frame. Screw in bolts with lock washers and fasten
them evenly crosswise to the appropriate torque according to table 2, page 11.
.
Fill housing frame (010.0) and housing cover (002.0) with the remaining grease.
.
Fix first stage of the plate with internal teeth on the housing cover (002.0).
.
Place complete housing cover with input drive shaft onto housing frame. Screw
in bolts with lock washers and fasten them evenly crosswise to the appropriate
torque according to table 2, page 11.
12.4 After maintenance
.
If applicable, mount multi-turn actuator.
.
Reset the end stops.
.
For gearboxes with multi-turn actuator, check the setting of the limit switching
according to the operation instructions for multi-turn actuators; if required, reset.
.
Perform test run to ensure the proper function.
.
Check worm gearbox for damage to paint finish. Do a thorough touch-up to
prevent corrosion. Original paint in small quantities can be supplied by AUMA.
22
ITEM 0520,
0530
13. Disposal and recycling
AUMA gearboxes have an extremely long lifetime. However, they have to be
replaced at one point in time.
Our gearboxes have a modular design and may therefore easily be disassembled,
separated and sorted according to materials, i.e.:
.
various metals
.
plastics
.
greases and oils
The following generally applies:
.
Collect greases and oils during disassembly. As a rule, these substances are
hazardous to water and must not be released into the environment.
.
Send disassembled material to a sound disposal or to separate recycling center
according to materials.
.
Observe the local regulations for waste disposal.
14. Service AUMA offers extensive services such as maintenance and inspection for
gearboxes.
The AUMA service department can be reached at:
phone: 724-743-AUMA (2862)
fax: 724-743-4711
www.auma-usa.com or www.auma.com.
23
ITEM 0520,
0530
15. Spare parts list worm gearboxes GS 50.3 GS 125.3 and reduction gearing
VZ 2.3 VZ 4.3
24
S
1
(
0
3
3
)
5
2
0
.
0
5
2
0
.
0
5
2
0
.
0
S
1
(
0
0
9
)
S
1
(
0
0
9
)
S
1
(
0
0
9
)
S
1
(
0
0
9
)
S
1
(
0
0
9
)
S
1
(
0
1
0
)
S
1
(
0
1
0
)
S
1
(
0
1
1
)
S
1
(
0
1
2
)
S
1
(
0
1
7
)
S
1
(
0
1
7
)
S
1
(
0
1
7
)
S
1
(
0
3
3
)
S
1
(
0
3
4
)
S
1
(
0
7
3
)
S
1
(
0
7
6
)
5
2
7
.
0
0
1
9
.
0
0
2
0
.
0
0
2
1
.
0
0
2
2
.
0
0
4
5
.
0
5
1
2
.
0
5
1
2
.
0
5
1
2
.
0
5
1
7
.
0
5
1
8
.
0
5
1
9
.
1
5
2
1
.
1
5
2
2
.
0
5
2
2
.
0
5
2
3
.
0
5
2
4
.
0
5
2
5
.
0
5
2
6
.
0
5
3
4
.
0
ITEM 0520,
0530
Note: Please state type and commission no. of the device (see name plate) when ordering spare parts. Only original
AUMA spare parts should be used. Delivered spare parts may slightly vary from the representation
in these instructions.
25
019.0 Housing VZ Sub-assembly
020.0 Housing cover VZ Sub-assembly
021.0 Input drive shaft VZ Sub-assembly
022.0 Planet carrier VZ Sub-assembly
045.0 Plate with internal teeth VZ Sub-assembly
512.0 Flange for actuator Sub-assembly
518.0 Housing cover Sub-assembly
519.1 Worm wheel Component
521.1 Travelling nut Component
522.0 Bearing cover Sub-assembly
523.0 Limit stop housing Sub-assembly
524.0 Pointer cover Sub-assembly
525.0 Coupling Sub-assembly
526.0 End stop nut Sub-assembly
527.0 Protection cover Sub-assembly
534.0 Input shaft Sub-assembly
536.0 Cap Sub-assembly
S1 Seal kit Set
ITEM 0520,
0530
S
1
(
0
0
9
)
S
1
(
0
0
9
)
S
1
(
0
1
0
)
S
1
(
0
1
0
)
S
1
(
0
1
1
)
S
1
(
0
1
2
)
S
1
(
0
1
7
)
S
1
(
0
5
6
)
S
1
(
0
7
3
)
5
1
2
.
0
5
1
7
.
0
5
1
8
.
0
5
1
9
.
1
5
2
0
.
0
5
2
1
.
1
5
2
2
.
0
5
2
3
.
0
5
2
4
.
0
5
2
5
.
0
5
2
6
.
0
5
2
7
.
0
5
3
6
.
0
5
3
7
.
0
5
3
8
.
0
5
3
8
.
1
5
1
3
.
1
16. Spare parts list worm gearboxes GS 160.3 GS 250.3
26
ITEM 0520,
0530
Note: Please state type and commission no. of the device (see name plate) when ordering spare parts. Only original
AUMA spare parts should be used.
Delivered spare parts may slightly vary from the representation in these instructions.
27
513.0 Grub screw Component
519.1 Worm wheel Component
521.1 Travelling nut Component
522.0 Bearing cover Sub-assembly
523.0 Limit stop housing Sub-assembly
524.0 Pointer cover Sub-assembly
525.0 Coupling Sub-assembly
526.0 End stop nut Sub-assembly
527.0 Protection cover Sub-assembly
536.0 Cap Sub-assembly
S1 Seal kit Set
ITEM 0520,
0530
17. Spare parts list reduction gearings GZ 160.3 GZ 250.3 (reduction ratios 4:1, 8:1 and 16:1)
28
S1(014)
006.0
S1(003)
S1(003)
S1(009)
S1(004)
001.0
S1(029)
S1(029)
003.3
003.0
002.0
512.0
013.0
010.0
011.1
GZ 200.1 GZ 250.1
16:1
001.0
002.0
003.0
003.3
006.0
512.0
S1(003)
S1(003)
S1(004)
S1(009)
S1(014)
GZ 160.1 GZ 250.1
4:1 / 8:1
S1(014)
006.0
S1(003)
S1(003)
S1(009)
S1(004)
001.0
S1(029)
S1(029)
003.3
003.0
002.0
512.0
013.0
010.0
011.1
GZ 200.1 GZ 250.1
16:1
ITEM 0520,
0530
Note:
spare parts should be used. Delivered spare parts may slightly vary from the representation in these instructions.
29
No. Designation
003.3 Input drive shaft Sub-assembly
006.0 Planetary gear Sub-assembly
010.0 Housing frame Sub-assembly
011.1 Pinion Sub-assembly
013.0 Planetary gear 1st stage Sub-assembly
S1 Seal kit Set
ITEM 0520,
0530
Notes
30
ITEM 0520,
0530
31
Index
B
Bolts for mounting actuators 10
C
Changing the swing angle 16
Corrosion protection 7
D
Disposal and recycling 23
E
Enclosure protection IP 68 18
F
Fitting the handwheel 7
H
Handwheel 7
L
Lubricant 19
M
Maintenance 3,19
Manual operation 12
Motor operation 13
Mounting positions 8
Mounting the multi-turn actuators 9
Mounting to valve 11
P
Packaging 7
R
Range of application 3
S
Safety instructions 3
Service support/ Parts 23
Setting the end stop
with mounted
multi-turn actuator 13
Setting the end stops
for manual operation 12
Spare parts list
GS 50.3 - GS 125.3 24,25
GS 160.3 - GS 250.3 26,27
GZ 160.3 - GZ 250.3
(4:1/8:1/16:1) 28,29
Storage 7
T
Technical data 4
Transport 7
ITEM 0520,
0530
Y003.822/031/us/1.06
North American Sales and Service:
US Headquarters and Factory:
AUMA Actuators, Inc.
100 Southpointe Blvd.
Canonsburg PA 15317
Tel: 724-743-AUMA (2862)
Fax: 724-743-4711
www.auma-usa.com
Regional Offices:
Northeast (Maryland and New York)
Southeast (South Carolina)
Midwest (Illinois)
Midwest (Kansas)
Houston (Texas)
West Coast (Northern and Southern California)
Representatives and Distributors
Anchorage
Atlanta
Baltimore
Baton Rouge
Birmingham
Boston
Charlotte
Chicago
Cincinatti
Corpus Christi
Dallas
Denver
Detroit
Hawaii
Houston
Indianapolis
Kansas City
Los Angeles
Mexicali (Mexico)
Mexico City
Milwaukee
Minneapolis
Montana
Monterrey (Mexico)
New York
Omaha
Orlando
Philadelphia
Phoenix
Pittsburgh
Rochester
Salt Lake City
San Diego
San Francisco
San Juan
Seattle
St. Louis
Toronto
Tulsa
International Headquarters:
AUMA Riester GmbH & Co. KG
Mllheim/ Germany
www.auma.com
International Sales and Service:
South America:
Argentina
Brazil
Chile
Colombia
Peru
Venezuela
Europe:
Austria
Benelux
Czech Republic
Denmark
Finland
France
Greece
Hungary
Italy
Norway
Poland
Portugal
Russia
Spain
Sweden
Switzerland
Turkey
Ukraine
United Kingdom
Africa
Egypt
South Africa
Asia, Australia
Australia
China
Hong Kong
India
Japan
Korea
Kuwait
Oman
Qatar
Singapore
Taiwan
Thailand
UAE
For the name and phone number of the office
nearest you, call us at 724-743-2862 or visit our
website at www.auma-usa.com/saleserv.htm
2005-06-27
ITEM 0520,
0530
Duo-Chek
II
High Performance
Check Valves
(CV-600)Duo-Chek II Cover 3/28/03 11:51 AM Page 1 Dan K. Snelson Clients:171-Crane Valves:171- Job Files:171-Open Jobs:0319-(CV-600
ITEM 0540
2
T: 936-588-4447 F: 936-588-4427 www.cranevalve.com
Duo-Chek
II Valves
Duo-Chek II high performance check valves are the original Mission wafer check valves introduced to the market in the late
50's. They are available in the sizes, pressure classes and configurations you need to meet the most demanding of applica-
tions. Our product range includes, but is not limited to,
Sizes: 2" to 72"
ASME Pressure Class 125 through 2500
API 6A and 6D pressure classes
DIN, JIS, BS, AS, and ISO standards are also available.
Wafer, lug, double flanged and extended body styles
Configurations available in retainerless style.
Body Materials:
Cast Iron, Ductile Iron, WCB Cast Steel,
316 Stainless Steel. All alloys.
Resilient Seat Materials:
EPDM, Buna-N, Neoprene,
Refrigeration-grade elastomer, Viton
Integral and overlaid metal seats also available
End Connections:
Raised Face, Plain Face, Ring Joint,
Weld-End, Hub-End.
Industry Standards*
API 594 Valve Design
API 598 Valve Pressure Testing & Inspection
ASME B16.5 & B16.47 Flanges
ASME B16.34 Pressure / Temperature Ratings
API 6D Pipeline Valves
API 6A Production Valves
*Duo-Chek II meets or exceed these industry standards.
Dual plate lightweight design
for efficient seating
and operation
Long-leg spring action
allows plates to open and
close without seat scrubbing.
Spring action closes plates
independently. (6" and larger)
Hinge support sleeve reduces
friction and minimizes water
hammer through independent
plate suspension (on larger
sizes).
Duo-Chek II The High Performance Check Valve
Retainerless valves for critical applications
without pin retainer penetration through
the body are available in Wafer and are
standard in Lug and Double Flange valves.
(CV-600)Duo-Chek II 3/28/03, 11:56 AM 2
ITEM 0540
4
Duo-Chek
II Valves
Specify the Duo-Chek II ...to your advantage
F
s
s
F
F
F
Spring with
valve wide
open
Unstressed
spring
Plate in
open
position
Spring with
valve closed
Plate in
closed position
140
55
The innovative dual-plate design of the
Duo-Chek II employs two spring-loaded
plates (disc halves) suspended on a
central vertical hinge pin. As flow begins,
the pl ates open i n response to a
resultant force (F) which acts as the
center of the sealed surface area. The
contact point of the reacting spring legs
force (Fs) acts beyond the center of the
plate area, causing the heel to open first.
This prevents rubbing of the seal surface
pri or to normal pl ate openi ng,
eliminating wear.
As the velocity of flow decreases, torsion
spring action reacts automatically. This
moves the plates closer to the body seats,
reducing the distance and time of travel
for closure. By having the plates closer to
the body seats at the time of flow reversal,
the valve dynamic response is greatly
accelerated. This dramatically reduces the
water hammer effect for non-slam
performance.
Leading engineering specifiers specify the Duo-Chek II for check valve applications because it provides high
performance. Extensive research and testing with demonstrated performance has earned worldwide
recognition, unmatched in the industry.
The Duo-Chek II wafer valve design is generally stronger, lighter, smaller, more efficient and less
expensive than conventional swing check valves. Its design meets API 594 which is approximately
one fourth the face to face dimension and 15% to 20% the weight, on most popular sizes, making
them less expensive than a swing check valve. It is much easier to install between standard gaskets
and line flanges. The savings compound during installation due to ease of handling and only one set
of flange studs is required. Therefore, it is more cost effective to install, and also to maintain.
The Duo-Chek II also offers special design features that make it a high performance non-slam check valve. These
include a scrub-free opening, and in most sizes a unique independent spring design as well as an independent plate support
system. These features may not be found in other check valves. Other configurations offered include lug, double flange and
extended body.
Plates in closed
position. Top view.
Heel opens first as
flow begins.
Plates fully opened (85) Plate toe closes first as
flow decreases.
Plates fully seated for
bubble-tight shutoff.
At closing, the point of spring force
causes the toe of the plates to close first.
This prevents dragging of the heels of
the plates and maintains seal integrity
for much longer periods.
Independent Spring Design
A spring design of the Duo-Chek II (sizes
6" and larger) allows higher torque to be
exerted agai nst each pl ate wi th
independent closing in response to the
process stream. Testing has proved this
action provides up to 25% improvement
in valve life and 50% reduction in water
hammer.
Each of the dual plates has its own spring
or springs, which provide independent
closing action. These independent
springs undergo less angular deflection,
only 140 as compared to 350 for
conventional springs with two legs.
Independent
Plate Suspension Design
The Duo-Chek II unique hinge design
reduces friction forces by 66%, which
improves valve response significantly.
Support sleeves are inserted through the
outboard hinges so that the upper hinge
is independently supported by the lower
sleeve during valve operation. This
allows both plates to close at the same
time for quick response, and exellent
dynamic performance.
(CV-600)Duo-Chek II 3/28/03, 11:56 AM 4
ITEM 0540
9
Duo-Chek
II Valves
Size A B C D Weight
in mm in mm in mm in mm in mm lbs. kg.
2" 50 4
1
8 105 2
3
8 60 1
15
16 49 6 3
2
1
2" 65 4
7
8 124 2
5
8 67 2
11
32 60 10 5
3" 80 5
3
8 137 2
7
8 73 2
29
32 74
1
4 6 13 6
4" 100 6
7
8 175 2
7
8 73 3
53
64 97
5
8 16 17 8
5" 125 7
3
4 197 3
3
8 86 4
13
16 122
7
8 22 27 12
6" 150 8
3
4 222 3
7
8 98 5
49
64 146 1
3
8 35 35 16
8" 200 11 279 5 127 7
5
8 194 2
1
8 54 70 32
10" 250 13
3
8 340 5
3
4 146 9
9
16 243 2
3
4 70 106 48
12" 300 16
1
8 410 7
1
8 181 11
3
8 289 3
1
4 83 172 78
14" 350 17
3
4 451 7
1
4 184 12
1
2 318 3
1
4 83 200 91
16" 400 20
1
4 514 7
1
2 191 15 381 4
7
16 113 275 125
18" 450 21
5
8 549 8 203 16
7
8 429 5
3
8 137 315 143
20" 500 23
7
8 606 8
5
8 219 18
13
16 478 6
5
16 160 435 197
24" 600 28
1
4 718 8
3
4 222 22
5
8 575 8
1
4 210 620 281
26" 650 30
1
2 775 14 356 24
1
4 616 8 203 1555 705
30" 750 34
3
4 883 13 330 29
1
4 743 9 229 1230 558
36" 900 41
1
4 1048 15
1
4 387 35 889 11
15
16 303 2017 915
42" 1050 48 1219 17 432 41 1041 15 381 2800 1270
48" 1200 54
1
2 1384 20
5
8 524 47 1194 16
3
4 425 3920 1178
54" 1350 61 1549 21
1
4 540 51
1
2 1308 19
3
4 502 6172 2800
60" 1500 67
1
2 1715 26 660 56 1422 7800 3538
66" 1650 74
1
4 1886 31 787 65
1
4 1657 12000 5443
72" 1800 80
3
4 2051 36 914 68 1727 14000 6350
Style G Installation Dimensions
Style G wafer style body valves are designed with flangeless
bodies with relatively short face-to-face dimensions. They
are clamped between mating flanges which are connected
by studs and nuts.
Duo-Cheks are available in accordance with DIN, BS, JIS, AS and ISO Dimensions.
For other sizes and pressure classes contact factory.
ASME Class 150
Size A B C D Weight
in mm in mm in mm in mm in mm lbs. kg.
2" 50 4
1
8 105 2
1
8 54 2
1
16 52 4 1.8
2
1
2" 65 4
7
8 124 2
1
8 54 2
15
32 63 6 2.7
3" 80 5
3
8 137 2
1
4 57 3
1
16 78
5
8 16 7 3.2
4" 100 6
7
8 175 2
1
2 64 4 102 1 25 12 5.4
5" 125 7
3
4 197 2
3
4 70 5 127 1
5
16 33 15 6.8
6" 150 8
3
4 222 3 76 6
1
16 154 1
15
16 35 20 9
8" 200 11 279 3
3
4 95 8 203 3
7
16 54 40 18
10" 250 13
3
8 340 4
1
4 108 10 254 3
3
8 70 65 29
12" 300 16
1
8 410 5
5
8 143 11
15
16 303 3
9
16 83 110 50
14" 350 17
3
4 451 7
1
4 184 12
1
2 318 3
1
16 83 183 83
16" 400 20
1
4 514 7
1
2 191 15 381 4
1
4 113 255 116
18" 450 21
5
8 549 8 203 16
7
8 429 5
3
8 137 315 143
20" 500 23
7
8 606 8
3
8 213 18
13
16 478 6
3
16 160 380 172
24" 600 28
1
4 718 8
3
4 222 22
5
8 575 8
1
4 210 575 261
30" 750 34
3
4 883 12 305 29
1
4 743 9
9
16 229 1070 486
36" 900 41
1
4 1048 14
1
2 368 35 889 12
5
16 303 1962 890
42" 1050 48 1219 17 432 41 1041 15 381 2800 1270
48" 1200 54
1
2 1384 20
5
8 524 47 1194 16
3
4 425 3920 1178
54" 1350 61 1549 21
1
4 540 51
1
2 1308 19
3
4 502 6172 2800
60" 1500 67
1
2 1715 26 660 56 1422 7800 3538
66" 1650 74
1
4 1886 31 787 65
1
4 1657 12000 5443
72" 1800 80
3
4 2051 36 914 68 1727 14000 6350
ASME Class 125 (Cast Iron valves only)
A
Raised Face
Valves Only
Serrated
Section A
Ring Joint
Facing A
B D
Plain Face
A
C
Minimum
Flange
Bore
This view is rotated 90 to show
the actual operating position of
the valve. The pin must be vertical
for horizontal flow.
Flow Direction
(CV-600)Duo-Chek II 3/28/03, 11:56 AM 9
ITEM 0540
14
Duo-Chek
II Valves
Styles G and H Stud Selection
2" 50 4
5
8 16 5
3
4 146 6
1
4 159
2
1
2" 65 4
5
8 16 6
1
4 159 7 178
3" 80 4
5
8 16 6
3
4 171 7
1
4 184
4" 100 8
5
8 16 6
3
4 171 7
1
4 184
5" 125 8
3
4 19 7
1
2 191 8 203
6" 150 8
3
4 19 8 203 8
1
2 216
8" 200 8
3
4 19 9
1
2 241 10 254
10" 250 12
7
8 22 10
1
2 267 11 279
12" 300 12
7
8 22 12 305 12
1
2 318
14" 350 12 1 25 12
3
4 324 13
1
4 337
16" 400 16 1 25 13
1
4 337 13
3
4 349
18" 450 16 1
1
8 29 14
1
4 362 14
3
4 375
20" 500 20 1
1
8 29 15 381 15
1
2 394
24" 600 20 1
1
4 32 15
3
4 400 16
1
4 413
26" 650 24 1
1
4 32 22
3
4 578 23
1
4 591
30" 750 28 1
1
4 32 21
1
4 540 22
3
4 578
36" 900 32 1
1
2 38 26
1
4 667 39 679
42" 1050 36 1
1
2 38 28
1
2 724 - -
48" 1200 44 1
1
2 38 33 838 - -
54" 1350 44 1
3
4 44 35 889 - -
60" 1500 52 1
3
4 44 - - - -
66" 1650 52 1
3
4 44 - - - -
72" 1800 60 1
1
8 29 - - - -
Valve
No. of
B C D
Size
Studs
Bolt Diameter Raised Face Ring Joint
in mm in mm in mm in mm
ASME Class 150
2" 50 4
5
8 16 5
1
4 133
2
1
2" 65 4
5
8 16 5
1
2 140
3" 80 4
5
8 16 5
3
4 146
4" 100 8
5
8 16 6
1
4 159
5" 125 8
3
4 19 6
3
4 171
6" 150 8
3
4 19 7 178
8" 200 8
3
4 19 8 203
10" 250 12
7
8 22 9 229
12" 300 12
7
8 22 10
1
2 267
Valve
No. of
B C
Size
Studs
Bolt Diameter Flat Face
in mm in mm in mm
ASME Class 125
*For larger sizes, see Class 150 table.
B
C
Min
D
Min
Flat or Raised Face flanges
Ring Joint flanges
(CV-600)Duo-Chek II 3/28/03, 11:57 AM 14
ITEM 0540
24
Duo-Chek
II Valves
Ordering Information
Figure Number System
Size Style Pressure Class Body & Plate Seal
Body
Configuration
Modification
Number
24" H 15 S M
End
Connection
F 3 9
DESCRIPTION: 24" Style H, ASME Class 150, Carbon Steel Body and Plates, Buna-N Seal, raised face flanges, with double flange
body, (modification number indicates Inconel X spring)
Nominal valve sizes are expressed in
inches or millimeters.
In Inches:
For use with ASME, API and BS Flange
Standards.
In Millimeters:
For use with DIN, AS or JIS rated
valves (size preceded by "M" for DIN,
"A" for AS or "J" for JIS).
Valve Size
Ordering Letter Body Type Size Range
G Standard Design, 2" through 88"
Wafer (50mm through 2200mm)
H Retainerless Duo-Chek Design 2" through 88"
Wafer, Lug or Double Flange (50mm through 2200mm)
X Extended Body Design 2" through 72"
(50mm through 1800mm)
U Underwriters Laboratories Listed 4" through 12" (except 5")
Valves for Fire Protection Service (U12 HMP Valves Only)
W* Bodies with Integral Weld-Ends 2" through 72"
(50mm through 1800mm)
Style
*Weld-end valves also require the additional designation of the pipe schedule they are designed to fit.
Pressure Classes
ASME API
DIN / JIS
1
BS / AS
2
Ordering Class Ordering Class Ordering PN Ordering Table
No. No. No. Rating No.
12 125 21 2000 Flange Standard: 6
15 150 10 B - BS A
31 3000 M - DIN 16 thru
30 300 25 A - AS T
40 400 51 5000 J - JIS 40
60 600 64
90 900 101 10000 100
150 1500 160
250 2500 151 15000 250
450 4500 320
API Class is shown in psig, cold working pressure.
1 Metric valves with DIN or JIS standard flanges are designated by having the nominal size expressed in millimeters, preceded by "M" or "J'. Flange ratings in PN numbers
are then listed after the valve style, as in ANSI or API Valves.
Example: M 100 (4" ) G16 SPF
Flange Standard
(M - DIN)
100mm Size
Pressure Rating, PN
for DIN or JIS
(in bars)
This specifies a metric valve, designed to fit between DIN
flanges. Nominal size is 100 millimeters (corresponding to
4"), Style G Duo-Chek II with a pressure rating of 16 bars,
carbon steel body and plate, metal seat, and raised face
end connections.
2 Valves designed for use with British Standard 10 or Australian Standard 2129 are defined by adding two letters between the style of construction and
pressure rating. First letter designates the standard, and the second letter denotes the table in that standard.
Figure number lists a 6" Style G Duo-Chek II, designed to fit
between British Standard 10, Table E Flanges, using a Class
150 Valve, having an aluminum bronze body and plates,
Neoprene seal and raised face end connections.
Example: 6" G B E 15 BNF
Flange Standard
B - British Std. 10
ANSI Class
is made from
Table in corresponding
Standard
(CV-600)Duo-Chek II 3/28/03, 11:57 AM 24
ITEM 0540
30" V P 9 G
2 H
25
Duo-Chek
II Valves
Number Material Changes Note:
-9 Inconel X-750 Springs
-14 316 S.S. Plate, Pins
-39 410 S.S. Plate, Pins & Inconel X-750 Springs
-201 316 S.S. Plate, Pins, Inconel X-750 Springs
-233 316 S.S. Plate, Pins, Inconel X-750 Springs and 316 S.S. Overlay Seat
-169 410 S.S. Plate, Pins, Inconel X-750 Springs and 410 S.S. Overlay Seat
-772 Monel Plate, Pins, Springs, Bearings and Monel Overlay Seat
Body and Plates
Ordering
Material Specification
Ordering
Material Specification
Letter Letter
B Aluminum Bronze ASTM B148 Alloy 952 T 317 S.S. ASTM A351, Gr. CG-8M
BS 1400, Alloy AB2 U WC6 Alloy Steel ASTM A217, Gr. WC6 (1
1
4% Cr)
C 316 Stainless Steel ASTM A351 Gr. CF-8M V 347 S.S. ASTM A351, Gr. CF-8C
E 410 Stainless Steel ASTM A217 Gr. CA15 (12% Cr) W 316 L S.S. ASTM A351, Gr. CF-3M
F Alloy 20 ASTM A351 Gr. CN7M Y C5 Alloy Steel ASTM A217, Gr. C5 (5% Cr)
G Low Temp. C.S. ASTM A352, Gr. LCB Z WC9 Alloy Steel ASTM A217, Gr. WC9 (2
1
2% Cr)
H Cast Iron with ASTM A126; BS 1452, Gr. 220 CA Duplex ASTM A351
Al. Br. Plates ASTM B148 (952); BS 1400 (AB2) DZ European S.S. UNS S31803
K Hastelloy

C A494, Gr. CW2M / CW12MW EA 6% Moly S.S. UNS S31254 (254 SMO)
L C12 Alloy Steel ASTM A217, Gr. C12 (9% Cr) FN Inconel
625 ASTM A494, Gr. CW-6MC

M Monel ASTM A494, Gr. M-35-1 GC LCC Low Temp. Steel ASTM A352, Gr. LCC
N Nickel ASTM A494, Gr. CZ-100 SC WCC Steel ASTM A216, Gr. WCC
S Carbon Steel ASTM A216, Gr. WCB TT Titanium ASTM B367, Gr. C2 or
ASTM B384, Gr. 2
Seal*
Ordering
Material
Operating Temperature
Letter
C F
A EPDM -29 to 149 -20 to 300
M Buna-N -23 to 121 -10 to 250
N Neoprene -12 to 107 +10 to 225
P Metal -267 to 537 -450 to 1000+
U Refrigeration -
Grade Elastomer -40 to 120 -40 to 250
V Viton-B
-18 to 204 0 to 400

* This range of operating temperatures is for general guidance. The range varies with application, body and plate material.
Metal seals may be furnished as integral or special overlay materials.
Viton is a registered name of DuPont.

End Connections
Ordering
Connections
Letter
F Serrated raised face
G Grayloc
Hub
P Plain Face
R Ring Joint
W Weld-End
Designation
Configuration
Number
None (Blank) Wafer Style, inserted between
mating flanges with studs
spanning entire length
1 Lug design w/threaded holes
bolted from each end
2 Lug design with through-bolt holes
to protect studs
3 Double flanged design with
valve flanges bolted to individual
line flanges
Special Body Configurations
Common Modifications
Numerous additional modifications
may be specified.
Please consult factory.
Standard trim (Wetted Parts) Materials
Typical Body
Seal
Hinge
Spring
Stop
Figure No. & Plate Pin Pin Retainer
BMF Al. Bronze Buna-N 316 S.S. 316 S.S. 316 S.S. 316 S.S.
CMF 316 Stainless Buna-N 316 S.S. 316 S.S. 316 S.S. 316 S.S.
CPF 316 Stainless 316 Stainless 316 S.S. Inconel 600 316 S.S. 316 S.S.
CVF 316 Stainless Viton-B
316 S.S. Inconel 600 316 S.S. 316 S.S.

EPF 410 Stainless 410 Stainless 410 S.S. Inconel 600 410 S.S. 410 S.S.
SMF Carbon Steel Buna-N 316 S.S. 316 S.S. 316 S.S. Steel
SNF Carbon Steel Neoprene 316 S.S. 316 S.S. 316 S.S. Steel
SPF Carbon Steel Carbon Steel 316 S.S. Inconel 600 316 S.S. Steel
SVF Carbon Steel Viton-B
316 S.S. Inconel 600 316 S.S. Steel

(CV-600)Duo-Chek II 3/28/03, 11:57 AM 25
ITEM 0540
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTION MANUAL
Equipment Description
Duo-Chek II & Marlin Valves
Installation and Operation
1. Remove the valve from carton or packing skid.
2. The protective rust proof coating on the internal parts of steel or cast iron valves should be removed
by brushing out with any standard petroleum solvent (Varsol, Kerosene), and air dry. Insure internal
parts operate freely.
3. Stainless Steel or Bronze valves need only to be wiped clean and installed.
4. In horizontal flow installation, the hinge pin must be vertical.
5. Insert the valve between two companion flanges of the same series as the valve and place gaskets
on flange faces. The arrow on the valve or name plate indicating direction of flow should coincide
with line flow. Install studs through companion flanges and tighten, using standard industry practice.
6. In liquid service we recommend valve be installed at least five (5) pipe diameters downstream from a
pump discharge and/or other pipe fittings for maximum service life. Consult factory.
Maintenance
Caution! Make sure the valve is not under pressure
before starting any maintenance.
Disassembly** (Refer to assembly drawing on next page.)
1. Lay valve down with the downstream side of the valve upward.
2. Remove stop pin retainers (6) and hinge pin retainers (7).
3. Remove stop pin (3), being careful with the short hooked spring legs on valves 6 and larger.
4. Remove hinge pin (4) out of the body (1) while holding spring(s) firmly as some are preloaded and
may snap out. Observe caution.
5. Remove springs (5), plates (2), and bearings (8), (9), and (10).
Assembly**
1. Lay body down with downstream side of valve upward.
2. Clean all parts in a suitable solvent.
3. Position both plates (2) in body (1) with hinge lugs together and align with pin holes. If valve is
equipped with support sleeves (11), assemble into plate with body bearings (9).
4. Lay springs (5) in plate (2) recess, between lugs, with short hooked leg extending upward on valves
6 and larger (other longer leg to contact plate). On smaller valves, spring(s) (5) without short leg,
wind spring legs 180, install with legs contacting each plate and hold to insert hinge pin (4) in
step 6.
5. Insert all bearings provided, (8), (9) and (10).
6. Insert hinge pin (4) through plate lugs (2), bearings, (8), (9), (10), and through spring coils (5).
7. Pull stop pin leg of spring (short hooked leg) toward plate leg and insert stop pin (3). Repeat until
stop pin is fully inserted in body holes.
8. Install hinge pin retainers (7) and stop pin retainers (6) using PTFE tape or a suitable thread seal-
ing compound.
** No Special tools are required.
ITEM 0540
Description
Body
Plate
Stop Pin
Hinge Pin
Spring
Stop Pin Retainer
Hinge Pin Retainer
Plate Lug Bearing
Body Lug Bearing
Spring Bearing
Support Sleeve
10*
10
1
3
6
7
4
8
11
9
5*
5
2
Item No.
1
2
3
4
5
6
7
8
9
10
11
No. Reqd
1
2
1
1
2*
2
2
4**
4**
3*
2
* Some valves require 4 springs & 5
spring bearings
** These quantities may vary according
to the valve size
Not required on valves smaller
than 24
Australia Operations Belfast Operations Crane Duo-Chek II
322 Settlement Road 6 Alexander Road 9860 Johnson Road
Thomastown, VIC 3074 Cregagh, Belfast BT6 9HJ Montgomery, TX 77316
tel: +613-9465-2755 tel: +44-2890-704222 tel: 936.588.4447
fax: +613-9466-1365 fax: +44-2890-401582 fax: 936.588.4427
Crane Duo-Chek II & Marlin Valves
ENGINEERED VALVES
ITEM 0540
EMERSON MOTOR COMPANY
8100 WEST FLORISSANT AVE.
P.O. BOX 3946 * BLDG. K * ST. LOUIS, MO 63136
FAX (314) 553-1101
DATE: 2/17/2006 P.O. NO.:
USEM Order/Line NO.: NA
TO:
Model Number: S677
Catalog Number: U10E1DC
U10E1DC,TEFC,ENE,AC MTR
60/50,208-230/460&190/380V
FUT,10HP,2P,215TC
REVISIONS:
ALL DOCUMENTS HEREIN ARE CONSIDERED CERTIFIED BY US ELECTRICAL MOTORS.
THANK YOU FOR YOUR ORDER AND THE OPPORTUNITY TO SERVE YOU.
Features:
HorsePower . . . . . . . . 10
Enclosure. . . . . . . . . TE
Poles. . . . . . . . . . . 02/00
RPM (Full Load). . . . . . 3510 / 2865
Motor Frame Size . . . . . 215TC
Phase. . . . . . . . . . . 3
Frequency. . . . . . . . . 60 / 50
Voltage. . . . . . . . . . 230-460-208 / 190-380
Motor Type Code. . . . . . FUT
Rotor Inertia (LB-FT) 0.390 LB-FT
Bearing Number PE (Shaft) 6208-2Z-J/C3
Bearing Number SE (OPP) 6206-2Z-J/C3
Emerson Motor Company is a division of Emerson Electric Co.
The Emerson logo is a trademark and service mark of Emerson Electric Co.
ITEM 0705
CATALOG NUMBER: U10E1DC NAMEPLATE PART #: 422702-002
MODEL S677 FR 215TC TYPE FUT ENCL TE
SHAFT
END BRG
6208-2Z-J/C3
OPP
END BRG
6206-2Z-J/C3
PH 3
MAX
AMB
40 C ID#
INSUL
CLASS
F
Asm.
Pos.
DUTY CONT
HP 10 RPM 3510
VOLTS 230 460 208
FL
AMPS
23.8 11.9 26.7
SF
AMPS
30 15
SF 1.25 DESIGN B CODE G
NEMA NOM
EFFICIENCY
89.5
NOM
PF
88.1 KiloWatt
GUARANTEED
EFFICIENCY
87.5
MAX
KVAR
2 HZ 60
HP 10 RPM 2865
VOLTS 190 380
FL
AMPS
29.8 14.9
SF
AMPS
SF 1.00 DESIGN # CODE E
NEMA NOM
EFFICIENCY
86.5
NOM
PF
88
GUARANTEED
EFFICIENCY
84.0
MAX
KVAR
1.7 HZ 50
UL DATA (IF APPLICABLE):
DIVISION CLASS I GROUP I
TEMP CODE CLASS II GROUP II
VFD DATA (IF APPLICABLE):
VOLTS
AMPS
TORQUE 1 TORQUE 2
VFD LOAD TYPE 1 VFD LOAD TYPE 2
VFD HERTZ RANGE 1 VFD HERTZ RANGE 2
VFD SPEED RANGE 1 VFD SPEED RANGE 2
SERVICE FACTOR FL SLIP
NO. POLES MAGNETIZING AMPS
VECTOR MAX RPM Encoder PPR
Radians / Seconds Encoder Volts
TEAO DATA (IF APPLICABLE):
HP (AIR OVER)
HP (AIR OVER
M/S)
RPM (AIR OVER)
RPM (AIR OVER
M/S)
FPM AIR
VELOCITY
FPM AIR
VELOCITY M/S
FPM AIR
VELOCITY SEC
ITEM 0705
ADDITIONAL NAMEPLATE DATA:
Decal / Plate WD=109144 Customer PN
Notes Non Rev Ratchet
Max Temp Rise OPP/Upper Oil Cap
Thermal (WDG) SHAFT/Lower Oil Cap
Altitude
EPACT Note EPACT Compliance CC 030A
COS Marine Duty
Balance Arctic Duty
3/4 Load Eff. Inrush Limit
Motor Weight Direction of Rotation
Sound Level Special Note 1
Vertical Thrust Special Note 2
Thrust Percentage Special Note 3
Bearing Life Special Note 4
Starting Method Special Note 5
Number of Starts Special Note 6
200/208V 60Hz Max Amps 32.6 SH Max. Temp.
190V 50 hz Max Amps SH Voltage
380V 50 Hz Max Amps SH Watts
NEMA Inertia Load Inertia
Sumpheater Voltage Sumpheater Wattage
Special Accessory Note 1 Special Accessory Note 16
ST. LOUIS, MO
TYPICAL NAMEPLATE DATA
ACTUAL MOTOR NAMEPLATE LAYOUT MAY VARY
SOME FIELDS MAY BE OMITTED
ITEM 0705
MODEL NO. CATALOG NO. PHASE TYPE FRAME
S677 U10E1DC 3 FUT 215TC
ORDER NO. NA LINE NO.
MPI: 8033 8034 8035 8036 8037
HP: 10 10 10 10 10
POLES: 2 2 2 2 2
VOLTS: 460 230 208 380 190
HZ: 60 60 60 50 50
SERVICE FACTOR: 1.25 1.25 1 1 1
EFFICIENCY (%):
S.F. 88.2 88.2
FULL 89.5 89.5 88.5 86.5 86.5
3/4 91 91 90.3 90 90
1/2 90.3 90.3 90.3 90.9 90.9
1/4 85.5 85.5 86.4 88.1 88.1
POWER FACTOR (%):
S.F. 87.8 87.8
FULL 88.1 88.1 87.7 88 88
3/4 86.7 86.7 87.8 88 88
1/2 82.1 82.1 84.9 84.8 84.8
1/4 66 66 72.1 71.2 71.2
NO LOAD 11.5 11.5 12.9 10.2 10.2
LOCKED ROTOR 37 37 36.3 40.4 40.4
AMPS:
S.F. 15.1 30
FULL 11.9 23.8 26.7 14.9 29.8
3/4 8.9 17.8 19.6 10.7 21.5
1/2 6.3 12.6 13.5 7.4 14.7
1/4 4.1 8.3 8.3 4.5 9
NO LOAD 3 6 5.4 3 5.9
LOCKED ROTOR 73.1 147.3 128.8 70 140.1
NEMA CODE LETTER G G E E E
NEMA DESIGN LETTER B B # # #
FULL LOAD RPM 3510 3510 3480 2870 2870
NEMA NOMINAL EFFICIENCY (%) 89.5 89.5 88.5 86.5 86.5
GUARANTEED EFFICIENCY (%) 87.5 87.5 86.5 84 84
MAX KVAR 2 2 1.7 1.6 1.6
AMBIENT (C) 40 40 40 40 40
ALTITUDE (FASL) 3300 3300 3300 3300 3300
SAFE STALL TIME-HOT (SEC) 23 23 30 28 28
SOUND PRESSURE (DBA @ 1M) 65 65 65 64 64
TORQUES:
BREAKDOWN{% F.L.} 271 271 216 209 209
LOCKED ROTOR{% F.L.} 160 160 125 126 126
FULL LOAD{LB-FT} 15 15 15.1 18.3 18.3
The Above Data Is Typical, Sinewave Power Unless Noted Otherwise
ST. LOUIS, MO
Emerson Motor Company is a division of Emerson Electric Co.
The Emerson logo is a trademark and service mark of Emerson Electric Co.
ITEM 0705
Connection Plate: B109144
Connection Decal: 344136
B109144
Motor Wiring Diagram
9 Lead, Dual Voltage (WYE Conn.)
T1
T4
T7
T8
T5
T2
T9
T6
T3
Y - Connection
Hi - Volts Lo - Volts
Line Line
B109144
6
1 1 2 2 3
7 8 9
3
7 8 9
4 5 6 4 5
To reverse direction of rotation interchange connections L1 and L2.
Each lead may have one or more cables comprising that lead.
In such case each cable will be marked with the appropriate lead number.
ITEM 0705
FRAMES - 182 THRU B256
UNIMOUNT TOTALLY ENCLOSED MOTORS
TYPES: FUT, FUT4, FUTF, FUTF4, FUTFN, FUTN, UT, UT1, UT2, UT3, UT4, UTE, UTE1, UTE3, UTE4, UTEF, UTEF1, UTEF4, UTEN, UTF,
UTF1, UTF4, UTFI, UTFN, UTI, UTI1, UTI4, UTN, UTNI, UTQ, UTV
THIS PARTS LIST IS GOOD FOR THE FOLLOWING TYPES:
Types Frames
UT 182T, TC, TCH, TD, TCZ
184T, TC, TCH, TD, TCZ
213T, TC, TD, TCZ
215T, TC, TD, TCZ
254T, TC, TD, TCZ
256T, TC, TD, TCZ
B215TC, TCZ
B256TC, TCZ
UT-1 182, 184, B184, 213, 215, B215, 254, 256, B256JP
UT-2 182, 184, B184JPY
UT-3 213, 215, B215JPZ
UT-4 182, 184, B184, 213, 215, B215, 254, 256, B256JM
UTE, UTN,
UTQ
182, 184, 213, 215, 254, 256T
Types Frames
UTF 182TC, TCH, TD
184TC, TCH, TD
213TC, TD
215TC, TD
254TC, TD
256TC, TD
UTV 182TCV, TCHV, JMV, JPV, JPYV
184TCV, TCHV, JMV, JPV, JPYV
213TCV, JMV, JPV
215TCV, JMV, JPV
B215TCV, JMV, JPV
254TCV, JMV, JPV
256TCV, JMV, JPV
WARNING:
Any disassembly or repair work on explosionproof motors will void the
Underwriters Laboratories, Inc. label unless done by the manufacturer,
or a facility approved by the Underwriters Laboratories, Inc. Refer to
your nearest U.S. Elecrical Motors office for assistance.
BEARINGS:
Refer to motor nameplate for the bearing
numbers.
PRICES:
Parts stocking distributors: refer to USEM
renewal parts numerical index. All Others:
refer to your nearest USEM parts distributor.
reference: Renewal Parts Section 700, Pages 14 & 15
ITEM 0705
FRAMES - 182 THRU B256
UNIMOUNT TOTALLY ENCLOSED MOTORS
TYPES: FUT, FUT4, FUTF, FUTF4, FUTFN, FUTN, UT, UT1, UT2, UT3, UT4, UTE, UTE1, UTE3, UTE4, UTEF, UTEF1, UTEF4, UTEN, UTF,
UTF1, UTF4, UTFI, UTFN, UTI, UTI1, UTI4, UTN, UTNI, UTQ, UTV
Copyright 2005 Emerson Electric Co. All rights reserved
ITEM
NO. QTY NAME OF PART
1 1 Fan Cover (not used on type UTN)
2 4 Self Tapping Screw (not used on type UTN)
3 1 Fan Assembly (not used on type UTN)
4 1 Bracket Assembly
5 2 Hex Countersunk Pipe Plug
6 1 Bracket Plug (type UTN only)
7 4 Hex Head Cap Screw
8 2 Lifting Lug (not used on type UTV)
9 1
Spring Wave Washer (not used on types UT-1, UT-2,
UT-3, UT-4 and UTV)
10 1 Ball Bearing
11 1 Rotor Assembly (includes items 12 and 13)
12 1 Rotor Core
13 1 Shaft
14-19 - Not Used
20 1 Wound Stator Assembly (includes itesm 21 and 22 if used)
21 2 Mounting Foot (not used on types UTF and UTV)
22 6 Hex Head Cap Screw (not used on types UTF and UTV)
23 1 Gasket
24 1 Outlet Box Base
26 1 Gasket
27 1 Outlet Box Cover
28 2 Self Tapping Screw
29-34 - Not Used
35 1 Ball Bearing
36 1
Retaining Snap Ring (qty. 2 on frames 182 & 184T, TC
TCH, TCV, TCHV, types UT, UTE, UTF, UTQ,& UTV)
(not used on frames 213T thru 256T, type UTN)
37 1 Bracket Assembly (type UT, UTE, UTN and UTQ only)
38 4 Hex Nut
39 2 Hex Countersunk Pipe Plug
40 1 Square Key
41-49 - Not Used
For types UT, UTF and UTV with "C" bracket, and types UT-1, UT-3 and
UT-4 omit items 9 & 37 and items 38 on frames 182 & 182TC, JPV,
types UT, UT-2 and UTF, and add the following parts
50 1 "C" Bracket Assembly
51 1 Clamping Plate
ITEM
NO. QTY NAME OF PART
53 1 Water Deflector
54 1
Hex head Cap Screw (used on frames 182 & 184JC, JPV,
types UT, UT-2 and UTF)
55-59 - Not Used
For types UT and UTF with "D" bracket, omit items 9 & 37, and item 38 on
frames 182 & 182 &184TD, and add the following parts
60 1 "D" Bracket Assembly
61 1 Clamping Plate
63 1 Water Deflector
64 1 Hex Head Cap Screw (used on 182 & 184 TD)
65-69 - Not Used
For type UTV and units with canopy cap, omit item 8 and add the following
70 1 Canopy Cap
71 3 Spacer (qty.1 on frames 182 and 184)
72 3
Hex Head Cap Screw and Lockwasher
(qty.1 on frames 182 and 184)
73 3 Square Nut (qty.1 on frames 182 and 184)
74 2 Lifting Lug
75-79 - Not Used
For SHUR-STOP brakes, omit items 1 & 3, and qty. one of item 8. Refer to
section 770 for part addition
For Dings and Stearns beake, omit items 1, 2 and 4, and qty. one of items 5,
and add the following
80 1
Brake (for replacement parts for brake, refer to
brake manufacturer)
81 4 Socket Head Cap Screw (qty. 2 on brakes under 10 lb.ft.)
82 1 Key
83 1 Baffle Plate
84 4 Brake Mounting Bracket
86 2 Groove Pin
87 1 Brake Adaptor Bracket
88 2 Screen
89 1 Nipple Fitting
90 1 Pipe Coupling
91 1 Nipple Fitting
92 1 Pipe Cap
WARNING:
Any disassembly or repair work on explosionproof motors will void the
Underwriters Laboratories, Inc. label unless done by the manufacturer,
or a facility approved by the Underwriters Laboratories, Inc. Refer to
your nearest U.S. Elecrical Motors office for assistance.
BEARINGS:
Refer to motor nameplate for the bearing
numbers.
PRICES:
Parts stocking distributors: refer to USEM
renewal parts numerical index. All Others:
refer to your nearest USEM parts distributor.
reference: Renewal Parts Section 700, Pages 14 & 15
ITEM 0705
GEARMOTORS
Installation, Operation &
For your safety, read and retain this manual
Emerson Motor Company
8050 West Florissant Ave.
PO Box 36912
St. Louis, MO 63136
Send for free brochure by product name 448888 Rev. 01/04
TITAN MOTORS
VERTICAL MOTORS
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HORIZONTAL
MOTORS
03-1900 _Emerson_tri.qxd 5/27/2004 7:47 AM Page 1
ITEM 0705
SAFETY FIRST
High voltage and rotating parts can cause serious or fatal injury.
Safe installation, operation and maintenance must be performed by
qualified personnel. Familiarization with, and adherence to, NEMA MG2, the National
Electrical Code (NEC), and local codes is required. It is important to observe safety
precautions to protect personnel from possible injury.
PERSONNEL SHOULD BE INSTRUCTED TO:
1. Be familiar with the equipment and read all instructions thoroughly before installing or working
on equipment.
2. Avoid contact with energized circuits or rotating parts.
3. Disconnect all power sources before initiating any maintenance or repair.
4. Act with care in accordance with prescribed procedures in handling and lifting this equipment.
5. Be sure unit is electrically grounded in accordance with code requirements.
6. Be sure equipment is properly enclosed or protected to prevent access by children or other
unauthorized personnel to prevent possible accidents.
7. Be sure shaft key is fully captive before unit is energized.
8. Avoid contact with capacitors until safe discharge procedures have been completed.
9. Provide proper guarding for personnel against rotating parts and applications involving high
inertia loads which can cause overspeed.
10. Avoid extended exposure to equipment with high noise levels.
INSPECTION AND HANDLING
Inspect unit to make sure no damage has occurred during shipment. Check nameplate for correct
speed, horsepower, voltage, hertz and phase for conformance with power supply and equipment.
Units should be lifted using all eyebolts or lugs if provided. These
eyebolts or lugs are provided for lifting this unit only and must not
be used to lift any additional weight. Lifting angle, from shank of eyebolt, must not exceed
30 degrees for machines with single and 45 degrees for machines with multiple lifting means.
Replacement eyebolts must be per ASTM A489 or equivalent. All eyebolts must be securely
tightened. Be careful not to touch overhead power lines with lifting equipment. Failure to
observe this warning may result in serious personal injury.
STORAGE
Units should be stored indoors, in a clean, dry location & winding should be protected from exces-
sive moisture absorption. NOTE: If motors are to be stored for over one year, refer to Emerson Motor
Company. If motors are to be stored for over one year and if gear and belt transmission units are to
be stored for over six months, refer to Emerson Motor Company.
LOCATION
Use only UL Listed Hazardous Location Motors for service in
Hazardous Locations as defined in Article 500 of the NEC. Units
should be located in a clean, well-ventilated area. Units should be located in a suitable
enclosure or protected to prevent access by children or other unauthorized personnel to
prevent possible accidents.
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INSTALLATION / MOUNTING
Mount unit on a firm, flat surface sufficiently rigid to prevent vibration. Drive belts and chains should
be tensioned in accordance with supplier recommendations. Couplings should be properly aligned
and balanced. For belt, chain and gear drive selection refer to the drive or equipment manufactur-
er. For application of drive equipment refer to applicable information in NEMA MG1.
Motors have been dynamically balanced using a half key the same length as the full key shipped
with the motor. If pulley length keyway is less than this length, rework long key by removing one-half
of excess length between pulley and end of key to maintain balance.
Do not restrict motor ventilation. Unless otherwise specified on nameplate, motor is designed for
operation in accordance with NEMA MG1 Usual Service Conditions which states an ambient tem-
perature range of -15 C to 40 C (5 F to 104 F). Standard grease lubricated units are suitable for
operation within this temperature range. Special lubricants may be required for ambient temperatures
outside of this range. Note: Motors operating under rated load and allowable ambient conditions may
feel hot when touched; this is normal and should not be cause for concern. When in doubt, measure
frame surface temperature and confer with nearest office. Enclosed motors normally have conden-
sation drain openings. Insure that drain openings are properly located and open (plugs removed) for
the motor mounting position. Drain openings should be at lowest point of end brackets, frame hous-
ing and terminal housing when the motor is installed. This may require modification of motor to
accomplish. If unit appears wet, and/or has been stored in a damp location, dry out thoroughly and
check for adequate insulation resistance to ground before operating.
Guards should be provided for all exposed rotating parts to
prevent possible personal injury. Keep fingers and foreign objects
away from ventilation and other openings. Applications involving high inertia loads may
damage this equipment due to motor overspeed during coast shutdown. Such applications
should be referred to Emerson Motor Company.
Do not force drive coupling or other equipment onto shaft, as
bearing damage may result.
POWER SUPPLY AND CONNECTIONS
The power supply must agree with values on nameplate. Terminal voltage should not vary more
than 10% of nameplate voltage at rated frequency. Unbalanced line voltage, greater than one per-
cent, can cause overheating. Do not exceed the rated load amperes on the nameplate. Starting con-
trols and overload protection should be properly sized in accordance with the NEC and the control
manufacturer's recommendations.
Motor connections should be made by following instructions on connection diagram. Determine direc-
tion of rotation before connecting driven equipment. If direction of rotation label is supplied, operate only
in specified direction. Rotation may be reversed on three phase motors by interchanging any two line
connections. On single phase motors interchange leads per connection diagram on motor. Wiring of
units, controls and grounding shall be in accordance with local and NEC requirements.
Failure to properly ground unit may cause serious injury to
personnel. Where unexpected starting could be hazardous to
personnel, do not use automatic reset starting devices.
USE OF VARIABLE FREQUENCY DRIVES
Electric motors can be detrimentally affected when applied with variable frequency drives (VFD's).
The non-sinusoidal waveforms of VFD's have harmonic content which causes additional motor
heating; and high voltage peaks.
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ITEM 0705
Other effects of VFD's on motor performance include reduced efficiency, increased load current,
vibration and noise. Standard motors utilized with VFD's must be limited to those application consid-
erations defined in NEMA MG-1 Part 30. Refer to PDS #811-215 available at www.usmotors.com.
NEMA MG-1 Part 31 defines performance and application considerations for Definite-Purpose
Inverter Fed Motors. To insure satisfactory performance and reliability, U.S. Electrical Motors offers
and recommends nameplated inverter duty motor products which meet the requirements of NEMA
MG-1 Part 31. The use of non-inverter duty motors may result in unsatisfactory performance or pre-
mature failure, which may not be warrantable under the Terms and Conditions of Sale. Contact your
Emerson Motor Company Field Sales Engineer for technical assistance for motor selection, appli-
cation and warranty details.
OIL LUBRICATION
Most oil lubricated units are shipped without oil. Refer to Instruction Manual with unit for specific type
and grade of oil to be used, change interval and level. If lubrication instructions specify synthetic oil,
do not substitute.
For applications in the food and drug industry (including animal
food), consult the petroleum supplier for lubricants that are
acceptable to the Food and Drug Administration and other governing bodies.
MAINTENANCE
Inspect units at regular intervals. Keep units clean and ventilation openings clear of dust, dirt or other
debris. Lubricate units per this operating instruction folder and instruction plate on unit. Excessive
lubrication may damage the unit. Do not over grease.
Disconnect all power sources to the unit and discharge all parts
which may retain an electrical charge before attempting any
maintenance or repair. Screen and covers must be maintained in place when unit is in
operation. Failure to observe this warning may result in personal injury.
U.L. Listed Motors for use in Hazardous Locations: Repair of these motors must be made by
the manufacturer or manufacturer's authorized service station approved to repair U.L. Listed
Motors. The U.L. listing applies to the electric motor only and not the belt or gear
transmissions or other devices that may be connected to the motor.
COOLING TOWER DUTY MOTORS
During installation, insure drain plugs are removed from lower drain holes in bracket and outlet box.
All upper drain holes must be plugged at all times. External umbrella seal must be in place for shaft
up applications. Motors with Bearing numbers XXXX-2RS are double sealed and not to be relu-
bricated.
VARIDRIVE UNITS
Do not turn speed control hand wheel while unit is not operating; this may cause damage to the unit.
Hand wheel position is a relative speed indication only. Use direct speed sensing accessory for pre-
cise speed indication. Units equipped with electric remote speed indicator accessory are not cali-
brated at the factory and must be calibrated at site. Refer to calibration instructions with the unit.
VARIDRIVES equipped with ENDOLUBE construction do not require lubrication of the sliding
Varidisc. Operate VARIDRIVE through its entire speed range weekly.
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ITEM 0705
Do not force control wheel beyond speed limits shown on the
nameplate. The mechanism and belt are designed for the rated
speed and horsepower shown on the nameplate. Operation beyond these limits may result in
damage to the belt and mechanism and possible injury to personnel. The covers on the frame
case must not be removed or left off while unit is in operation. Do not attempt to disassemble
or repair the driven pulley discs because high spring tension may be released causing injury
to personnel. Refer to authorized Service Center. Refer to VARIDRIVE Installation and
Maintenance Manual for complete belt changing instructions. For additional detailed
information, request specific product installation and maintenance manual.
GREASE LUBRICATION INSTRUCTIONS
Units are prelubricated at the factory and do not require initial lubrication. Relubricating interval
depends upon speed, type of bearing and service. Refer to Table 1 for suggested regreasing inter-
vals. Operating conditions may dictate more frequent lubrication. Motor must be at rest and electri-
cal controls should be locked open to prevent energizing while motor is being serviced (refer to sec-
tion on Safety). If motor is being taken out of storage, refer to storage procedures.
To relubricate bearings, remove the drain plug. Inspect grease drain and remove any blockage with
a mechanical probe taking care not to damage bearing.
Under no circumstances should a mechanical probe be used while
the motor is in operation. Add new grease at the grease inlet, refer
to Table 1 for replenishment quantities. New grease must be compatible with grease in the
motor (See Caution Note). Run the motor for 15 to 30 minutes with the drain plug removed
to allow purging of any excess grease. Shut off unit and replace the drain plug. Return motor
to service. Some motors have sealed bearings and are not regreasable.
Over greasing can cause excessive bearing temperatures, premature lubricant breakdown
and bearing failure. Care should be exercised against over greasing.
Table 1
Recommended Grease Replenishment Quantities & Intervals
(For lubrication of units in service)
For motors mounted vertically or in hostile environments, reduce intervals shown by 50 percent.
Refer to motor nameplate for bearings provided on a specific motor.
For bearings not listed in table above, the amount of grease required may be calculated by the
formula:
G=0.11 x D x B
Where;
G = Quantity of grease in fluid ounces.
D = Outside diameter of bearing in inches.
B = Width of bearing in inches.
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Bearing Bearing Grease
Number-Common Number-AFBMA FL Oz. Lubrication Interval
62XX
6203-6207
6208-6212
6213-6215
6218-6220
6221-6228
63XX
6303-6306
6307-6309
6310-6311
6312-6315
6316-6320
XXBC02
17-35
40-60
65-75
80-100
105-140
XXBC03
17-30
35-45
50-55
60-75
80-100
0.2
0.4
0.6
1.0
1.8
3600 RPM
2 Years
1 Year
1 Year
6 Mos.
6 Mos.
1800 RPM
3 Years
2 Years
2 Years
1 Year
1 Year
1200 RPM
3 Years
2 Years
2 Years
2 Years
1 Year
ITEM 0705
Table 2
RECOMMENDED GREASES
THE FOLLOWING GREASES ARE INTERCHANGEABLE WITH THE GREASE AS PROVIDED IN
UNITS SUPPLIED FROM FACTORY (UNLESS STATED OTHERWISE ON A LUBRICATION
NAMEPLATE PROVIDED ON MOTOR).
MANUFACTURER GREASE (NLGI No. 2)
EXXON CORP. POLYREX - EM
CHEVRON U.S.A. INC. SRI NO. 2
Greases of different bases (lithium, polyurea, clay, etc.) may not be
compatible when mixed. Mixing such greases can result in reduced
lubricant life and premature bearing failure. When necessary, prevent such intermixing by
disassembling the motor, removing all old grease from bearings and housings (including all
grease fill and drain holes). Inspect and replace damaged bearings. Fill bearing housings and
bearing approximately 30% full of new grease. Remove any excess grease extending beyond
the edges of the bearing races and retainers. Refer to Table 2 for recommended greases.
WARRANTY
LIMITED WARRANTY
All U.S.E.M. products are warranted against defects in workmanship and materials for 12 months
from date of installation, not to exceed 18 months from date of shipment from EMC. Some of
U.S.E.M's products carry a warranty period longer than 12 months. Please refer to the current price
catalog or to EMC for details on specific products. This limited warranty does not apply to any prod-
uct which has been subject to misuse, misapplication, neglect (including without limitation, inade-
quate maintenance), accident, improper installation, modification, adjustment, or repair. This consti-
tutes EMC's only warranty in connection with this sale and is in lieu of all other warranties, expressed
or implied, written or oral. THERE ARE NO IMPLIED WARRANTIES OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE THAT APPLY TO THIS SALE. No employee, agent,
dealer or other person is authorized to give any warranties on behalf of EMC nor to assume for EMC
any other liability in connection with any of its products.
EXCLUSIVE REMEDY
EMC's liability shall be limited exclusively to repairing or replacing any product found by EMC to be
defective, or at EMC's option, to refund the purchase price of its product. Such product shall be
returned, freight prepaid, to the nearest U.S.E.M. authorized service station or EMC factory. It is
agreed that such replacement, repair, or refund be the sole and exclusive remedies available from
EMC. EMC shall not be liable for damages of any sort whatsoever beyond these exclusive reme-
dies including incidental and consequential damages regardless of whether any claim is based upon
contract, negligence, strict liability, tort, warranty, or other basis. The repair or replacement of the
product, or the refund of the purchase price, at EMC's option, constitutes fulfillment of all liabilities
of EMC to the buyer for defective products.
RENEWAL PARTS AND WARRANTY SERVICE
When inquiring for renewal parts, call the nearest U.S. Electrical Motors Parts Stocking Distributor.
For warranty service, call the nearest U.S. Electrical Motors Authorized Service Station. Give them
complete Nameplate data, including identification number, etc.
Request installation and maintenance manuals by product name.
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C 3E B C 143J
C 3E B C 162
ITEM 0705
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ITEM 0705
Moduflow
Series
IL2/RF2/CF2 Low Pressure Filters
35
Global Filtration Technology
ITEM 0740
Low Pressure Filters
Moduflow
Series
Parker Hannifin Corporation
Hydraulic Filter Division
Metamora, OH
Flanges
s NPT or
SAE to 2
s Lightweight
aluminum
Bypass/Diverter
(not visible)
s 5 different
pressure settings
s No bypass option
available
Indicators
s Visual or electrical
s Mounted on either side
s Optional no element
indication
Cover
s Slotted for
quick release
s Lightweight
aluminum
Bowl
s Single or
double length
s Durable steel
construction
Element
(not visible)
s Available in
cellulose, wire
mesh or high
performance
Microglass II media
s Single or
double length
37
Feature Advantage Benefit
Top access element service Oil remains in housing No spills
Quicker element change Reduced maintenance costs
Slotted cover Quick release cover Reduced maintenance costs
Cap screws remain in housing No loose parts to lose
Closed bottom elements Removes all contaminant No downstream
(RF2 and IL2 only) during element service contamination from servicing
Visual or electrical indicators Know exactly when to service Helps prevent bypass condition
elements No premature disposal
Flange face ports Flexible mounting (3/4 to 2) Easy plumbing to your system
Features
ITEM 0740
Moduflow
Series
Metamora, OH
Specifications: DIL2
Pressure Ratings:
Maximum Allowable Operating Pressure
(MAOP): 200 psi (13.8 bar)
Design Safety Factor: 2:1
Rated Fatigue Pressure: 150 psi (10.3 bar)
Element Burst Rating: 70 psid (4.8 bar)
Filter Materials:
Diverter Valve Assembly: die cast aluminum
Check Valve Assembly: die cast aluminum
Filter Assembly: see IL2 specifications
Operating Temperatures:
Buna: -40F to 225F (-40C to 107C)
Fluorocarbon: -15F to 275F (-26C to 135C)
Weight (approximate):
Single: 55 lbs. (24.9 kg) / Double: 65 lbs. (29.5 kg)
Indicators:
Visual (optional)
Electrical (optional) 15A@250VAC/ .5A@125 VDC
Electrical (D option) 5A@250VAC / 3A@28 VDC
Color Coding:
White (normally closed)
Red (normally open)
Black (common)
479.3
18.87
30.2
1.19
OPTIONAL
FLANGE
345.9
13.62
INLET
OUTLET
AIR BLEED
EACH FILTER
177.8
7.00
402.8
15.86
OPTIONAL MECHANICAL INDICATOR
SINGLE
DOUBLE
-18 NPT
DRAIN VENT
CONNECT
TO TANK
173.0
6.81
-13 SHCS
TORQUE
32-38 FT-LB
110.5
4.35
79.0
3.11
116.8
4.60
76.2
617.5
24.31
330.2
13.0
3.00
25
20
15
10
5
1.75
1.5
1.25
0.75
0.5
0.25
0
1
FLOW LPM GPM
L
P
M
G
P
M
D
I
F
F
.

P
R
E
S
S
U
R
E
0 10 20 30 40 50 60 70 80 90 100
0 25 50 75 100 125 375 150 175 200 225 250 275 300 325
3
0
0
0

S
U
S
2
0
0

S
U
S
Typical Flow/Pressure Curves For Duplex Valves Approximate handle torque required for changeover.
System Pressure (psi)
T
o
r
q
u
e

(
F
t
-
L
b
s
)
30
20
10
100 200 300
0
*Diverter/check valves combined
(Add to differential pressure of
filter assembly for total duplex
pressure differential)
3.3
.013
43
Linear Measure:
millimeter
inch
BOTH CHECK VALVES
MOVE SAME DIRECTION
FILTER SCHEMATIC
DRAIN
VENT
BYPASS BYPASS
FILTER FILTER
OUTLET
INLET
ITEM 0740
Moduflow
Series
Metamora, OH
Accessories
OPTIONAL MOUNTING BRACKET (924904)
45
Linear Measure:
millimeter
inch
10.3
0.406
DIA. THRU
8 PLACES
OPTIONAL TANK FLANGE (925167)
8.7
0.344
DIA. THRU
6 PLACES
4.60
.18
MATERIAL
THICKNESS
149.2
5.875
DIA. B.C.
196.9
7.750
TYPICAL
98.4
3.875
TYPICAL
235.0
9.25
122.9
4.84
161.5
6.5
114.3
4.500
13.5
0.531
DIA. THRU
4 PLACES
114.3
4.500
R
60
TYP
7.9
0.31
8.7
0.344
DIA. THRU
PLACES
6.44
0.25
114.3
4.500
25.4
1.00
57.2
2.25
13.5
.531
41.1
1.62
DIA. THRU TYP.
M OPTION-VISUAL INDICATOR,
NO ELEMENT WARNING
V OPTION-VISUAL INDICATOR
E OPTION-ELECTRICAL INDICATOR
ITEM 0740
"D"
Moduflow
Series
Metamora, OH
1 Screws, Nameplate .............................. 900028 2
2 Name Plate, Unstamped ...................... 924928 1
3 Cover Screws, 5/16-18 UNC x 1 ........ 926633 6
4 Bowl Screws, 5/16-18 UNC x 1 .......... 926633 6
5 Cover, Without nameplate .................... 924634 1
6 O-Ring, cover, bowl and diverter
Buna ................................................. N72350 3
Fluorocarbon..................................... V72350 3
7 Diverter/Bypass Valve Assembly ....... 1
35 psid, Purple.................................. 926783
25 psid, Metalic Aluminum................ 926582
15 psid, Light Blue ............................ 926581
3 psid, Yellow .................................... 926580
2 psid, Pink ....................................... 926579
No Bypass ........................................ 926578
8 Head, Machined only ............................ 925972 1
9 Flange Kits Refer
to Table 1
10 Grommet (Buna) .................................. 924433 2
Grommet, (Fluorocarbon) .................... 925026 2
11 Single Elements, RF, IL Refer to 1
Table
12 Bowl, Select desired model ..................
IL2-1.................................................. 925916
IL2-2.................................................. 924816
RF2-1 ................................................ 925917
RF2-1 with 2 inch NPTF fitting .......... 924676
RF2-2 ................................................ 924815
RF2-2 with 2 inch NPTF fitting .......... 924818
CF1-1 with 2 inch NPTF fitting .......... 926207
CF2-2 with 2 inch NPTF fitting .......... 924817
13 Double Elements, CF Refer to 1
Table
14 Plug Kit, Fastener, self-sealing,
o-ring seal included with fastener ......... 925974 2
15 Indicator Electrical .............................. Optional
35 psid .............................................. 926643
25 psid .............................................. 924964
15 psid .............................................. 924965
3 psid ................................................ 924966
2 psid ................................................ 924967
16 Indicator Visual ................................... Optional
35 psid 4-band .................................. 926748
25 psid 4-band .................................. 924776
15 psid 4-band .................................. 924777
3 psid 4-band .................................... 924778
2 psid 4-band .................................... 924779
35 psid 3-band .................................. 926750
25 psid 3-band .................................. 924929
15 psid 3-band .................................. 924824
3 psid 3-band .................................... 924927
2 psid 3-band .................................... 924926
Flange, In-tank mounting ..................... 925167 Optional
Bracket, Inline mounting ...................... 924904 Optional
Indicator Kit Remote mount ................ 924894 Optional
Indicator Kit, Bulkhead mount ............. *925021 Optional
17 Check Valve Assy. (Submersible) ........ 925120 Optional
18 Check Rod Assy. ................................. Optional
2 - 1 CF............................................ 926954
2 - 2 CF............................................ 925140
19 Changeover Valve Assy., Duplex ........ 926758 Optional
20 Check Valve Assy., Duplex .................. 926757 Optional
Index Quanity
Part
No.
Description
RF2 / IL2 / DIL2 Replacement Elements
BUNA Fluorocarbon
MEDIA Single Double Single Double
02Q 932686Q 932692Q 932689Q 932695Q
05Q 932687Q 932693Q 932690Q 932696Q
10Q 932688Q 932694Q 932691Q 932697Q
20Q 933116Q 933117Q 933118Q 933119Q
03C 932361 932567 932367 932574
10C 932360 932467 932366 932473
20C 932359 932469 932365 932474
40SA 932358 932468 932364 932475
25W 932563 932566 932570 932573
40W 932562 932565 932569 932572
74W 932561 932564 932568 932571
WR 932363 932476 932370 932575
Buna Fluorocarbon
inch NPTF YB 924788 926013
1 inch NPTF YC 924787 926012
1 inch NPTF YD 924912 926004
1 inch NPTF YE 924786 926011
2 inch NPTF YF 924785 926010
SAE - 12 YM 924784 926009
SAE - 16 YN 924783 926008
SAE - 20 YO 924913 926005
SAE - 24 YP 924782 926007
BLANK FLANGE 924781 926006
Part Number
Size Code
Flange Kits (flange, 4 bolts, o-ring)
CF2 Replacement Elements
BUNA Fluorocarbon
MEDIA Single Double Single Double
05Q 924452Q 934264Q 925039Q 935534Q
10Q 924453Q 934265Q 925040Q 935535Q
03C 924449 924791 925036 925046
10C 924450 924792 925037 925047
20C 924451 924793 925038 925048
40SA 924448 924790 925035 925045
25W 924454 924796 925041 925051
40W 924455 924797 925042 925052
74W 924456 924798 925043 925053
WR 927584 927585 928908 928925
46
Parts List
*Two kits required for differential indication
ITEM 0740
Moduflow
Series
Metamora, OH
Filter Assembly Exploded View
47
10
13
10
6
6
10
11
4
12
17
19 20
15
16
18
1
2
6
5
3
7
8
6
9
12
4
14
ITEM 0740
Moduflow
Series
Metamora, OH
HOW TO ORDER: Select the desired symbol (in the correct position) to construct a model code.
Example:
BOX 1: Seals
Symbol Description
None Buna
F3 Fluorocarbon
E8 EPR
BOX 2: Basic Assembly
Symbol Description
CF2 Suction filter,
inlet on bottom;
outlet on side
RF2 Return-line filter,
inlet on side;
outlet on bottom
IL2 In-line filter
DIL2 In-line duplex
Note: Add W before 2 for HWCF modification.
BOX 3: Length
Symbol Description
1 Single element
2 Double element
BOX 4: Filter Media
Symbol Description
74W 74-micron wire mesh
40SA 40-micron synthetic
20C 20-micron cellulose
02Q* Microglass III
05Q* Microglass III
10Q* Microglass III
20Q Microglass III
WR Water removal
*Not available for CF2 model
Symbol Description
P Pressure ports
drilled and
plugged; no
indicator
M Visual indicator
w/ no element
warning
E Electrical indicator;
no visual
V Visual indicator
D Electrical indicator;
3-pin male quick
disconnect
S Pressure or
vacuum switch
(Selected based on
bypass setting.)
Note A: (First letter of indicator code =
left side of filter head when looking
into inlet with bowl down; second
letter = right side of filter head
when looking into inlet with
bowl down.)
Note: Indicators installed on filters will
be matched to the bypass valve.
BOX 1 BOX 2 BOX 3 BOX 4 BOX 5 BOX 6 BOX 7 BOX 8 BOX 9
BOX 5: Indicators (See Note A)
IL2 1 10Q MP 35 Y9Y9 1
Filter Inlet Outlet
Model Symbol/Description Symbol/Description
Y9 2 flange face Y9 2 flange face
F9 2 NPTF P9 SAE-24
integral threads
CF2
F8 External E9 1 NPTF
check valve integral threads
*See table below
Y9 2 flange face 99 No fitting
P9 SAE-24 F9 2 NPTF
RF2 integral threads
E9 1 NPTF F8 External
integral threads check value
*See table below
P9 SAE-24 P9 SAE-24
integral threads integral threads
IL2
E9 1 NPTF E9 1 NPTF
integral threads integral threads
*See table below *See table below
DIL2
*See table below *See table below
BOX 7: Port Options
1)First pair of symbols denotes inlet for all filter styles;
second pair of symbols denotes outlet.
2)Four symbols required: two for inlet, two for outlet.
3)Unused ports in CF2 and RF2 filters come plugged
with a blank flange.
4)On CF2, F8 option includes internal rod assembly.
* Available Port Flange Options For Filter Head
BOX 8: Modifications
Symbol Description
1 None
3 Magnets
11 No-bypass
(Two
Required)
NPTF flange
1 NPTF flange
1 NPTF flange
1 NPTF flange
2 NPTF flange
SAE-12 flange
SAE-16 flange
SAE-20 flange
SAE-24 flange
YB
YC
YD
YE
YF
YM
YN
YO
YP
Symbol Pressure Setting
BOX 6: Bypass & Indicator Setting
2 2 psid
3 3 psid
15 15 psid
25 25 psid
35 35 psid
48
Design number
assigned
by Parker
BOX 9: Design Number
Applied to the filter by Parker Hydraulic Filter
Division. Use the full model code, including the
design number when ordering replacement parts.
Please note the bolded options reflect
standard options with a reduced
lead-time. Consult factory on all
other lead-time options.
ITEM 0740
DIL2
MDMD
2
V-SERIES VALVES
11
V
-
S
E
R
I
E
S
V
A
L
V
E
S
Standard
with Screw
Connections
Standard
with Flange
Connections
Stainless Steel
with Screw
Connections
Handwheel
with Screw
Connections
Handwheel
with Flange
Connections
APPLICATION
The Fulflo V Series range in size from 1/4
through 2 and operate efficiently with liquids of
any viscosity at pressures from 2 to 1000 P.S.I.
The V series valves are available in flange or
screw type...cartridge or handwheel in a choice
of brass, cast iron, steel and stainless steel.
Widely used in a variety of applications, the V
series valves are ideally suited in hydraulic and
lubricating systems for load regulation and
system protection. Special trim or packings are
available for use with fire resisting fluids and
other liquids of this type. Unusual applications
and special requirements should be referred to
our engineering staff for recommendation.
INSTALLATION
Fulflo valves can be mounted in any position. A
tee may be inserted in the pump discharge line
to mount the valve. The correct size of valve
should be installed, preferably matching the
pump discharge line. Screw the valve into the
nipple in the tee, or in the case of the flange
style, bolt the valve to the companion flange
screwed into the nipple. When the valve is used
for frequent bypassing of oil pressure, its outlet
should be piped back to the tank. Care must be
taken to have the discharge well below the oil
level in the tank to prevent air entrainment and
erratic operation.
Only if the valve is used as safety or overload
relief and operates infrequently may its
discharge be piped back into the pump suction
line. Frequent or continuous operation under
these conditions will cause excessive heating of
the oil and possible damage.
ITEM 0750
V-SERIES
12
V
-
S
E
R
I
E
S
V
A
L
V
E
S
SETTING VALVES
Valves may be set with a hydraulic hand pump for
cracking pressure. If a test stand is available, valve
should be connected to the discharge header with the
pump bypass open, and the bypass gradually closed
until the desired pressure registers on the gauge.
Adjust valve adjusting screw until valve slightly bleeds
at the set bypass pressure and lock adjusting screw.
Fulflo valves are not designed to be positive shut-off,
and will pass a minimal amount of leakage before the
set pressure. If a valve is required to bypass a given
amount of fluid at a given pressure, a test stand
TYPICAL DISASSEMBLY OF STANDARD TYPE VALVE
having a flow meter in the pump discharge line must
be available. With a valve adjusted for cracking
pressure as above, continue closing bypass until the
required flow registers on the flow meter and observe
pressure. Readjust pressure, if necessary, to obtain
desired pressure at desired flow.
MAINTENANCE
Fulflo valves provide reliable chatter-free operation
when the system is free of abrasives and foreign
matter. Continuous filtration of the liquid used is
strongly recommended.
To dismantle valve for inspection or cleaning:
1. Remove cap B
2. Remove O-Ring E
3. Remove lock nut F
4. Remove adjusting screw C
5. Remove retainer D
6. Remove spring G
7. Remove piston I
8. Remove stop ring H (Not Recommended)
(Special tooling is required to install new stop ring.)
Inspect valve bore and piston for wear and scoring. Replace
broken or damaged parts. Clean all parts thoroughly and
re-assemble by reversing the above procedure.
TYPICAL DISASSEMBLY OF HANDWHEEL TYPE VALVE
To dismantle the valve for inspection or cleaning:
1. Release spring tension by backing off handwheel as far as it
will go.
2. Remove lock nut A or set screw and take off handwheel B
3. Remove lock nut D
4. Unscrew and remove gland E
5. Unscrew and remove bonnet F
6. Remove O-Ring H
7. Remove adjusting screw C (turn clockwise and pull out from
bottom of bonnet F)
8. Remove O-ring packing G
9. Remove spring J
10. Remove piston K
11. Remove stop ring L (Not Recommended)
(Special tooling is required to install new stop ring.)
Inspect valve bore and piston for wear or scoring. Replace broken
or damaged parts. Clean all parts thoroughly and re-assemble by
reversing the above procedure.
B
E
F
C
D
A
H
I
G
C
G
E
D
B
A
J
F
K
H
L
I
ITEM 0750
V-SERIES
13
V
-
S
E
R
I
E
S
V
A
L
V
E
S
ASSEMBLY NUMBER IDENTIFICATION CHART
Symbol No. Designation Code Description
1 Style None
H
Standard Model
Handwheel Model
2 Series V
3 Material J
B
S
SS
Cast iron
Brass
Steel
316 Stainless Steel
4 Connections None
F
Screw Connections
Flange Connections 300# Flange Class Standard (250# Flange Class - Cast Iron Standard)
5 Size -1
-2
-3
-4
-5
-6
-7
-8
1/4
3/8
1/2
3/4
1
1
1
/4
1
1
/2
2
6,7,8
ASA
Flange
Rating
None
-150
-600
300# Flange Standard (no designation required)
9
Flange
Style
150# & 600#
Only
A
B
C
D
Raised Face, Staggered Bolt Centers (standard on all Flange rating)
Smooth Face, Staggered Bolt Centers
Raised Face, Bolts on Valve Centerline
Smooth Face, Bolts on Valve Centerlne
10 O-Ring
Material
R
RV
RS
RT
RA
Buna O-Ring Cap Seal (standard)
Viton O-Ring Cap Seal
Silicone O-Ring Cap Seal
Teflon O-Ring Cap Seal (standard on VSS Series)
Aflas O-Ring Cap Seal
11 Options SP
P
Steel Parts (used on cast iron only)
Panel Mount on Handwheel Series
12 Piston
Material
/HS
/SS
/3SS
Hardened Steel
416 Stainless Steel
303 Stainless Steel
13 Spring AS
US
WS
XS
YS
ZS
14 Setting Desired Pressure Setting
EXAMPLES:
VJ-1RVSP/HS/WS
V
Series
J
Cast Iron
-1
1/4
SP
Steel Parts
RV
Viton O-Ring
/HS
H.S. Piston
WS
WS Spring
VJF-5R/HS/WS
V
Series
J
Cast Iron
F
Flanged
-5
1
R
Buna O-Ring
/HS
H.S. Piston
WS
WS Spring
VJF-5-150AR/HS/WS
V
Series
J
Cast Iron
F
Flanged
-5
1
-150
Rating
A
Style
R
Buna O-Ring
/HS
H.S. Piston
WS
WS Spring
NOTE: Stainless steel pistons are supplied on brass valves, unless hardened steel is specified. Hardened steel pistons are supplied on cast iron or steel unless stainless steel is
specified. Buna O-Rings are supplied as standard unless other material is specified.
STANDARD PRESSURE RANGE CHART
SPRING PRESSURE AND IDENTIFICATION NO. Valve
Pipe
Size
Valve
Flange
Size
BLACK-AS RED-US GREEN-WS YELLOW-XS WHITE-YS BLUE-ZS PURPLE-TS BROWN-RS
1/4
3/8
1/2
3/4
1
1
1
/4
1
1
/2
2
1
1
1
/4
1
1
/2
2
Low
3
3
3
3
3
3
3
3
High
15
15
15
15
15
15
15
15
Low
7
7
7
7
7
7
7
7
High
35
35
35
35
35
35
35
35
Low
30
30
30
30
30
30
30
30
High
100
100
100
100
100
100
100
100
Low
60
60
60
60
60
60
60
60
High
175
175
175
175
175
175
175
175
Low
150
150
150
150
150
150
150
150
High
350
350
350
350
350
350
350
350
Low
300
300
300
300
300
300
300
250
High
500
500
500
500
500
500
500
600
Low
400
400
400
High
600
600
600
Low
550
550
550
High
750
750
750
ITEM 0750
15
V
-
S
E
R
I
E
S
V
A
L
V
E
S
V-SERIES
VJF Cast Iron
VBF Brass
VSF Steel
VSSF Stainless Steel VJF-SP Cast Iron with Steel Parts
DIMENSIONS
PARTS LIST
SYM. NAME MODEL
VALVE SIZE
1 1
1
/4 1
1
/2 2
A
B
C
D
E
F
G
H
I
J
K
BODY
CAP
(O-RING SEAL)
ADJUSTING
SCREW
RETAINER
O-RING
LOCK NUT
SPRING
STOP RING
PISTON
CAP
(GASKET SEAL)
GASKET
VJF, VJF-SP
VBF
VSF
VSSF
VJF, VJF-SP
VBF
VSF
VSSF
VJF, VBF
VSF, VJF-SP
VSSF
VJF, VBF
VSF, VJF-SP
VSSF
VJF, VJF-SP
VBF, VSF
VSSF
VJF, VJF-SP
VBF, VSF
VSSF
ALL MODELS
VJF, VBF
VJF-SP, VSF
VSSF
HARDENED STEEL
416 STAINLESS STEEL
303 STAINLESS STEEL
VJF, VJF-SP
VBF
VSF
VJF, VBF
VJF-SP, VSF
500-F
500-BF
500-SF
500-SSF
501-R
501-BR
501-SR
501-SSR
502-B
502-S
502-SS
503-B
503-S
503-SS
504*
504-*
504-RT
505-S
505-S
505-SS
507-**
508-B
508-S
508-SS
506
506-A
506-SS
501
501-B
501-S
504
504-S
600-F
600-BF
600-SF
600-SSF
601-R
601-BR
601-SR
601-SSR
602-B
602-S
602-SS
603-B
603-S
603-SS
604*
604-*
604-RT
605-S
605-S
605-SS
607-**
608-B
608-S
608-SS
606
606-A
606-SS
601
601-B
601-S
604
604-S
700-F
700-BF
700-SF
700-SSF
701-R
701-BR
701-SR
701-SSR
702-B
702-S
702-SS
703-B
703-S
703-SS
704*
704-*
704-RT
705-S
705-S
705-SS
707-**
708-B
708-S
708-SS
706
706-A
706-SS
701
701-B
701-S
704
704-S
800-F
800-BF
800-SF
800-SSF
801-R
801-BR
801-SR
801-SSR
802-B
802-S
802-SS
803-B
803-S
803-SS
804*
804-*
804-RT
805-S
805-S
805-SS
807-**
808-B
808-S
808-SS
806
806-A
806-SS
801
801-B
801-S
804
804-S
* See o-ring selection chart
** See spring pressure chart
Recommended spare parts
B
B
4
5
4
5
A
A

R
E
F
.
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
22
1
/2
22
1/2
45
BB
P
I
P
E

S
I
Z
E
PIPE SIZE
DIMENSIONS IN INCHES
Valve
Size
AA BB
1
1
1
/4
1
1
/2
2
9
1
/2
10
13
/16
12
7
/16
14
9
/16
3
1
/2
3
3
/4
4
1
/16
4
9
/16
J
K
B
C
F
E
D
G
A
I
H
CAP
(GASKET SEAL)
FOR 2VALVE ONLY
Note: Dimensions reflect
150# and 300# only
ITEM 0750
This page is formatted for printing: To print, hold down the control key (Ctrl) then press the letter "P".
(Ctrl+P)

ITEM 0770
AB - 1010 - 13 - G - DS-13 - CH (CH is for Chain)
Solberg Oil Mist Eliminators
1

SOLBERG OIL MIST ELIMINATORS
Installation, Operation and Maintenance Instructions

DISCLAIMER

Although instructions and recommendations are included for installation of the Oil Mist Eliminator, the
Manufacturer (Solberg Manufacturing, Inc. or Solberg International Ltd) does not assume any
responsibility for the final installation of this Oil Mist Eliminator. The Manufacturer will not be held
liable for direct or any consequential damages resulting from inappropriate methods of handling or
installation. The Oil Mist Eliminator needs to have adequate support or the unit may suffer a
premature failure due to stress and vibration. Designs and layouts may change based on specific
application conditions.

All the information in this manual has been thoroughly perused; the Manufacturer assumes no
accountability for any possible errors or omissions.

This is only intended to be a guide and it is to be used by the customer with proper caution. If there are
any doubts or questions, please contact a Solberg office or representative before installation.

For inquiries within the USA, please call Solberg Manufacturing, Inc. at +1-630-616-4400
For all inquiries outside of the USA, please call Solberg International, Ltd at +1-630-616-4900
or contact your local Solberg sales representative. For a list of our international offices and
representatives please visit our website at www.solbergmfg.com and click on International
Representatives at the bottom of our homepage.

DESCRIPTION

The Solberg Oil Mist Eliminator (OME) is designed to remove oil mist emissions from a polluted
air/gas stream and discharge clean air to the atmosphere. The filter element inside the OME vessel is a
coalescing separator (Item 2 on schematic) which operates at an efficiency of 99.97% for 0.3 micron
oil mist. Mist laden air goes through the element, coalesces and drains to the bottom of the vessel. The
collected oil is drained out of the filter through a drain port back to the oil reservoir, crankcase or waste
receptacle. Clean air is discharged to the atmosphere through the outlet.

There are two primary types of mist eliminators: Static (CV Series) and Vacuum Assisted Oil Mist
Eliminator (VAE Series)

CV Series: The CV product line is designed to remove all visible oil mist emissions. It is easily
installed and can operate for a number of years with little to no maintenance while maintaining high
efficiency. This is not vacuum extraction model, and is usually installed on systems that tolerate
positive pressure. With these systems, the reservoir or crankcase can usually handle the differential
pressure contributed by the air/gas flow through the Oil Mist Eliminator.

ITEM 0772
2
VAE Series: This product line is designed to remove all visible oil mist emissions. Many turbines and
compressors are designed to operate with the oil reservoir or crankcase maintained at a negative
pressure typically between -25 to -200 mm/1-4 of H20. The VAE uses a blower or fan to create
vacuum and overcome the differential pressure created by the filter element. The result is negative
pressure inside the oil reservoir/crankcase. With the help of valves or a VFD (Variable Frequency
Drive), the negative pressure is controlled.

OPERATION

Pressure Differential & Efficiency:
Pressure differential is a very significant factor in designing OMEs for lube oil applications. This
value varies throughout the life of the OME, and will have an effect on maintaining the pressure inside
the reservoir/crankcase. The customer requirement determines the size of the internal filter element,
connection sizes and vessel.

Most Solberg OME filter elements are rated 99+% for 0.3 micron oil mist which typically results in
low outlet oil concentrations. The elements are sized properly, so the saturated pressure differential is
as low as possible. The increase in pressure differential from the clean initial reading to the saturated
reading should also be kept to a minimum.

Differential pressure increases as the filter element saturates and reaches equilibrium after a certain
time period (usually 48-72 hours). Also, over the element life span, it becomes dirty and contaminated
with particulate from the oil reservoir/crankcase. This causes an increase in differential pressure,

Drain Port:
All the oil mist eliminators used to eliminate visible emissions are equipped with a drain port (Item 4
on schematic) so coalesced oil can be returned to the lube oil reservoir, crankcase or waste receptacle.
The drain line is typically supplied by the operator/end-user. The filter vessels are typically installed
vertically; thus the oil uses the force of gravity to drain. The drain port and installed line must be free
of any kinks, obstructions and debris. Any of these occurrences can cause oil to collect in the line and
migrate into the vessel resulting in oil bypass out into the atmosphere.

Solberg Static Oil Mist Eliminator (CV Series) Schematic
4
1
3

2
5

6
ITEM 0772
3

Temperature:
Since the OME is designed to capture and coalesce oil mist emissions, temperature is an important
factor. Solberg recommends a maximum air/gas stream temperature of 180 degrees F. Oil tends to
stay vaporized at higher temperatures, and this can lead to oil carryover past the filter element.
Mounting height above the mist source and/or a heat exchanger are two methods to limit the effect of
temperature.

Applications:

1. The Solberg OME is intended for separation of only oil mist. It is neither an inlet air filter nor
a dust collector. It should be not be used to capture solid particulate.

2. It is also important to note that certain applications such as metal shearing may result in a
build-up of heavy solid particulate on the OMEs high efficiency filter element. In these
cases, the results may be excessive differential pressure, limited life span and resulting oil mist
emissions.

3. It is important that an OME is properly sized for each application. The air flow is a critical
parameter. Air flow from the oil reservoir or crankcase determines the differential pressure
contributed by the filter element(s) and the type/size of the vacuum source for a VAE.

4. Questions regarding the sizing of the units can be directed to the Solberg Oil Mist Solutions
team at askengineering@solbergmfg.com or by visiting the Solberg Oil Mist Solutions
website at http://www.oilmistsolutions.com

INSTALLATION

1. Inspection: Inspect the shipping box or the skid carefully for damage. If everything is intact,
open and check the unit for damage. Care should be taken to check the blower thoroughly if it
is a VAE unit. If any damage has occurred, please notify the shipping company. All units are
inspected for quality before shipment

2. Orientation: Solberg OMEs are installed vertically. Please refer to the manufacturers sales
drawings for information as this varies from unit to unit. The drawings will show the correct
inlet and outlet markings for correct direction of flow. (Items 1 and 3 respectively on the
schematic) Also, adequate clearance should be given for the drain line as well as the removal
of top cover and filter element.

3. Location: The unit is typically mounted as close as possible to the source of the oil mist
emissions. This will minimize the pressure differential contributed by the piping. However,
the temperature of the air/gas stream is important. Mounting height can determine the
temperature of oil mist when it reaches the OME.

4. Vessel Connections: The OMEs typically are equipped with a male pipe, female coupling or
a flange on the inlet side of the vessel. This must be secured properly to the
reservoir/crankcase connection. If ducting is used, Solberg recommends that the length and
number of bends are minimized to reduce pressure differential across the pipe span.

5. Drain Line Connections: Either rigid or flexible hose are acceptable for the drain connection.
Solberg recommends that the line is vacuum rated to avoid collapse under negative pressure.
Sometimes, larger units are equipped with two drain connections. The two drain lines should
never be connected or manifolded together.

6. First 24-72 Hours: As the coalescing filter element becomes saturated with lube oil, the
pressure differential will increase and then stabilize.

7. Filter Element Life Span: As the coalescing filter element ages, it will capture particulate that
is present in the lube oil. This will increase the differential pressure over time. Periodically
monitor your reservoir or crankcase pressure level to ensure the proper level is maintained.
This can be done with a digital or analog gauge. (Item 5 on the schematic) When pressure
ITEM 0772
4
levels in the reservoir or crankcase reach the maximum tolerated levels, the internal element
should be replaced.

MAINTENANCE
The maintenance of the mist eliminator requires an inspection of the filter element differential pressure
at regular intervals. This is easily accomplished with a digital or analog gauge. The replacement
interval is a function of the solid contaminants in the lube oil and subsequent mist emissions. When
only clean oil mist is being fed to the OME, it will function for an extended period of time (usually a
year or more) without maintenance of any kind. In applications where excessive solid contaminant or
high humidity is present in the air stream, frequent filter replacements may be necessary.

Filter Element Replacement

1. Never run the unit with the vessel cover removed. With smaller units, the v-band style clamp
(Item 6 on schematic) will need to be removed in order to access the filter.

2. Remove the bolt which holds the element in position.

3. Lift out the element(s). Care should be taken when removing them as the saturated weight
may exceed normal handling limits. Large elements will have lifting handles to facilitate
removal.

4. IMPORTANT: The used elements cant be used again. They should be disposed immediately
after removal. Since the elements are saturated with used oil, please dispose in accordance
with local regulations. They cant be cleaned, and no attempt should be made to clean or re-
use these cartridges.

5. Check the filter vessel covers o-ring or gasket for damage and replace if necessary. Also,
check the sealing butterfly gasket for damage, which is located on the bottom of some vessel
sizes. Replace if necessary. Ensure that gaskets adhered to the replacement element are intact.
These are critical for proper sealing and performance

6. Center the element seals seals positively to the canister and top plate of the element. Tighten
the bolt to secure the cartridge. Close the top cover by clamping the v-band or by tightening
the bolts.

7. Solberg recommends a maintenance plan for monitoring pressure differential readings and
pressure/vacuum readings in the reservoir/crankcase.

8. Line Inspection: Periodically, check hoses and drain lines for any possible leaks. Solberg
suggests a planned maintenance program to ensure optimum performance

9. Cleaning: Do not use any hydrocarbon based solvents or toxic solvents for cleaning. Vapors
discharged from any residues will cause health hazards. Detergents or soaps may be used in
cleaning the vessel.

The remaining components require no regular maintenance and only need to be replaced in the case of
damage. When ordering replacement parts always reference the sales drawing number or the full model
number of the OME on your request. For parts and service information, please contact Solberg team at
+1-630-616-4400 (USA inquiries) or +1-630-616-4900 (International inquiries); or by visiting
www.solbergmfg.com or www.oilmistsolutions.com to email our Customer Service Representatives.

ITEM 0772
I T E M 0 7 7 2
INSTALLATION
Except when the hot fluid is dirty or is prone to fouling, it is preferable to pass the cooling medium through the
tubes and the hot medium through the shell. Since the tubes can be mechanically cleaned it is sometimes
advantageous to pass the hot dirty fluid through the tubes. When installing a single pass unit the shell inlet must
be at the same end of the exchanger as the tubeside outlet (counter current flow).
When the BASCO Type 500 is used with steam as the heating medium, the steam must be in the shell. Either or
both shell connections may be used as steam inlets. Water to be flowing prior to injection of steam to avoid
differential expansion.
OPERATIONS
At start up or after maintenance inspection, both shell and tubeside should be carefully vented and full of liquid.
Improper venting and fouling are the most common causes of heat exchanger malfunction.
To obtain maximum performance the following precautions should be taken:
1. Make sure all other equipment in the fluid ciruits are functioning properly.
2. Maintain rated flow of both fluids but be sure flow rates are not excessive. Frequently, tube failures can be
directly traced to excessive fluid flow, causing tube erosion and corrosion. In the case of heavy oils high
flow rates can reduce cooler efficiency.
3. A periodic venting program should be followed if air or vapor tends to accumulate in the system.
4. Observe a regular maintenance program.
INSPECTION
A periodic inspection and maintenance program should be followed with any heat exchanger. To ensure
continuous satisfactory performance of your Type 500 exchanger the following steps should be taken.
1. Inspect filters in system and replace or clean as required.
2. Remove bonnets from heat exchanger and inspect the zinc pencils for erosion or oxide deposits. Scrape to
bright surface and replace if more than half corroded away.
3. Carefully examine tubes for scale and clean if necessary. After cleaning, examine for erosion or corrosion.
CLEANING
The interior surfaces of the tubes can be cleaned in several ways. Many deposits can be removed by flushing a
high velocity stream of water through them. For more stubborn deposits, wire brushes or rods can be used. If the
special air or water gun is available rubber plugs can be forced through the tubes.
Both shell and tubeside can be cleaned chemically by circulating cleaning solutions through the exchanger. For
most deposits a mild oakite solution is satisfactory. Circulate the cleaning solution until exchanger is clean. Be sure
to wash out all chemicals thoroughly with clean water before returning the exchanger to service.
OPERATING INSTRUCTIONS
BASCO TYPE 500 EXCHANGERS
API Basco
2777 Walden Avenue
Buffalo, New York 14225
Toll Free - 877-API-HEAT
Fax (716)684-2129
sales@apiheattransfer.com
www.apiheattransfer.com
...world leaders in heat transfer technology
ITEM 0800
I T E M 0 8 0 0
A5E00331168D-01 GN: 30380_TH100
Operating Instructions Edition 06/2006
Siemens Aktiengesellschaft
Automation and Drives
Process Instrumentation and Analytics
76181 KARLSRUHE
GERMANY
Temperature transmitter
SITRANS TH100
for sensor head installation
7NG3211-0*N00
www.siemens.com/processinstrumentation
sitrans
A5E00331168-01
SITRANS TH100
A5E00331168--01
1
SITRANS TH100
7NG3211--0*N00
Edition 06/2006
Temperature transmitter for sensor head installation
Operating instructions
www.siemens.com/sitranst
ITEM 1110, 1140, 1190,
1270, 1280, 1290
!
!
!
!
Siemens corporation A5E00331168
2
SITRANS TH100
A5E00331168--01
Safety information
This manual contains instructions which must be complied with for the sake of your personal safety and also to prevent
damage to property. The information concerning your personal safety is indicated with a warning triangle; information
solely concerning damage to property is given without a warning triangle. Depending on the level of danger, the warn-
ings are given in decreasing order, as follows:
Danger
means that death or severe injury will result if the corresponding precautions are not taken.
Warning
means that death or severe injury may result if the corresponding precautions are not taken.
Caution
with a warning triangle means that slight injury may result if the corresponding precautions are not taken.
Caution
without a warning triangle means that damage to property may result if the corresponding precautions are not taken.
Notice
means that an undesirable event or condition may result if the corresponding note is not observed.
If more than one level of danger applies, warnings for the highest level will always be given. If a warning against personal
injury is given with a warning triangle, it may contain an additional warning against damage to property.
Qualified personnel
This device/system may only be installed and operated together with this document. Commissioning and operation of
devices/systems are to be carried out only by qualified personnel. Qualified personnel is defined within the context of
the safety information contained in this document as persons who have been authorized to operate, ground or mark
devices, systems and electrical circuits in accordance with accepted technical safety standards.
Intended use
Observe the following:
Warning
The device may only be used in the cases prescribed in the catalog and in the technical description and only in con-
junction with third-party devices and components recommended or approved by Siemens. Proper shipping, storage,
installation, operation and maintenance of the product are essential for ensuring correct and safe operation.
Trademarks
All names marked with the symbol are registered trademarks of Siemens AG. Other names in this document may be
trademarks, whose use by a third party for their own purposes may impinge on the rights of the owner.
Copyright Siemens AG All rights reserved.
The reproduction, transmission or use of this document or its contents is not
permitted without express written authority. Offenders will be liable for damages.
All rights, including rights created by the granting of patents or registration of a
utility model or design, are reserved.
Exclusion of liability
We have checked to ensure that the information contained in this document
corresponds to the characteristics of the actual hardware and software. Neverthe-
less, we cannot assume responsibility for any deviations that may arise. The
information contained in this document is checked regularly for errors. Necessary
corrections made to the text appear in later editions.
Siemens AG
Automation and Drives, Postfach 4848, D--90327 Nrnberg
Siemens AG
Technical changes may be made without prior notice.
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Operating instructions 7NG3211--0*N00
SITRANS TH100
A5E00331168--01 3
Table of contents
1 Introduction 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Purpose of this documentation 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 History 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Additional information 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 General safety notes 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 General instructions 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Correct usage 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Laws and directives 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 Qualified personnel 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Description 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Field of application 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Product features 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Structure of the type plate 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 How It works 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Installation 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Installation in the connection head 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Installation on DIN rail and G rail 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Electrical connection 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 General connection notes 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Connection in hazardous areas 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Connection assignment 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Commissioning 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Functions 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 General information 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 Output current in case of error 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 Wire break monitoring 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4 Short circuit monitoring 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.5 Line compensation 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6 Type of characteristic curve (rising or falling) 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 Operating with PC and modem 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 Technical data 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 Ordering data 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 Dimensional drawing 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 Maintenance 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 Certificates 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SITRANS TH100
A5E00331168--01
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A5E00331168--01 5
1 Introduction
1.1 Purpose of this documentation
This programming manual contains all the information you need for commissioning and using the
transmitter.
It is aimed at persons who install the device mechanically, connect it electrically, parameterize and
commission it, as well as at service and maintenance engineers.
1.2 History
This history establishes the correlation between the current documentation and the valid firmware of
the device.
The documentation of this edition is applicable for the following firmware:
Edition Firmware identifier
on type plate
System integration Installation path for PDM
01
06/2006
FW: 01.01.00 TH100: SIPROM T V1.07 TH100: not relevant
The most important changes in the documentation when compared with the respective previous
edition are given in the following table.
Edition Remark
01
06/2006
First edition
1.3 Additional information
Information
The contents of this programming manual shall not become part of or modify any prior or existing
agreement, commitment or legal relationship. All obligations on the part of Siemens AG are contained
in the respective sales contract, which also contains the complete and solely applicable warranty
conditions. Any statements contained in the programming manual do not create new warranties or
modify the existing warranty.
The content reflects the technical status at the time of printing. We reserve the right to make technical
changes in the course of further development.
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A5E00331168--01
Regional offices
If you need more information or have particular problems which are not covered sufficiently by this
programming manual, contact your local Siemens regional office. You will find your local Siemens
regional office on the Internet at:
www.siemens.com/processinstrumentation/contacts
Click on Contact and select your closest city/town.
Product information on the Internet
The programming manual is a constituent part of the CD sitrans t -- temperature transmitters, order
number A5E00364512 and are available on the homepage at:
Click on More Info and then --> Instructions and Manuals.
On the CD, you will find an extract of the catalog FI 01 Field Instruments for Process Automation
with the current ordering data. The entire FI 01 catalog is also available at the above web address.
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A5E00331168--01 7
2 General safety notes
2.1 General instructions
This device left the factory free from safety problems. In order to maintain this status and to ensure
safe operation of the device, please observe the notes and warnings contained in this programming
manual.
2.2 Correct usage
The device may only be used for the purposes specified in this programming manual.
Insofar as they are not expressly stated in this programming manual, all changes to the device are the
sole responsibility of the user.
2.3 Laws and directives
The regulations of the test certification valid in your country are to be observed.
!
WARNING
This device may only be installed and operated once qualified personnel have ensured that
appropriate power supplies are in use. These power supplies must guarantee that no
hazardous voltage can reach the device, whether during normal operation or in the event of
a malfunction of the system or one of its parts.
2.4 Qualified personnel
Qualified personnel means those who are familiar with the installation, mounting, commissioning and
operation of the product. They must have the following, appropriate qualifications for their activities:
D Training or instruction/authorization in operating and maintaining devices/systems according to the
safety regulations for electrical circuits, high pressures and aggressive media.
D Training and instruction in maintenance and use of adequate safety equipment according to safety
regulations.
D For devices with explosion protection: Training or instruction/authorization in carrying out work on
electrical circuits for hazardous systems.
D First aid training
.
NOTE
The general regulations for operation of the system must be followed during operation and
maintenance of the transmitter.
The content reflects the technical status at the time of printing. We reserve the right to make
technical changes in the course of further development.
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A5E00331168--01
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3 Description
3.1 Field of application
The SITRANS TH100 transmitter is suitable for measuring Pt100 resistance thermometers in all
industry sectors. Its compact size means that it can be installed in connection head of type B
(DIN 43729) or larger.
The output signal is an output current of 4 to 20 mA that is proportional to the temperature.
Parameters are assigned to the device using a PC and the SIPROM T parameterization software together
with the modem for SITRANS TH100/TH200. If you already have a modem for SITRANS TK (order
number 7NG3190--6KB), you can use it for the parameterization of the SITRANS TH100.
The version of the transmitter with the protection type intrinsically safe can be installed in hazardous
areas. The devices are compliant with Directive 94/9/EC (ATEX) and the FM regulations.
3.2 Product features
D Transmitter with two--wire technology
D Installation in connection heads of type B (DIN 43729) or larger, or on a DIN rail
D Programmable: sensor activation, measuring range and many other variables can be programmed
D Intrinsically safe version for use in hazardous areas
3.3 Structure of the type plate
The type plate is located on the housing and carries the order number and other important product
information.
(1)
(7) (4)
(3) (2)
(6) (5)
(1) Manufacturer (5) Firmware revision
(2) Product name (6) Hardware revision
(3) Order number (7) Place of manufacture
(4) Pay attention to the operating instructions
Figure 1 Structure of the type plate
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3.4 How It works
The measurement signal sent by a Pt100 resistance thermometer (two-wire, three-wire, four-wire
connection) is amplified in the input stage. The voltage proportional to the input variable is then
converted to digital signals by a multiplexer in an analog-to-digital converter. In the microcontroller,
they are recalculated according to the sensor characteristic curve and other factors (measuring range,
damping, etc.).
After being prepared in this way, the signal is converted in a digital-to-analog converter into an output
current of 4 to 20 mA.
The input circuit and the output circuit are both protected from electromagnetic interference by EMC
filters.
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A5E00331168--01 11
6
5
3
4
EMC_1
Pt100
MUX
A/D
D/A
C
U
I
U
ref
EMC_2 4 ... 20 mA
U
ref
I
c
+1
--2
U
aux
, I
out
Input:
Pt100 Pt100 resistance thermometer
EMC_1 Input stage with protective components
I
c
Constant-current source
MUX Multiplexer
A/D Analog-to-digital converter
Output:
D/A Digital-to-analog converter
U/I Voltage transformer, current transformer, constant-voltage source and reference-voltage source
EMC_2 Output stage with protective components
U
aux
Auxiliary power
I
out
Output current
Microcontroller:
C Computing functions and saving of all parameters
Figure 2 Function diagram of the SITRANS TH100
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4 Installation
4.1 Installation in the connection head
CAUTION
The following must be observed before the head--mounted transmitter is installed:
- The SITRANS TH100 transmitter needs to be installed in a suitable housing.
- The degree of protection and housing material need to be adapted to meet the relevant
requirements.
- The ambient conditions specified in the technical data (chapter 9, page 25) need to be
adhered to.
Springs and screws for securing the transmitter are included with the device.
The SITRANS TH100 can be secured either in the base of the connection head or in the raised cover
of the connection head.
Transmitter
Figure 3 Securing the transmitter in the connection head cover
Transmitter
Figure 4 Securing the transmitter in the connection head base
!
WARNING
When installing the device in hazardous areas (Zone 1), the housing must have at least
IP54 degree of protection according to the IEC 60529.
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4.2 Installation on DIN rail and G rail
The transmitters can be secured either on a 35 mm DIN rail (DIN EN50022) or a 32 mm G rail
(DIN EN50035). The DIN rail adapter required for installation can be ordered as an accessory under
the order number 7NG3092--8KA.
The ambient conditions in the technical data (chapter 9, page 25) need to be adhered to for rail
installation.
Figure 5 Securing the transmitter on the DIN rail
Figure 6 Securing the transmitter on the G rail
(0.55)
(1.99)
(1.30)
(
2
.
3
5
)
Figure 7 DIN rail dimensions (7NG3092--8KA)
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5 Electrical connection
5.1 General connection notes
!
WARNING
Electrical connection in hazardous areas
The national directives and laws for hazardous areas valid in your country must be observed
for electrical connection. In Germany these are, for example:
- the working reliability regulation
- the directive for Installation of electrical systems in hazardous areas, DIN EN60079--14
(previously VDE 0165, T1)
- the EC type examination certificate
Where power supply is required, we recommend checking the power supply to ensure that it
corresponds with that on the type plate and with the test certification valid for your country.
D Connection of the sensor, see Figure 8
D Power supply
Connect the wires for the power supply to terminals 1(+) and 2(--), as shown in Figure 8,
ensuring polarity is correct (device is reverse polarity protected). .
D Connection cable
Max. cable cross section 2.5 mm
2
Lay signal cables separately from cables with voltages >60 V
Use cable with twisted wires.
Avoid getting too close to large electrical systems or use shielded cables.
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Three--wire connection
1)
Two--wire connection
(programmable line
resistance)
Four--wire connection Connection of power supply (U
aux
)
+ --
U
aux
1)
Terminal no. 5 does not have any function in the device version with three-wire connection and must not be connected. If the
three-wire connection is selected, wires of the unused fourth sensor cable should be isolated electrically using insulation tape
when using RTDs in the device version with four--wire connection.
Figure 8 Terminal plate for Pt100 resistance thermometer and power supply
5.2 Connection in hazardous areas
Zones 0 and 1
The transmitter is only allowed to be connected to devices that are certified as intrinsically safe in
accordance with the EC type examination certificate. The parameters and limit values listed there
must be complied with.
Zone 2 in protection type nL -- Limited energy
The transmitter is only allowed to be connected to the following devices:
D Devices that are certified as intrinsically safe in category 1 or 2.
D nL--certified devices (limited energy) in category 3.
The maximum permitted input voltage is U
i
= DC 30 V. The relevant permitted values for external
capacitance and inductance must be adhered to.
Zone 2 in protection type nA -- Non-sparking
The conditions for installers applicable to this protection type must be adhered to. The maximum
permitted input voltage is U = DC 35 V.
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5.3 Connection assignment
1(+) and 2 (--) Power supply U
aux
, output current I
out
3, 4, 5 and 6 Sensor (Pt100) (connections see chapter 5 Electrical Connection, page 15)
(1.73)
(1.3)
Internal diameter of center hole 6.3 (0.25)
(
0
.
8
2
)
Fixing screw M4x25
Figure 9 Connection assignment
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6 Commissioning
The operating data of the transmitter have to be set in accordance with the requirements of the
measurement task at hand. Ensure that the operating data corresponds to the data on the type plate.
When the transmitter is installed in the connection head, the connection head cover needs to be
closed after the sensor and the power supply are connected. When you switch the power supply on,
the transmitter begins operation after a response time of about 10 seconds.
ITEM 1110, 1140, 1190,
1270, 1280, 1290
20
SITRANS TH100
A5E00331168--01
ITEM 1110, 1140, 1190,
1270, 1280, 1290
SITRANS TH100
A5E00331168--01 21
7 Functions
7.1 General information
You can use the SIPROM T parameterization software to carry out the following functions for the
SITRANS TH100:
- Setting the upper/lower overrange of the output current
- Storing data for the identification of measuring points
- Setting the sensor activation (two-wire, three-wire, four-wire connection)
- Set sensor offset, measuring range, unit and damping
- Setting the output current in case of error (e.g. ensor failure)
7.2 Output current in case of error
Sensor wires and transmitter electronics are continuously monitored. In the event of a fault, the output
current is set to fault current. The fault current can be freely selected within the preset limits of the
current control range (3.6 mA to 23 mA).
7.3 Wire break monitoring
All sensor wires are permanently monitored for wire breaks. The programmed fault current (3.6 mA to
23 mA) is output in case of error. The wire break monitoring cannot be switched off.
7.4 Short circuit monitoring
The sensor connected to the transmitter is permanently monitored for sensor short circuits. A sensor
short circuit has occurred if the measured resistance for the connected Pt100 is less than 10 Ohm.
The programmed fault current (3.6 mA to 23 mA) is output in the event of a sensor short circuit.
Sensor short circuit monitoring cannot be switched off. The short circuit limit is fixed at 10 Ohm and,
likewise, cannot be changed.
7.5 Line compensation
Line compensation is required when measuring the Pt100 in two--wire input.
The trimming is performed by numerical preset of the measured line resistance (combined total of
sending and return conductors).
7.6 Type of characteristic curve (rising or falling)
The type of the characteristic curve at the 4 to 20 mA analog output can be selected (rising or falling).
The characteristic curve type is defined as follows by setting the parameters for the start of scale
value and full scale value:
D Rising characteristic: Full scale value is greater than start of scale value
D Falling characteristic: Full scale value is smaller than start of scale value
ITEM 1110, 1140, 1190,
1270, 1280, 1290
22
SITRANS TH100
A5E00331168--01
ITEM 1110, 1140, 1190,
1270, 1280, 1290
SITRANS TH100
A5E00331168--01 23
8 Operating with PC and modem
NOTICE
Parameters may only be assigned to the SITRANS TH100 when offline using the modem
for SITRANS TH100/TH200 and the SIPROM T parameterization software. Any 4 to 20 mA
current loop connected to the transmitter needs to be completely disconnected before the
parameterization process.
The transmitter can be configured using a PC and the SIPROM T parameterization software together
with the modem for SITRANS TH100/TH200. To do so, simply connect the transmitter to the PC via
the modem. The power required by the transmitter is provided by:
- the USB port on the PC (in the case of a USB modem)
- an external power adapter (in the case of an RS232 modem)
ITEM 1110, 1140, 1190,
1270, 1280, 1290
24
SITRANS TH100
A5E00331168--01
Connector
power
adapter 6 V
(included in the
scope of
delivery)
COM1
COM2
COM 3
COM 4
USB
USB cable
(included in
the scope of
delivery) PC
Modem for
SITRANS
TH100/TH200
via USB
7NG3092--8KU
POWER
Comm.
Error
PC
COM1
COM2
COM 3
COM 4
USB
+ --
+ (positive)
(red)
+ --
-- (negative)
(black)
POWER
Comm.
Error
+ (positive)
(red)
-- (negative)
(black)
Modem for
SITRANS
TH100/TH200
via RS232
7NG3092--8KM
Figure 10Parameterization of SITRANS TH100
via the USB modem
Figure 11Parameterization of SITRANS TH100
via the RS232 modem
For detailed information on the parameterization of the transmitter, please refer to the operating
instructions for the following products:
- Modem for SITRANS TH100/TH200 and the SIPROM T parameterization software (order number:
7NG3092--8KM and 7NG3092--8KU, respectively)
- CD sitrans t -- temperature transmitters, order number A5E00364512
.
NOTE
If you already have a modem for SITRANS TK (order number 7NG3190--6KB), you can
use it for the parameterization of the SITRANS TH100. A description of how to connect the
SITRANS TH 100 to the modem for SITRANS TK is given in the operating instructions for
the modem.
ITEM 1110, 1140, 1190,
1270, 1280, 1290
SITRANS TH100
A5E00331168--01 25
9 Technical data
Input
Resistance thermometer
Measured variable Temperature
Input type Pt100 as per IEC 60751
Characteristic curve Linear to temperature
Type of connection Two--wire, three--wire and four--wire connection
Resolution 14 bit
Measuring accuracy
Measuring span < 250_C (450_F) < 0,25_C (0.45_F)
Measuring span > 250_C (450_F) < 0,1% of the measuring span
Repeatability < 0,1_C (0.18_F)
Measured current approx. 0.4 mA
Measuring cycle < 0,7 s
Measuring range --200 ... 850_C (--328 ... 1562_F)
Measuring span 25 ... 1050_C (77 ... 1922_F)
Unit _C or _F
Offset Programmable: --100 ... +100_C (--180 ... 180_F)
Line resistance Max. 20 (combined total of sending and return
conductors)
Noise suppression 50 and 60 Hz
Output
Output signal 4 ... 20 mA, two--wire
Power supply 8,5 ... 36 V DC (30 V for Ex)
Max. load (U
aux
--8.5 V)/0.023 A
Overrange 3,6 mA ... 23 mA infinitely adjustable
(default range: 3,84 mA ... 20,50 mA)
Error signal (in case of sensor
failure)
3,6 mA to 23 mA, infinitely adjustable
(default value: 3,6 mA or 22.8 mA)
Damping time 0 ... 30 s
Protection Against reverse polarity
Resolution 12 bit
Accuracy at 23_C < 0,1% of the measuring span
Temperature influence Max. 0.1%/10_C (0.1%/18_F)
Influence of power supply < 0,01% of the measuring span/V
Influence of load <0,025% of the maximum measuring span/100
Long--term drift <0,025% of the maximum measuring span in the first
month
<0,035% of the maximum measuring span after one year
<0,05% of the maximum measuring span after five years
Ambient conditions
Range of ambient temperature --40 ... +85_C (--40 ... +185_F)
Range of storage temperature --40 ... +85_C (--40 ... +185_F)
Relative humidity 98%, condensing
Electromagnetic compatibility According to EN 61326--2 and NAMUR NE21
Error due to EMC influences (when
installed in metallic connection head)
ESD according to EN 61000--4--2 < 0,10% of the measuring span
ITEM 1110, 1140, 1190,
1270, 1280, 1290
26
SITRANS TH100
A5E00331168--01
RF irradiation according to
EN61000--4--3
< 1,0% of the measuring span
Burst according to EN 61000--4--4 < 0,2% of the measuring span
RF energizing according to
EN 61000--4--6
< 0,3% of the measuring span
Greater measuring errors may occur if the transmitter is installed on a DIN rail in an environment with severe interference.
The applicable ESD directives must be adhered to.
Construction
Weight 50 g
Dimensions See Figure 12, page 29
Material Plastic, potted
Cross section of the connecting
cables
Max. 2.5 mm
2
(AWG 13)
Degree of protection According to IEC 60529
Housing IP40
Terminals IP00
Certificates
Operation in the territory of EC member states
EC type examination certificate PTB 05 ATEX 2049X
Protection type intrinsic safety
according to ATEX
II 1 G EEx ia IIC T6/T4 II 2 (1) G EEx ia/ib IIC T6/T4
Protection type non--sparking and
power--limited resources II 3G EEx nAL IIC T6/T4
Refer to the EC--type examination certificate for detailed electrical specifications and conditions
for operating in hazardous areas.
Operation in the USA and in Canada
FM approval PID 3024169, applies
to USA and Canada (cFMus)
Protection types IS Cl I, II, III, Div 1, GP ABCDEFG T4/T5/T6
IS Cl I, ZN 0.1 AEx ia IIC T4/T5/T6
NI Cl I, II, III, Div 2, GP ABCDFG T4/T5/T6
Cl I, ZN 2, GP IIC T4/T5/T6
Refer to the FM Certificate of Compliance no. 3024169 and the corresponding Control Drawing
C10145--A4--X2--33 for electrical specifications, operating conditions and installation notes for
operating in hazardous areas.
ITEM 1110, 1140, 1190,
1270, 1280, 1290
SITRANS TH100
A5E00331168--01 27
10 Ordering data
Designation Order number
Temperature transmitter SITRANS TH100
for installation in connection heads of type B (DIN 43729),
two-wire technology 4 to 20 mA, programmable, without electrical isolation
without explosion protection
with protection typ -intrinsically safe explosion protection
-- EEx ia (ATEX)
-- FM (cFMUS)
7NG3211--0NN00
7NG3211--0AN00
7NG3211--0BN00
Modem for SITRANS TH100 and TH200 including the SIPROM T
parameterization software
with USB connection
with RS232 connection
7NG3092--8KU
7NG3092--8KM
CD sitrans t -- temperature transmitters containing documentation in
German/English/French/Spanish/Italian/Portuguese and the SIPROM T
parameterization software
A5E00364512
DIN rail adapter for sensor head (packing unit = 5 pcs.) 7NG3092--8KA
Additional specifications
Complete order no. with --Z, add abbreviated specification
Abbreviated
specification
Adjust operational data as desired
(Operational data should be described in plain text)
Y01
with test report (five measurement points) C11
Factory setting
- Pt100 in three-wire connection
- Measuring range 0 ... 100_C (32 ... 212 _F)
- In case of sensor failure 22.8 mA
- Sensor offset 0_C (0_F)
- Damping 0.0 s
You can obtain all instructions, catalogs and certificates for SITRANS T from the following website:
ITEM 1110, 1140, 1190,
1270, 1280, 1290
28
SITRANS TH100
A5E00331168--01
ITEM 1110, 1140, 1190,
1270, 1280, 1290
SITRANS TH100
A5E00331168--01 29
11 Dimensional drawing
1(+) and 2 (--) Power supply U
aux
, output current I
out
3, 4, 5 and 6 Sensor (Pt100) (connections see chapter 5 Electrical Connection, page 15)
(1.73)
(1.3)
Internal diameter of center hole 6.3 (0.25)
(
0
.
8
2
)
Fixing screw M4x25
Figure 12SITRANS TH100, dimensions in mm (inch)
ITEM 1110, 1140, 1190,
1270, 1280, 1290
30
SITRANS TH100
A5E00331168--01
ITEM 1110, 1140, 1190,
1270, 1280, 1290
SITRANS TH100
A5E00331168--01 31
12 Maintenance
The transmitter is maintenance--free.
13 Certificates
You can find the certificates on the sitrans t -- temperature transmitters CD, which can be ordered
separately, order number A5E00364512; and on the Internet at
www.siemens.com/processinstrumentation/certificates.
ITEM 1110, 1140, 1190,
1270, 1280, 1290
32
SITRANS TH100
A5E00331168--01
ITEM 1110, 1140, 1190,
1270, 1280, 1290
Type7NG3211-0B***
EngineeringObligationforDelivery
C10145-A3-X2-33
FK:
Siemensd.d.
A &DPD
Changefor:
Date:
Revision:
Fab-Gr.:
Approvedby: Dateofchange:
Editedby:
Product:
ChangeNo.:
Doc. Type:
Sheet
of
1
2
Title:
Tol.:
SAP No.: Scale:
1
DocumentNo.:
Modifyby:
Pieta
14.03.2006
Sudeta
ControlDrawing
forDIV1,Zone0,1
Thisdocumentcontainssafety-relevantinformationbasedontechnicalstandards
(i.e.Norms,internalstandards)orcertificationsthattheapparatusissubjectto
andmayonlybealteredwiththeapprovalofthenormexpert(NFM)
(+)
(-)
Temperature Transmitter
SITRANS TH100
1
3
5
6
2
4
+
_
Non-hazardouslocation
T6 =-40C...+55C @ Ta
T5@ T =-40C...+70C
T4@ T =-40C...+85C
a
a
Hazardouslocation
Entityparameters:
U,V
I ,I =100mA
P,P =0.75W
L =106 H
C =13nF
Terminals1(+),2(-):
i max
i max
i max
i
i
=30VDC
m
Terminals3,4,5,6:
U , V
, I
,
o oc t
o sc t
o t
o a
o a
V , = 6VDC
I I , =7.6mA
P P =12.5mW
L , L =290mH
C , C =3.5 F
9.
m
Temperature
Transmitter
TH100
seenote3
seenote2
ForIntrinsicSafety
applicationuse
approvedassociated
apparatusorbarrier
PE
ClI,DIV1,GP A,B,C,D
ClII,DIV1,GP E,F,G
ClIII,DIV1
ClI,ZN0,1GP IIC
Entityparameters:
orV
orI 100mA
orP 0.75W
t
t
t
30VDC V
I
P
oc
sc
o
C >Sum(C)+C
L
a i cable
a i cable >Sum(L) +L
Notes:
1. Thenonintrinsicallysafeterminals(powerrail)mustnotbeconnectedtoanydevice
whichusesorgeneratesmorethan250Vrmsord.c.unlessifhasbeendeterminated
thatthevoltagehasbeenadequatelyisolated.
2. TheinstallationmustmeettherequirementsoftheNationalElectricalCode/
CanadianElectricalCode
3. TheSITRANS TH100mustbeinstalledinahousing,e.g. TypeBconnectionhead
seenote1
Connection
head
ITEM 1110, 1140, 1190,
1270, 1280, 1290
Type7NG3211-0B***
EngineeringObligationforDelivery
C10145-A3-X2-33
FK:
Siemensd.d.
A &DPD
Changefor:
Date:
Revision:
Fab-Gr.:
Approvedby: Dateofchange:
Editedby:
Product:
ChangeNo.:
Doc. Type:
Sheet
of
2
2
Title:
Tol.:
SAP No.: Scale:
1
DocumentNo.:
Modifyby:
Pieta
14.03.2006
Sudeta
ControlDrawing
forDIV2,Zone2
Thisdocumentcontainssafety-relevantinformationbasedontechnicalstandards
(i.e.Norms,internalstandards)orcertificationsthattheapparatusissubjectto
andmayonlybealteredwiththeapprovalofthenormexpert(NFM)
(+)
(-)
Temperature Transmitter
SITRANS TH100
1
3
5
6
2
4
+
_
Non-hazardouslocation
T6 =-40C...+55C @ Ta
T5@ T =-40C...+70C
T4@ T =-40C...+85C
a
a
Hazardouslocation
Entityparameters:
U,V
I ,I
L =106H
C =13nF
Terminals1(+),2(-):
i max
i max
i
i
=30VDC
seenote2
Terminals3,4,5,6:
U , V
, I
o oc t
o sc t
o a
o a
V , = 6VDC
I I ,
L , L =290mH
C , C =3.5 F
9.
seenote2
m
Temperature
Transmitter
TH100
seenote5
seenote3
Zone2Non-Sparking
Applicationsand
DIV2 Applications:
PE
ClI,Zone2,GP IIC
ClI,DIV2,GP A,B,C,D
ClII,DIV2,GP F,G
ClIII,DIV2
V
Observenote3!
max = 30VDC
FunctionalRatings:
I =4...20mA normal
C >Sum(C)+C
L
a i cable
a i cable >Sum(L) +L
Zone2andDivision2Installations(forCurrentControlledCircuits):
Note 1: Thenonincendivefieldwiringconceptallowsinterconnectionofnonincendivefield
wiringapparatuswithassociatednonincendivefieldwiringapparatusnotspecificallyexamined
incombination.
Note2:Forcurrentcontrolledcircuits,theinputcurrent(I )ofthereceivingdeviceneed
notmatchtheoutputcurrent(I orI )ofthebarrierorassociatednonincendivefieldwiring
apparatussource.
Note3: TheinstallationmustmeettherequirementsoftheNationalElectricalCode/
CanadianElectricalCode
Note4: Thesupplyterminalsmustnotbeconnectedtoanydevicewhichusesor
Note5: TheSITRANS TH100mustbeinstalledinahousing,e.g. TypeBconnectionhead
max
t sc
generates
morethan250Vrmsord.c.unlessadequatelyisolattionisused.
seenote4
Connection
head
ParametersforZone2
LimitedEnergy Applications
andNIFieldWiring
ApparatusConcept:
U V
I , I
o t
o t
, 30 VDC
see note 2
V ,
I ,
oc
sc
ITEM 1110, 1140, 1190,
1270, 1280, 1290

ITEM 1110, 1140, 1190,
1270, 1280, 1290
A5E00331168D-01 GN: 30380_TH100
Process Instrumentation and Analytics
76181 KARLSRUHE
GERMANY
Temperature transmitter
SITRANS TH100
for sensor head installation
7NG3211-0*N00
sitrans
A5E00331168-01
ITEM 1110, 1140, 1190,
1270, 1280, 1290

A5E00047092D-06 GN: 30060_DuoDrDif
Automation and Drives (A&D)
Sensors and Communication
Process Sensors
76181 KARLSRUHE
GERMANY
Pressure transmitter
SITRANS P, DS III series
with HART communication

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A5E00047092-06
@1PA5E00047092@
A5E00047092
ITEM 1120, 1340, 1355
ITEM 1120, 1340, 1355

Introduction

1
General safety notes

2
Description

3
Install

4
Connecting

5
Operation

6
Operating functions through
HART

7
Functional safety

8
Commissioning

9
Service and maintenance

10
Technical data

11
Dimension drawings

12
Spare parts/accessories

13
Appendix

A
List of abbreviations

B
SITRANS
SITRANS P, DS III series with
HART communication
Operating Instructions
12/2007
A5E00047092-06
7MF4*33
ITEM 1120, 1340, 1355

Safety Guidelines
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The device/system may only be set up and used in conjunction with this documentation. Commissioning and
operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes
in this documentation qualified persons are defined as persons who are authorized to commission, ground and
label devices, systems and circuits in accordance with established safety practices and standards.
Prescribed Usage
Note the following:
WARNING
This device may only be used for the applications described in the catalog or the technical description and only
in connection with devices or components from other manufacturers which have been approved or
recommended by Siemens. Correct, reliable operation of the product requires proper transport, storage,
positioning and assembly as well as careful operation and maintenance.
Trademarks
All names identified by are registered trademarks of the Siemens AG. The remaining trademarks in this
publication may be trademarks whose use by third parties for their own purposes could violate the rights of the
owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

Siemens AG
Postfach 48 48
90327 NRNBERG
GERMANY
Ordernumber: A5E00047092
03/2008
Copyright Siemens AG 2007.
Technical data subject to change
ITEM 1120, 1340, 1355

SITRANS P, DS III series with HART communication
Operating Instructions, 12/2007, A5E00047092-06 3
Table of contents
1 Introduction................................................................................................................................................ 9
1.1 Objective of this documentation.....................................................................................................9
1.2 History............................................................................................................................................9
1.3 Scope of this manual ...................................................................................................................10
1.4 Further information.......................................................................................................................10
2 General safety notes................................................................................................................................ 11
2.1 General information .....................................................................................................................11
2.2 Correct usage...............................................................................................................................11
2.3 Laws and directives .....................................................................................................................11
2.4 Measures .....................................................................................................................................11
2.5 Qualified Personnel......................................................................................................................13
3 Description............................................................................................................................................... 15
3.1 System configuration ...................................................................................................................15
3.2 Application range .........................................................................................................................16
3.3 Structure.......................................................................................................................................17
3.4 Structure of the type plate and approval plate.............................................................................18
3.5 Functional principle......................................................................................................................20
3.5.1 Overview of mode of operation....................................................................................................20
3.5.2 Operation of the electronics.........................................................................................................20
3.5.3 Measuring cell operation..............................................................................................................21
3.5.3.1 Measuring cell for gauge pressure...............................................................................................22
3.5.3.2 Measuring cell for differential pressure and flow rate..................................................................23
3.5.3.3 Measuring cell for level ................................................................................................................24
3.5.3.4 Measuring cell for absolute pressure from the differential pressure series .................................25
3.5.3.5 Measuring cell for absolute pressure from the gauge pressure series........................................26
3.5.3.6 Measuring cell for gauge pressure, front-flush membrane..........................................................26
3.5.3.7 Measuring cell for absolute pressure, front-flush membrane ......................................................27
3.6 Remote seal .................................................................................................................................28
3.7 SIMATIC PDM..............................................................................................................................28
4 Install ....................................................................................................................................................... 29
4.1 Safety notes for installation..........................................................................................................29
4.2 Installation (except level) .............................................................................................................31
4.2.1 Instructions for installation (except level).....................................................................................31
4.2.2 Installation (except level) .............................................................................................................32
4.2.3 Fastening .....................................................................................................................................32
4.3 "Level" installation........................................................................................................................34
ITEM 1120, 1340, 1355
Table of contents

4 Operating Instructions, 12/2007, A5E00047092-06
4.3.1 Instructions for level installation.................................................................................................. 34
4.3.2 Installation for level ..................................................................................................................... 35
4.3.3 Connection of the negative pressure line.................................................................................... 36
4.4 "Remote seal" installation ........................................................................................................... 38
4.4.1 Remote seal installation.............................................................................................................. 38
4.4.2 Installation of the remote seal with the capillary line................................................................... 40
4.5 Turing the measuring cell against housing ................................................................................. 46
4.6 Turning the digital display ........................................................................................................... 47
5 Connecting .............................................................................................................................................. 49
5.1 Safety notes for connection......................................................................................................... 49
5.2 Connecting the device................................................................................................................. 50
5.3 Connecting the Han plug............................................................................................................. 52
5.4 Connecting the M12 connector ................................................................................................... 52
6 Operation................................................................................................................................................. 55
6.1 Overview of operation ................................................................................................................. 55
6.2 Safety information for operation.................................................................................................. 56
6.3 Instructions for operation............................................................................................................. 56
6.4 Digital display .............................................................................................................................. 57
6.4.1 Elements of the digital display .................................................................................................... 57
6.4.2 Units display................................................................................................................................ 58
6.4.3 Error display ................................................................................................................................ 59
6.4.4 Mode display ............................................................................................................................... 60
6.4.5 Status display.............................................................................................................................. 60
6.4.6 Overflow range............................................................................................................................ 61
6.5 Local operation............................................................................................................................ 63
6.5.1 Local control elements ................................................................................................................ 63
6.5.2 Operation using buttons.............................................................................................................. 65
6.5.3 Start of scale value/full scale value............................................................................................. 66
6.5.3.1 Difference between setting and adjusting................................................................................... 66
6.5.3.2 Setting/adjusting the start of scale value .................................................................................... 70
6.5.3.3 Setting/adjusting the full scale value........................................................................................... 71
6.5.4 Setting/adjusting electrical damping ........................................................................................... 72
6.5.5 Blind start of scale value/full scale value .................................................................................... 73
6.5.5.1 Difference between setting/adjusting and blind setting/adjusting............................................... 73
6.5.5.2 Blind setting of start of scale value ............................................................................................. 75
6.5.5.3 Blind setting of full scale value.................................................................................................... 76
6.5.5.4 Blind adjusting of the start of scale value.................................................................................... 76
6.5.5.5 Blind adjustment of the full scale value....................................................................................... 77
6.5.6 Trimming the zero point .............................................................................................................. 77
6.5.7 Current transmitter ...................................................................................................................... 78
6.5.8 Output current in case of fault ..................................................................................................... 79
6.5.9 buttons and function lock ............................................................................................................ 80
6.5.10 Releasing key lock or function lock............................................................................................. 81
6.5.11 Flow rate measurement (only differential pressure) ................................................................... 82
6.5.12 Measured value display .............................................................................................................. 85
6.5.13 Unit .............................................................................................................................................. 86
7 Operating functions through HART.......................................................................................................... 91
ITEM 1120, 1340, 1355
Table of contents

7.1 Operating functions through HART communication ....................................................................91
7.2 Process tag data..........................................................................................................................92
7.3 Selecting the measuring modes...................................................................................................92
7.3.1 Overview of measuring modes ....................................................................................................92
7.3.2 Measuring mode selector.............................................................................................................93
7.3.3 Variable mapper...........................................................................................................................93
7.3.4 Measuring mode "Pressure" ........................................................................................................94
7.3.5 Customized characteristic curve..................................................................................................95
7.3.6 Measuring mode "Level" ..............................................................................................................95
7.3.7 Measuring mode "Flow rate"........................................................................................................98
7.3.8 Measuring mode "User" ...............................................................................................................99
7.3.9 Measured value status...............................................................................................................101
7.3.10 Analog output .............................................................................................................................105
7.3.11 Scaling the digital display value.................................................................................................106
7.4 Setting zero point and limit point................................................................................................107
7.5 Blind setting of zero point and limit point ...................................................................................108
7.6 Zero point calibration (position correction).................................................................................108
7.7 Electrical damping......................................................................................................................109
7.8 Fast response mode ..................................................................................................................109
7.9 Current sensor ...........................................................................................................................109
7.10 Fault current ...............................................................................................................................109
7.11 Setting the current limits ............................................................................................................110
7.12 Key lock and write protection.....................................................................................................111
7.13 Measured value display .............................................................................................................112
7.14 Selection of the physical unit .....................................................................................................113
7.15 Bar graph ...................................................................................................................................113
7.16 Sensor calibration ......................................................................................................................113
7.16.1 Sensor trim.................................................................................................................................113
7.16.2 Trimming of the sensor trim point ..............................................................................................114
7.17 Current sensor trim....................................................................................................................115
7.18 Factory calibration......................................................................................................................116
7.19 Static configuration data ............................................................................................................117
7.20 Flow rate measurement (only differential pressure) ..................................................................118
7.21 Diagnostic functions...................................................................................................................119
7.21.1 Overview....................................................................................................................................119
7.21.2 Operating hours counter ............................................................................................................119
7.21.3 Calibration timer and service timer ............................................................................................120
7.21.4 Min/max indicator.......................................................................................................................120
7.21.5 Limit modules.............................................................................................................................121
7.22 Simulation ..................................................................................................................................123
7.22.1 Overview of simulation...............................................................................................................123
7.22.2 Simulation as fixed value ...........................................................................................................124
7.22.3 Simulation with a ramp function.................................................................................................124
7.23 Limit monitor...............................................................................................................................125
ITEM 1120, 1340, 1355
Table of contents

8 Functional safety.................................................................................................................................... 129
8.1 General safety instructions........................................................................................................ 129
8.1.1 Safety-instrumented system...................................................................................................... 129
8.1.2 Safety Integrity Level (SIL)........................................................................................................ 130
8.2 Device-specific safety instructions ............................................................................................ 131
8.2.1 Safety function .......................................................................................................................... 131
8.2.2 Requirements............................................................................................................................ 132
8.2.3 Settings ..................................................................................................................................... 132
8.2.4 Behavior in case of faults.......................................................................................................... 133
8.2.5 Maintenance/Checking.............................................................................................................. 133
8.2.6 Safety characteristics................................................................................................................ 134
9 Commissioning ...................................................................................................................................... 135
9.1 Safety notes for commissioning................................................................................................ 135
9.2 Notes on commissioning........................................................................................................... 136
9.3 Introduction to commissioning .................................................................................................. 136
9.4 Gauge pressure, absolute pressure from the differential pressure series and absolute
pressure from the gauge pressure series ................................................................................. 137
9.4.1 Commissioning for gases.......................................................................................................... 137
9.4.2 Commissioning with steam or liquid.......................................................................................... 138
9.5 Differential pressure and flow rate ............................................................................................ 139
9.5.1 Safety notes for commissioning with differential pressure and flow rate.................................. 139
9.5.2 Commissioning in gaseous environments ................................................................................ 140
9.5.3 Commissioning for liquids ......................................................................................................... 142
9.5.4 Commissioning with vapor ........................................................................................................ 144
10 Service and maintenance ...................................................................................................................... 147
10.1 Notes for servicing .................................................................................................................... 147
10.2 Display in case of a fault ........................................................................................................... 147
10.3 Modular structure ...................................................................................................................... 148
10.4 Notes for servicing of the remote seal ...................................................................................... 149
11 Technical data ....................................................................................................................................... 151
11.1 Overview of technical data........................................................................................................ 151
11.2 Input point.................................................................................................................................. 152
11.3 Output........................................................................................................................................ 157
11.4 Measuring accuracy.................................................................................................................. 158
11.5 Operating conditions ................................................................................................................. 164
11.6 Construction.............................................................................................................................. 167
11.7 Display, keyboard and auxiliary power ..................................................................................... 171
0

Certificates and approvals........................................................................................................................ 172
11.9 HART communication ............................................................................................................... 173
12 Dimension drawings .............................................................................................................................. 175
ITEM 1120, 1340, 1355
Table of contents

12.1 SITRANS P, DS III series for gauge pressure and absolute pressure from the gauge
pressure series...........................................................................................................................175
12.2 SITRANS P, DS III series for differential pressure, flow rate and absolute pressure from
the differential pressure series...................................................................................................176
12.3 SITRANS P, DS III series for level.............................................................................................179
12.4 SITRANS P, DS III series (flush mounted) ................................................................................180
12.4.1 Note 3A and EHDG....................................................................................................................181
12.4.2 Connections as per EN and ASME............................................................................................181
12.4.3 F&B and pharma flange.............................................................................................................182
12.4.4 PMC Style ..................................................................................................................................185
12.4.5 Special connections...................................................................................................................186
13 Spare parts/accessories ........................................................................................................................ 187
13.1 Order data..................................................................................................................................187
13.2 Order data for SIMATIC PDM....................................................................................................190
A Appendix................................................................................................................................................ 195
A.1 Certifications ..............................................................................................................................195
A.2 Literature and standards............................................................................................................195
A.3 SIL Declaration of Conformity....................................................................................................196
A.4 exida proven in use....................................................................................................................199
A.5 Overview of HART operating structure......................................................................................203
A.6 Pressure equipment directive ....................................................................................................206
B List of abbreviations............................................................................................................................... 209
B.1 Functional safety........................................................................................................................210
Glossary ................................................................................................................................................ 211
Index...................................................................................................................................................... 215
ITEM 1120, 1340, 1355
Table of contents

ITEM 1120, 1340, 1355

Introduction
1
1.1 Objective of this documentation
This programming manual contains all information that you will require to commission and
use the device.
It is aimed at persons who install the device mechanically, connect it electrically,
parameterize and commission it, as well as at service and maintenance engineers.
This document also contains special information and safety notes that you will require when
using an SIL-certified device in safety-instrumented systems.
1.2 History
This history establishes the correlation between the current documentation and the valid
firmware of the device.
The documentation of this edition is applicable for the following firmware:

Edition Firmware identification type
plate
System integration Installation path for PDM
08/2007 FW: 11.03.03, FW: 11.03.04,
FW: 11.03.05, FW: 11.03.06,
FW: 11.03.07
PDM 6.0
1)
; Dev. R.3
DD Rev. 2
SITRANS P DSIII.2

1)
up to SP02
The most important changes in the documentation when compared with the respective
previous edition are given in the following table.
Edition Remark
06
08/2007
Illustrations of the device have been changed owing to the changes in the device
housing.
The following chapters have also been changed:
Chapter "Description" > "Functional principle" has
new enhanced contents for the "flush mounted diaphragm" topic
Chapter "Description" > "SIMATIC PDM" - NEW
Chapter "Functional safety" - NEW
Chapter "Technical data" has
new enhanced contents for the "flush mounted diaphragm" topic
Chapter "Dimension drawings"
has new contents for the "flush mounted diaphragm" topic
Chapter "Appendix"
has new contents for the "Functional safety" topic
ITEM 1120, 1340, 1355
Introduction
1.3 Scope of this manual
1.3 Scope of this manual
Table 1-1 "7MF4*33" stands for:
Order number SITRANS P, DS III series for
7MF4033 Gauge pressure
7MF4133 Gauge pressure, flush mounted diaphragm
7MF4233 Absolute pressure from the gauge pressure series
7MF4333 Absolute pressure from the differential pressure series
7MF4433 Differential pressure and flow rate, PN 32/160 (MWP 464/2320 psi)
7MF4533 Differential pressure and flow rate, PN 420 (MWP 6092 psi)
7MF4633 Level
1.4 Further information
Information
The contents of these instructions shall not become part of or modify any prior or existing
agreement, commitment or legal relationship. All obligations on the part of Siemens AG are
contained in the respective sales contract which also contains the complete and solely
applicable warranty conditions. Any statements contained herein do not create new
warranties or modify the existing warranty.
The content reflects the technical status at the time of printing. We reserve the right to make
technical changes in the course of further development.
Worldwide contact person
If you need more information or have particular problems which are not covered sufficiently
by the operating instructions, get in touch with your contact person. You can find contact
information for your local contact person in the Internet.
Product information on the Internet
The Programming Manual is an integral part of the companion CD, which may be ordered
separately. In addition, the Programming Manual is available on the Internet on the Siemens
homepage.
On the CD you will also find the technical data sheet containing the ordering data, the Device
Install software for SIMATIC PDM for subsequent installation and the required software.
See also
Contacts (http://www.siemens.com/processinstrumentation/contacts)
Product information on SITRANS P in the Internet (http://www.siemens.com/sitransp)
Instructions and Manuals (http://www.siemens.com/processinstrumentation/documentation)
ITEM 1120, 1340, 1355

2
2.1 General information
This device left the factory free from safety problems. In order to maintain this status and to
ensure safe operation of the device, please observe the safety information and warnings
contained in these instructions.
See also
Safety-instrumented system (Page 129)
2.2 Correct usage
The device may only be used for the purposes specified in these instructions.
Insofar as they are not expressly stated in these instructions, all changes to the device are
the sole responsibility of the user.
2.3 Laws and directives
Observe the test certification, provisions and laws applicable in your country during
connection, assembly and operation.
For hazardous areas, these are for example:
IEC 60079-14 (international)
National Electrical Code (NEC - NFPA 70) (USA)
Canadian Electrical Code (CEC) (Canada)
EN 60079-14 (formerly VDE 0165, T1) (EU, Germany)
The working reliability regulation (Germany)
2.4 Measures
For the sake of safety, the following precautions must be observed:
ITEM 1120, 1340, 1355
2.4 Measures

WARNING
"Explosion-proof" type of protection
Devices with the "explosion-proof" type of protection may only be opened in the hazardous
area only in a de-energized state.

WARNING
"Intrinsically safe" protection type
"Intrinsically-safe" devices lose their certification as soon as they are operated on circuits
which do not correspond with the test certification valid in their country. The "ia" protection
level of the device is decreased to the "ib" protection level when intrinsically safe circuits
having the "ib" protection level are connected.

WARNING
Protection type "limited energy" nL (zone 2)
Devices with "limited energy" may be connected and disconnected while in operation.
Protection type "non-sparking" nA (zone 2)
Devices with "non-sparking" protection may only be connected and disconnected when off
circuit. Refer to the specifications on the examination certificate for exceptions to this
standard.

WARNING
Exposure to aggressive and hazardous media
The device can be operated both at high pressure and with aggressive and hazardous
media. Therefore, improper use of this device may lead to serious injury and or
considerable damage to property. Above all, it must be noted when the device was in use
and is to be exchanged.

CAUTION
Electrostatic Sensitive Devices (ESD)
This device contains electrostatic sensitive devices. Electrostatic sensitive devices may be
destroyed by voltages that are undetectable to a human. Voltages of this kind occur as
soon as a component or an assembly is touched by a person who is not grounded against
static electricity. The damage to a module as a result of overvoltage cannot usually be
detected immediately. It may only become apparent after a long period of operation.

ITEM 1120, 1340, 1355
2.5 Qualified Personnel
Qualified personnel are people who are familiar with the installation, mounting,
commissioning, and operation of the product. These people have the following qualifications:
They are authorized, trained or instructed in operating and maintaining devices and
systems according to the safety regulations for electrical circuits, high pressures and
aggressive as well as hazardous media.
For explosion-proof devices: They are authorized, trained, or instructed in carrying out
work on electrical circuits for hazardous systems.
They are trained or instructed in maintenance and use of appropriate safety equipment
according to the safety regulations.
ITEM 1120, 1340, 1355
ITEM 1120, 1340, 1355

Description
3
3.1 System configuration
Overview
The pressure transmitter can be used in a number of system configurations:
as a stand-alone version, supplied with the necessary auxiliary power
as part of a complex system environment, e.g. SIMATIC S7
System communication
Communication is via the HART protocol, using:
HART communicator with at least 4 MB available memory
PC with HART modem, on which appropriate software is available, e.g. SIMATIC PDM
Control system which is able to communicate via the HART protocol, e.g. SIMATIC S7
with ET 200M
+
-
+
-
A
SlMATlC PDM
Control system
or
Transmitter
Load
Auxiliary power
HART
Communicator
or HART
Modem
PC/laptop with
SlMATlC PDM
S7 400
ET 200M
RS-232-C

Figure 3-1 Possible system configurations
ITEM 1120, 1340, 1355
Description
3.2 Application range
3.2 Application range
Overview
Depending on the version, a transmitter measures corrosive, non-corrosive and hazardous
gases, vapors and liquids.
It can be used for the following measurement types:
Gauge pressure
Absolute pressure
Differential pressure
With appropriate parameterization, it can also be used for the following additional
measurement types:
Level
Volume
Mass
Volume of flow
Mass flow rate
The output signal is always a load-independent direct current between 4 and 20 mA.
You can install the "intrinsically-safe" or "explosion-proof" version of the transmitter in
hazardous areas. The devices have an EC type examination certificate and comply with the
appropriate harmonized European CENELEC directives.
Transmitters with remote seals of different shapes can be delivered for special applications.
For example, measuring high-viscosity substances is a special application.
Gauge pressure
This version measures aggressive, non-aggressive and hazardous gases, vapors and
liquids.
The smallest measuring span is 0.01 bar g (0.145 psi g), and the largest 400 bar g
(5802 psi g).
Differential pressure and flow rate
This version measures corrosive, non-corrosive and hazardous gases, vapors and liquids.
You can use this version for the following measurement types:
differential pressure, e.g. effective differential pressure
small positive or negative overpressure
in combination with a restrictor device: flow rate q ~
p

The smallest measuring span is 1 mbar (0.0145 psi), the largest 30 bar (435 psi).
ITEM 1120, 1340, 1355
Description
3.3 Structure
Level
This version with mounting flange measures the level of non-corrosive, corrosive and
hazardous liquids in open and closed containers. The smallest measuring span is 25 mbar
(0.363 psi), the largest 5 bar (72.5 psi). The nominal diameter of the mounting flange is DN
80 or DN 100 or 3" or 4".
The negative connection of the measuring cell is kept open when measuring the level of
open containers. This measurement is referred to as "measurement against atmosphere".
The negative connection is normally connected with the container when measuring the level
of closed containers. This balances the static pressure.
Wetted parts are made of various materials, depending on corrosion resistance
requirements.
Absolute pressure
This version measures the absolute pressure of aggressive, non-aggressive and hazardous
gases, vapors and liquids.
There are two series: a "differential pressure" series and a "gauge pressure" series. The
"differential pressure" series is distinguished by a high overload capability.
The smallest measuring span of the "differential pressure" series is 8.3 mbar a (0.12 psi a),
and the largest is 100 bar a (1450 psi a).
The smallest measuring span of the "gauge pressure" series is 8.3 mbar a (0.12 psi a), and
the largest is 30 bar a (435 psi a).
3.3 Structure
Depending on a customer-specific order, the device comprises different parts.
The electronic housing is made of aluminum die casting or stainless steel precision casting.
The housing has a removable circular cover at the front and the back. Depending on the
device version, the front cover is designed as an inspection window. You can directly read
the measured values on the digital display through this inspection window. The infeed for
the electrical terminal compartment is provided on either side, optionally at the right or the
left. The corresponding unused opening is closed with a blanking plug . The protective
conductor connection is provided at the back of the housing.
The electrical terminal compartment for power supply and shield is accessible when you
remove the rear cover . The measuring cell with a process connection is provided in the
lower section of the housing. This measuring cell is secured against twisting using a
retaining screw . Thanks to the modular structure of the transmitter, the measuring cell, the
electronic unit or the network card can be replaced if required.
A keyboard cover is provided at the top of the housing. This cover can be opened. The
keypad is provided below this cover.
ITEM 1120, 1340, 1355
Description
3.4 Structure of the type plate and approval plate
Electrical
terminal
compartment
1
2
3
4
6
7
8
5
9
10
11
12
13

Figure 3-2 Device view of the transmitter

Type plate
Infeed with a cable gland
Keyboard cover for accessing the buttons
Removable cover, optionally with an inspection window
Digital display
Measuring point label
Retaining screw
Process connection
Blanking plug
Removable cover for accessing the electrical terminal compartment
Protective conductor connection
Alternative measuring point label
Approval plate

See also
Safety notes for installation (Page 29)
Structure of the type plate
The type plate which bears the order number and other important information such as design
or technical data is provided at the side of the housing.
ITEM 1120, 1340, 1355
Description
Filling
Silikonl
Mat.: Connec. Diaphr.
V :DC1 0.5-45 V (not intr.s ave) outp.:4-20 mA
H
Measuring span
Ove rrange limits
Type of protection IP 65
Fab. Nr. N1LN1 1-004711
Tr ansmit ter for pressur e
1.4404 2.481 9
7MF4033-1EB1 0-1DA1
: 0.6 3 - 63 bar
: - 1 - 100 bar
Made in Fr ance
0032
PED:SEP
SITRANS P
D-76181 Karlsr uhe
1
2

Figure 3-3 Example of a type plate
Order number (machine-readable product code)
Serial number
Structure of the approval plate
The approval plate is provided on the opposite side. The approval plate has information
about the version of the hardware and firmware.
V :DC 10. 5 - 45 V outp.: 4 - 20 mA
H
II 1/2 G EE x d IIC T4/T6
PTB 99 ATEX 1160
FW : 13.01.02 HW : 01.02.03
T = -40 ... 85/60 C
a
Observ e EC-T ype Examination Cer tifcate !
SITRANS P
D-76181 Karlsr uhe
FW: xx.yy.zz HW: xx.yy.zz
Compatibility mark
Product version connection board
Serial number
FW version
Document Revision
Device type

Figure 3-4 Example of an approval plate
ITEM 1120, 1340, 1355
Description
3.5 Functional principle
3.5.1 Overview of mode of operation
This chapter describes how the transmitter works.
First the electronics are described, then the physical principle of the sensors which are used
with the various device versions for the individual measurement types.
3.5.2 Operation of the electronics
Description
10
2 3
8
9
4
5
7
6
1
HART modem
EEPROM
Electr.
E
E
P
R
O
M
C
e
l
l
Sensor
A
D
D
A
C
l
A
U
H

Figure 3-5 Operation of the electronics with HART communication
Measuring cell sensor
Measuring amplifier
Analog-to-digital converter
Microcontroller
Digital-to-analog converter
Each with an EEPROM in the measuring cell and in the electronics
HART modem
Buttons (local operation)
Digital display
Connection for external ammeter
IA Output current
UH Auxiliary power
ITEM 1120, 1340, 1355
Description
The input pressure is converted into an electrical signal by the sensor . This signal is
amplified by the measuring amplifier and digitized in an analog-to-digital converter . The
digital signal is analyzed in a microcontroller and corrected with regard to linearity and
thermal characteristics. It is then converted in a digital-to-analog converter to the output
current of 4 to 20 mA. A diode circuit provides reverse voltage protection. You can make an
uninterrupted current measurement with a low resistance ammeter at the connection . The
data specific to the measuring cell, the electronic data and parameterization data are stored
in two EEPROMs . The first memory is linked with the measuring cell, the second with the
electronics.
The buttons can be used to call up individual functions, so-called modes. If you have a
device with a digital display , you can track the mode settings and other messages on it.
The basic mode settings can be changed with a computer via the HART modem .
3.5.3 Measuring cell operation

CAUTION
If the measurement signal fails because of sensor breakage, the separating diaphragm may
also be destroyed. In the worst case scenario, the process medium leaks from the
reference pressure opening in the devices used for gauge pressure with a measuring span
of 63 bar.

In the following sections, the process variable to be measured is called general input
pressure.
Overview
The following modes of operation are described:
Gauge pressure
Absolute pressure
Differential pressure and flow rate
Level
The following process connections are available, for example:
G, -14 NPT
EN61518 compliant flanged connection
Flush mounted diaphragm
ITEM 1120, 1340, 1355
Description
3.5.3.1 Measuring cell for gauge pressure
p
e
3
4
5
6
1
2

Figure 3-6 Function chart of measuring cell for gauge pressure
Reference pressure opening
Measuring cell
Process connection
Separating diaphragm
Fill liquid
Gauge pressure sensor
pe Input pressure
The input pressure (pe) is transferred to the gauge pressure sensor via the separating
diaphragm and the fill fluid , displacing its measuring diaphragm. The displacement
changes the resistance value of the four piezo resistors in the measuring diaphragm in a
bridge circuit. The change in the resistance causes a bridge output voltage proportional to
the input pressure.
Transmitters with measuring span 63 bar measure the input pressure against atmosphere,
those with spans 160 bar against vacuum.
ITEM 1120, 1340, 1355
Description
3.5.3.2 Measuring cell for differential pressure and flow rate
-
+
1 9
6 7
2
3
4 5
8

Figure 3-7 Function chart of the measuring cell for differential pressure and flow rate
Input pressure P+
Pressure cap
O-ring
Measuring cell body
Silicon pressure sensor
Overload diaphragm
Fill liquid
Input pressure P-
Differential pressure is transmitted to the silicon pressure sensor through the separating
diaphragms and the fill fluid . When measuring limits are exceeded, the overload
diaphragm is displaced until one of the separating diaphragms rests on the measuring
cell body . The separating diaphragm thus protects the silicon pressure sensor from
overload. The measuring diaphragm is displaced using differential pressure. The
displacement changes the resistance value of the four piezo resistors in the measuring
diaphragm in a bridge circuit. The change in the resistance causes a bridge output voltage
proportional to the differential pressure.
ITEM 1120, 1340, 1355
Description
3.5.3.4 Measuring cell for absolute pressure from the differential pressure series
p
e
8
2
1
3
6 7 4 5

Figure 3-9 Function chart of measuring cell for absolute pressure
Pressure cap
Separating diaphragm on the measuring cell
O-ring
Measuring cell body
Silicon pressure sensor
Overload diaphragm
Fill liquid of the measuring cell
Reference pressure
pe Pressure input variable
Absolute pressure is transmitted to the silicon pressure sensor through the separating
diaphragm and the fill fluid . When measuring limits are exceeded, the overload
diaphragm is displaced until the separating diaphragm rests on the measuring cell
body . The separating diaphragm thus protects the silicon pressure sensor from
overload. The pressure difference between the input pressure (pe) and the reference
pressure on the negative side of the measuring cell displaces the measuring diaphragm.
The displacement changes the resistance value of the four piezo resistors in the measuring
diaphragm in a bridge circuit. The change in the resistance causes a bridge output voltage
proportional to the absolute pressure.
ITEM 1120, 1340, 1355
Description
3.5.3.5 Measuring cell for absolute pressure from the gauge pressure series
1
2
3
4
5
p
e

Figure 3-10 Function chart of measuring cell for absolute pressure
Measuring cell
Process connection
Fill liquid
Absolute pressure sensor
pe Input pressure
The input pressure (pe) is transferred to the absolute pressure sensor via the separating
the input pressure.
3.5.3.6 Measuring cell for gauge pressure, front-flush membrane
1
2
3
5
6
4 p
e

Figure 3-11 Function chart of the measuring cell for gauge pressure, flush mounted diaphragm
Reference pressure opening
Measuring cell
Process connection
ITEM 1120, 1340, 1355
Description
Fill liquid
Gauge pressure sensor
pe Input pressure
The input pressure (pe) is transferred to the gauge pressure sensor via the separating
the input pressure.
Transmitters with measuring span 63 bar measure the input pressure against atmosphere,
those with measuring spans 160 bar against vacuum.
3.5.3.7 Measuring cell for absolute pressure, front-flush membrane
p
e
1
2
5
4
3

Figure 3-12 Function chart of the measuring cell for absolute pressure, flush mounted diaphragm
Measuring cell
Process connection
Fill liquid
Absolute pressure sensor
pe Input pressure
The input pressure (pe) is transferred to the absolute pressure sensor via the separating
the input pressure.
ITEM 1120, 1340, 1355
Description
3.6 Remote seal
3.6 Remote seal
Product description
A remote seal measuring system comprises the following elements:
Remote seal
Transmission line, e.g. capillary line
Measuring device
Do not separate these components under any circumstance. The measuring system based
on a hydraulic principle is used to transfer pressure. The capillary line and the remote
separating diaphragm are the most sensitive components in the remote seal measuring
system. The material thickness of the remote separating diaphragm is only ~0.1 mm. The
smallest of leakages in the transmission system leads to the loss of transmission fluid. The
loss of transmission fluid leads to inaccuracies in the measurement and the failure of the
measuring system. In order to avoid leakages and measuring errors, please observe the
following general installation and maintenance instructions in addition to the safety notes.
3.7 SIMATIC PDM
SIMATIC PDM is a software package for the configuration, paramaterization, commissioning,
diagnostics, and servicing of the device and other process devices.
SIMATIC PDM includes simple process monitoring of process values, alarms, and device
status information.
Using SIMATIC PDM, you can do the following with process device data:
display
set
change
compare
check for plausibility
administer
simulate
ITEM 1120, 1340, 1355

Install
4
4.1 Safety notes for installation
Condition
You can install the transmitter in different areas of application.
Depending on the area of application and the system configuration, there may be differences
in the installation.

WARNING
Protection against incorrect use of the measuring device
Take particular care to ensure that the selected materials for the wetted parts are suitable
for the process media used.
Ignoring these safety measures may cause bodily and life-threatening injury and be harmful
to the environment.

WARNING
"explosion-proof" type of protection

ITEM 1120, 1340, 1355
Install
4.1 Safety notes for installation
WARNING
"Intrinsically-safe" protection type
Information for operating the intrinsically-safe version in hazardous areas:
Operation is only permissible in certified intrinsically-safe circuits. The transmitter
corresponds to category 1/2 and may be installed in Zone 0.
The EC-type examination certificate applies to installation of the device in the walls of
containers and pipes in which explosive gas/air or vapor/air mixtures occur only under
atmospheric conditions (pressure: 0.8 bar to 1.1 bar; temperature: -20 C to +60 C). The
permissible range of ambient temperature is -40 C to +85 C; -40 C to a maximum of
+85 C (at T4) in hazardous areas.
The operator may use the device under non-atmospheric conditions outside the limits
specified in the EC-type examination certificate (or the certification applicable in the country
of use) at the operator's own risk if safety measures which may be necessary in
accordance with use conditions (explosive mixture) have been taken. The limit values
specified in the general technical data are to be complied with in all cases.
Additional information for zone 0
Additional requirements apply for installation in zone 0:
The installation must be sufficiently tight (IP67 according to EN 60 529). For instance, an
industry standard (e.g. DIN, NPT) threaded connector is suitable.
When operating intrinsically safe supply units of category "ib" or in the case of device
version flameproof enclosure "Ex d" and simultaneous use in zone 0, the protection against
explosion of the transmitter depends on the tightness of the sensor diaphragm. Under these
operating conditions, the transmitter may only be used for such combustible gases and
liquids for which diaphragms are sufficiently resistant to chemicals and corrosion.

CAUTION
Touch protection is required for surface temperatures > 70 C.
The touch protection must be designed in such a way that, if there is a buildup of heat, the
maximum permissible ambient temperature at the device is not exceeded.
The permissible ambient temperature can be found in the technical data.

CAUTION
The device may only be used within the measuring spans, overload pressure limits and
voltage limits dependent on the protection type specified on the type plate.

NOTICE
Install the device such that automatic emptying is ensured.
For example, do not install the device at the bottom of the tank, instead of its side.
External loads may not be allowed to affect the transmitter as this may result in an incorrect
measured value or even destruction of the device. In the worst case scenario, the process
medium will escape.

ITEM 1120, 1340, 1355
Install
4.2 Installation (except level)
4.2.1 Instructions for installation (except level)
Conditions
NOTICE
Compare the desired operating data with the data on the type plate.

NOTICE
The housing may only be opened for maintenance or to make electrical connections.

Note
Protect the transmitter against:
Direct heat radiation
Rapid temperature fluctuations
Heavy contamination
Mechanical damage

The installation location is to be as follows:
Easily accessible
As close as possible to the measuring point
Vibration-free
Within the permitted ambient temperature values
Installation configuration
The transmitter may in principle be configured above or below the pressure tapping point.
The recommended configuration depends on the medium.
Installation configuration for gases
Install the transmitter above the pressure tapping point.
Lay the pressure tubing with a constant gradient to the pressure tapping point, so that any
condensate produced can drain in the main line and thereby avoid corruption of the
measured values.
Installation configuration for vapor and liquid
Install the transmitter below the pressure tapping point.
ITEM 1120, 1340, 1355
Install
Lay the pressure tubing with a constant gradient to the pressure tapping point so that any
gas pockets can escape in the main line.
4.2.2 Installation (except level)

NOTICE
When installing the process connection of the pressure transmitter, do not turn it on the
housing.

Procedure
To install the transmitter for pressure or absolute pressure, proceed as follows:
Attach the transmitter to the process connection with an appropriate tool.
See also
Introduction to commissioning (Page 136)
4.2.3 Fastening
Fastening without the mounting bracket
You can fasten the transmitter directly on the process connection.
Fastening with the mounting bracket
You can fasten the mounting bracket as follows:
On a wall or a mounting frame using two screws
On a vertical or horizontal mounting tube ( 50 to 60 mm) using a tube bracket
Fasten the transmitter mounting bracket using the two screws provided.
ITEM 1120, 1340, 1355
Install

Figure 4-1 Fastening the transmitter on the mounting bracket

Figure 4-2 An example of fastening the transmitter on the mounting bracket in the case of
differential pressure and horizontal differential pressure lines
ITEM 1120, 1340, 1355
Install
4.3 "Level" installation
Figure 4-3 An example of fastening on the mounting bracket in the case of differential pressure and vertical differential
pressure lines
4.3.1 Instructions for level installation
Conditions
NOTICE
Compare the desired operating data with the data on the type plate.

NOTICE
The housing may only be opened for maintenance or to make electrical connections.

Note
Protect the transmitter against:
Direct heat radiation
Rapid temperature fluctuations
Heavy contamination
Mechanical damage

ITEM 1120, 1340, 1355
Install
Note
Select the height of the container flange for recording of the transmitter (measuring point)
such that the lowest level to be measured is always over the flange or at its upper edge.

The installation location is to be as follows:
Easily accessible
The measuring point must be as close as possible
Vibration-free
Within the permitted ambient temperature values
4.3.2 Installation for level

Note
Seals are required for the installation.
Seals are not included in the delivery.

Procedure
To install the transmitter for level, proceed as follows:
1. Attach the seal to the container's mating flange.
Ensure that the seal is centrically positioned and that it does not restrict the movement of
the flange's seal diaphragm in any way as otherwise the tightness of the process
connection is not guaranteed.
2. Screw on the transmitter's flange.
3. Observe the installation position.
ITEM 1120, 1340, 1355
Install
4.3.3 Connection of the negative pressure line
Measurement in an open container
A line is not required when taking measurements in an open container since the negative
chamber is connected with the atmosphere. The open connection gland should point
downwards to prevent dirt from entering.

+
Full scale value
Start of scale value
h
O
h
U

Measurement assembly on an open container
Formula:
Start of scale value:
pMA = g hU
Full scale value:
pME = g hO

hU Start of scale value pMA Start of scale value to be adjusted
hO Full scale value pME Full scale value to be adjusted
p Pressure Density of the measured medium in the
container
g Local gravitational acceleration

ITEM 1120, 1340, 1355
Install
Measurement in a closed container
When taking measurements in a closed container without or with little condensate formation,
the negative pressure line is not filled. Lay the line such that condensate pockets do not
form. Install a condensation container if required.

Full scale value
Maximum level
Static
Pressure
h
O
h
U
gas-filled negative
pressure line
Transmitter
reference line

Measurement assembly on a closed container (no or
little condensate separation)
Formula:
pMA = g hU
Full scale value:
pME = g hO

p Pressure Density of the measured medium in the
container

When taking measurements in a closed container with strong condensate formation, you
must fill the negative pressure line (mostly with the condensate of the measured medium)
and install a condensate pot. You can cut off the device using the dual pneumatic block
7MF9001-2.

ITEM 1120, 1340, 1355
Install
4.4 "Remote seal" installation
'
-
h
O
h
U
Full scale value
Maximum level
Static
Pressure
constant
comparison
level
liquid-filled
negative pressure line
Transmitter
reference line
h
Measurement assembly on a closed container (strong
condensate formation)
Formula:
pMA = g (hU - hV ')
Full scale value:
pMA = g (hO - hV ')

hV Gland distance Density of the measured medium in the
container
p Pressure ' Density of fluid in the negative pressure
line, corresponds to the temperature
prevailing there

The process connection on the negative side is a female thread
1
/4-18 NPT or an oval flange.
Lay the line for the negative pressure using a seamless steel tube 12 mm x 1.5 mm.
4.4.1 Remote seal installation
General installation instructions
Keep the measuring system in the factory packing until it is installed in order to protect it
from mechanical damage.
When removing from the factory packing and installing: ensure that damage to and
mechanical deformations in the diaphragm are prevented.
ITEM 1120, 1340, 1355
Install
Never loosen the sealed filling screws on the remote seal and the measuring device.
Do not cause damage to the remote separating diaphragm; scratches on the remote
separating diaphragm, e.g. due to sharp-edged objects, are the main starting points for
corrosion.
Select suitable gaskets for sealing.
Use a gasket having an adequately large inner diameter for flanging. Insert the gasket
concentrically; contact with the diaphragm leads to deviations in measurements.
When using gaskets made of soft materials or PTFE: follow the guidelines of the gasket
manufacturer, especially regarding the tightening torque and setting cycles.
At the time of installation, use suitable fastening components such as screws and nuts
that are compliant with fitting and flange standards.
Excessive tightening of screwed joints on the process connection may displace the zero
point on the pressure transmitter.
Note: Commissioning
Follow the instruction given below if a shut-off valve exists: Open the shut-off valve slowly
when commissioning in order to avoid pressure surges.
Note:
permissible ambient and operating temperatures
Install the pressure measuring device such that the permissible limits of ambient and
measured medium temperatures are not overshot or undershot even with the consideration
of the effect of convection and heat radiation. Pay attention to the effect of temperature on
the accuracy of display. When selecting the remote seals, ensure that fittings and flange
components have adequate pressure-temperature resistance by selecting suitable materials
and pressure ratings. The pressure rating specified on the remote seal is applicable for
ambient temperatures. For the maximum permissible pressure at higher temperatures,
please refer to the standard specified on the remote seal.
Using remote seals with pressure measuring devices for hazardous areas:
When using remote seals with pressure measuring devices for hazardous areas, the
permissible limits of ambient temperatures for the transmitter should not be exceeded.
Hot surfaces on the cooling section (capillaries or cooling elements) are a possible
source of ignition. Initiate suitable measures.
When remote seals with a flame arrester are used, the pressure measuring device
determines the permissible ambient temperature. In the case of potentially explosive
gaseous atmosphere, the temperature around the flame arrester should not exceed
+60 C.
ITEM 1120, 1340, 1355
Install
4.4.2 Installation of the remote seal with the capillary line
Notes
Do not rest the measurement assembly on the capillary line.
Do not bend capillary lines; risk of leakages and/or risk of considerable increase in the
setting time of the measuring system.
Owing to the risk of bending and breakages, pay attention to mechanical overloads at the
joints such as capillary line-remote seal and capillary line-measuring device.
Unwinding the excess capillary lines with a radius of at least 150 mm.
Fasten the capillary line such that there are no vibrations.
Permissible height differences
When installing the pressure measuring device above the measuring point, keep the
following in mind: in the case of remote seal measuring systems with silicon, glycerin or
paraffin oil filling, the height difference of H1should not exceed a maximum of 7 m.
If halocarbon oil is used as a fill fluid, this maximum height difference should be H1 4 m
(see installation types A and B).
If negative overpressure is observed during measurements, reduce the permissible height
difference accordingly.
Installation type for gauge pressure and level measurements (open containers)

Installation type A

H
1
H
H
u
H
o

Pressure transmitter above the
measuring point
pMA = FL * g * HU + oil * g * H1
Full scale value:
pME = FL * g * HO + oil * g * H1
ITEM 1120, 1340, 1355
Install
Installation type B

H
1
H
H
u
H
o

Pressure transmitter below the
measuring point

pMA = FL * g * HU - oil * g * H1
Full scale value:
pME = FL * g * HO - oil * g * H1
H1 7 m (23 ft), for halocarbon oil, however only H1 4 m(13.1 ft)

Legend
pMA Start of scale value to be adjusted
pME Full scale value to be adjusted
FL Density of the measured medium in the container
oil Density of the filling oil in the capillary line of the remote seal
HU Start of scale value
HO Full scale value
H1 Distance between the container flange and the pressure transmitter
For absolute pressure measurements (vacuum), install the measuring device at least at the
height of the remote seal or below it (see installation types C).
Installation types for absolute pressure measurements (closed containers)

Installation type C1

p
abs
H
1

pMA = pstart + oil * g * H1
Full scale value:
pME = pend + oil * g * H1
ITEM 1120, 1340, 1355
Install
Installation type C2

p
abs
H
1

Pressure transmitter for absolute pressure always below the measuring point: H1 200 mm
(7.9 inch)

Legend
pstart Start of scale value
pend Full scale value
H1 Distance between the container flange and the pressure transmitter

Note
Effects of temperature
Keep the following instructions in mind in order to minimize keep the effects of temperature
in remote seal measuring systems with the differential pressure measuring device:
Install the device such that the positive and negative sides are symmetrical as far as ambient
effects, especially ambient temperatures, are concerned.

ITEM 1120, 1340, 1355
Install
Installation type for differential pressure and flow rate measurements

Installation type D

H
1
H
V
H
2

pMA = pstart - oil * g * HV
Full scale value:
pME = pend - oil * g * HV

Legend
pstart Start of scale value
pend Full scale value
HV Gland distance
Installation types for level measurements (closed containers)

Installation type E

H
H
O
H
V
H
U

pMA = FL * g * HU - oil * g * HV
Full scale value:
pME = FL * g * HU - oil * g * HV

Legend
ITEM 1120, 1340, 1355
Install
HO Full scale value
HV Gland distance

Installation type G

H
1 H
H
o
H
V
H
u
H
2

Pressure transmitter for differential
pressure above the upper
measuring point, no vacuum
H1 7 m (23 ft), for halocarbon oil, however only
H1 4 m(13.1 ft)
Full scale value:
pME = FL * g * HO - oil * g * HV
Installation type H

H
1
H
2

Below the lower measuring point
Full scale value:
ITEM 1120, 1340, 1355
Install
Installation type J

H
1
H
2

Between the measuring points, no
vacuum
H2 7 m (23 ft), for halocarbon oil, however only
H1 4 m(13.1 ft)
Full scale value:

Legend
HO Full scale value
HV Gland distance

ITEM 1120, 1340, 1355
Install
4.5 Turing the measuring cell against housing
4.5 Turing the measuring cell against housing
Description
You can turn the measuring cell against the housing. Turning simplifies the transmitter
operation in the case of an angled installation environment. The buttons and the current
connection can thus also be operated for an external measuring device. The digital display
also remains visible in the case of housing covers with an inspection window.
Only limited turning is permissible! The turning range is marked at the foot of the
electronic housing. An orientation mark is provided at the throat of the measuring cell.
This mark must remain in the marked section when turning.
1
2
1
1
3

Figure 4-4 Example: turning range of transmitters for pressure and absolute pressure from the
gauge pressure series
Turning range
Retaining screw
Orientation mark
The turning range for transmitters for differential pressure and flow rate, absolute pressure
from the differential pressure series and level is identified in a similar manner.
Procedure
CAUTION
Follow the turning range, otherwise electrical connections of the measuring cell may get
damaged.

1. Loosen the retaining screw (Allen screw 2.5 mm).
2. Turn the electronic housing against the measuring cell. Follow the marked turning range
while doing so.
3. Tighten the retaining screw (torque: 3.4 to 3.6 Nm).
ITEM 1120, 1340, 1355
Install
4.6 Turning the digital display
Description
You can rotate the digital display in the electronic housing. You can then read the digital
display better when the device is not operated in a vertical installation position.
Procedure
WARNING
"Explosion-proof" type of protection

Proceed as follows:
1. Unscrew the housing cover of the electronic compartment.
2. Unscrew the digital display. Depending on the application position of the transmitter, you
can reinstall it at four different positions. You can turn it by 90 or 180.
3. Screw the housing cover back into place.
ITEM 1120, 1340, 1355
Install
ITEM 1120, 1340, 1355

Connecting
5
5.1 Safety notes for connection

WARNING
Laying of cables
Connect the devices that are operated in hazardous areas as per the stipulations applicable
in your country, e.g. for Ex "d" and "nA", permanent cables must be laid.

WARNING
Cable glands
If you use the provided cable glands M20x1.5 and -14" NPT, only the cables having a
diameter of 6 to 12 mm must be laid into the device.
"nA" type of protection
In the case of devices with "nA" type of protection (zone 2), only use cables having a
diameter of 8 to 12 mm owing to the required tensile strength, or use a suitable cable gland
in case of smaller diameters.

WARNING
When connecting and installing, follow only the test certifications, stipulations and laws
applicable in your country.
For example, for hazardous areas these are:
IEC 60079-14 (international)
National Electrical Code (NEC - NFPA 70) (USA)
Canadian Electrical Code (CEC) (Canada)
EN 60079-14 (earlier VDE 0165, T1) (EU, Germany)
Ordinance on Industrial Safety and Health (Germany)

WARNING
If auxiliary power is required, check that it corresponds with that on the type plate and with
the test certification valid for your country.

ITEM 1120, 1340, 1355
Connecting
5.2 Connecting the device
WARNING
Replace the sealing caps in cable entries with suitable cable glands or blanking plugs that
are certified for transmitters of the "explosion-proof" type of protection.

Note
To improve the reliability:
Install the signal cable separately from cables with voltages > 60 V.
Use cable with twisted strands.
Stay away from large electrical systems.
Use shielded cable to guarantee the full specification according to HART.
Connect a load of at least 230 ohm into the signal circuit in sequence in order to
guarantee fault-free HART communication. When using supply isolation for SMART
transmitters, for example: Siemens 7NG4021 a load is already installed in the device.

Procedure
To connect the device, proceed as follows:
1. Unscrew the cover of the electrical cable compartment.
An identification text "FIELD TERMINAL" is provided at the side of the housing.
2. Insert the connecting cable through the cable gland.
3. Connect the wires to the connecting terminals "+" and "-".
Observe the polarity when doing this.
4. Place a shield on the shield support screw if required. This is electrically connected with
the external protective conductor connection.
5. Screw the cover back into place.

WARNING

In the case of transmitters with the "explosion-proof" type of protection, screw the
housing cover firmly and secure it with a cover latch.
ITEM 1120, 1340, 1355
Connecting
230
+
-
1
2
3
4
5
6
7
8

Figure 5-1 Schematic electrical connection

Feed separator with integrated load
Auxiliary power
Cable entry for auxiliary power/analog output
Connecting terminals
Test connector for direct current measuring device or connection for external display
Shield support
Protective conductor connection/equipotential bonding terminal
Cable entry for sensor signals

ITEM 1120, 1340, 1355
Connecting
5.3 Connecting the Han plug
5.3 Connecting the Han plug
Introduction
The contact parts for the coupling socket are also supplied.
Procedure
To connect the plug, proceed as follows:
1. Slide the sleeve and the screwed joint on the cable.
2. Strip approx. 8 mm of the cable ends.
3. Crimp the contact parts on the cable ends.
4. Assemble the coupling socket.

IA Output current
l
A
U
H
1 2
3 4
5
6 7
+ -

Connector pin assignment with
Han 7D or Han 8U plug
UH Auxiliary power
5.4 Connecting the M12 connector
Procedure
CAUTION
A conductive connection should not exist between the shield and the connector housing.

For devices in which a connector is already assembled on the housing, the connection is
established using a jack coupling.
1. Thread the parts of the jack coupling as described by the connector manufacturer.
2. Strip approximately 18 mm of the bus cable .
3. Twist the shield.
4. Thread the shield in the insulating sleeve.
5. Draw 8 mm of shrink sleeve over the cable, wires and shield up to the reference edge .
ITEM 1120, 1340, 1355
Connecting
6. Screw the cable ends and the shield in the pin insert.
7. Fix the parts of the jack coupling as described by the connector manufacturer.
4
20+1
3
8
1
2
3
4

Figure 5-2 Preparing the fieldbus cable

Reference edge for stripping Insulating sleeve over the shield
Reference edge for the dimension
specifications for cable assembly
Shrink sleeve
Pin assignment

1
4 3
2
1
2

Layout for M12 connector
2
3 4
1
1

Layout for M12 jack
M12 x 1 thread Positioning slot
Positioning catch
1 + 1 +
2 Not connected 2 Not connected
3 - 3 -
4 Shield 4 Shield
Middle jack not assembled

ITEM 1120, 1340, 1355
Connecting
ITEM 1120, 1340, 1355

Operation
6
6.1 Overview of operation
Introduction
The following description contains an overview of the operating functions that you can
execute using the pressure transmitter, and the safety notes that are to be observed when
doing so. You can operate the transmitter on-site through HART communication. First, the
on-site operation and then, the operating functions using HART are described.
Contents of the chapter
Safety information for operation (Page 56)
Instructions for operation (Page 56)
Digital display (Page 57)
Local operation (Page 63)
Overview of operating functions
You can configure basic settings of the pressure transmitter using the buttons on the device.
You can configure all settings through HART communication.
The following table describes the basic operating functions. More operating functions for
special applications are accessible through HART. Basic variables of the device are marked
in bold.
Table 6-1 Operating functions
Function Using buttons Using HART
Start of scale value Yes Yes
Full scale value Yes Yes
Electrical damping Yes Yes
Blind adjustment of the start of scale
value
Yes Yes
Blind adjustment of the full scale value Yes Yes
Zero point calibration (position
correction)
Yes Yes
Current transmitter Yes Yes
Fault current Yes Yes
ITEM 1120, 1340, 1355
Operation
6.2 Safety information for operation
Function Using buttons Using HART
Keyboard lock and write protection Yes Yes, release except for write
protection
Unit type, unit Yes Yes
Characteristic curve (lin., rad.)
(Not relevant for absolute
and gauge pressure)
Yes Yes
Customized characteristic curve No Yes
Diagnostic function No Yes
More operating functions for special applications are accessible through HART.
If a device that does not have a digital display, its operations are limited. This is however not
applicable for selecting functions using HART.
6.2 Safety information for operation

NOTICE
If you have set the basic functions of the pressure transmitter as user defined, the display
and measurement output terminal can be adjusted such that the true process pressure is
not reproduced.
The basic variables should therefore be checked prior to commissioning.

6.3 Instructions for operation
The following rules are applicable for the operation of the pressure transmitter:
The device counts numerical values always in an ascending order step by step starting
from the least significant digit displayed.
If you keep the button pressed for a longer time, it counts the next higher digit displayed.
This procedure is used for fast coarse adjustment over a wide number range. Release
the [] or [] button again for fine adjustment. Press the button again.
Violations of the measured value limits are displayed on the digital display with or .
The keyboard must have been unlocked in order to operate the device using the
keyboard.
If you are operating the transmitter locally, write access is denied through HART during
this time.
However, it is always possible to read the data, e.g. measured values.
ITEM 1120, 1340, 1355
Operation
6.4 Digital display

Note
The setting is saved and the measured values are automatically displayed again if more
than two minutes have passed after a button was pressed for the last time.
The operating instructions mentioned in the "Local operation without digital display"
chapter are applicable if the device has been delivered with a blind cover.
6.4 Digital display
6.4.1 Elements of the digital display
Structure
1
2 3 4
5
6
7
8

Figure 6-1 Structure of the digital display

Measured value Violation of lower limit
Unit/bar graph Symbol for measured value
Root display Violation of higher limit
Mode/button lock Communication display
Description
The digital display is used for local display of the measured value with:
Unit
Mode
Sign
Statuses and
Depending on the customer setting, the displayed measured value represents the
following:
ITEM 1120, 1340, 1355
Operation
6.4 Digital display
The current emitted by the transmitter
The percentage measurement value of the adjusted measurement type, e.g. level, related
to the adjusted measurement range.
The measurement value in a selectable physical unit
The Violation of lower limit and Violation of upper limit displays are also referred to as
status since they have meanings dependent on the settings.
If the communication display blinks, this indicates an active communication.
6.4.2 Units display
Description
The unit display comprises five 14-segment fields for representing the unit as a percentage
value, physical unit or current value. A bar graph showing the percentage measured value
range from 0 to 100% can be displayed as an alternative to the unit. The bar graph function
is disabled by default.
Display

Figure 6-2 Examples for measured value display for current and bar graph
The following messages may appear as a ticker in the bottom line of the digital display. They
have no influence on the current output.
Table 6-2 Message as ticker
Ticker Meaning
"DIAGNOSTIC WARNING" Is always displayed if:
An event configured by the user is to be signaled with a
warning. For example:
Limit reached
Event counter for limit values exceeded
Calibration time expired
Current saturation reached
The status of one of the device variables is
"UNCERTAIN".
"SIMULATION" Is always displayed when the simulation of a pressure value
or temperature value is active.
ITEM 1120, 1340, 1355
Operation
6.4 Digital display
See also
Measured value status (Page 101)
6.4.3 Error display
Description
If hardware faults, software errors or diagnostic alarms occur in the transmitter, the message
"Error" appears in the measured value display.
A ticker appears in the lower line of the digital display indicating the type of error. This
diagnostic information is also available via HART communication.
Display

Figure 6-3 Example of error message
The following messages may appear as a ticker in the bottom line of the digital display.

Ticker Meaning
"HARDWARE FIRMWARE ALARM" Contains hardware faults such as:
incorrect checksum
incorrect EEPROM data
Defective EEROM
RAM fault
ROM fault
inconsistent data
EEPROMs not initialized
"DIAGNOSTIC ALARM" Is always displayed if
an event configured by the user is to be signaled
with an alarm.
For example:
Limit reached
Event counter for limit values exceeded
Calibration time expired
Current saturation reached
the status of one of the device variables is "BAD".
"SENSOR BREAK" Appears when there is a sensor break.
ITEM 1120, 1340, 1355
Operation
6.4 Digital display
See also
6.4.4 Mode display
Description
The selected active mode is shown in the mode display.
Display

Figure 6-4 Example for mode display
In the example, a damping of 0.2 seconds was set in mode 4.
6.4.5 Status display
Description
The arrows of the status display have a different meaning depending on the mode setting.
The table below shows the meanings of the arrows in the respective functions.
Meaning
Table 6-3 Meaning of the arrow displays
Function Mode Display Display
Adjusting start of
scale value
2 if the upper current limit is
exceeded
if the value falls below the
lower current limit
Adjusting full scale
value
3 if the upper current limit is
exceeded
lower current limit
Adjusting damping 4 if the upper damping value is
exceeded
only for the pressure device version
lower damping value
only for the pressure device
version
ITEM 1120, 1340, 1355
Operation
6.4 Digital display
Function Mode Display Display
Blind adjustment of
the start of scale
value
5 if the upper sensor limit is
exceeded
lower sensor limit
Blind adjustment of
the full scale value
6 if the upper sensor limit is
exceeded
lower sensor limit
Position correction 7 if the max span is exceeded by
more than 5% of the upper current
limit
lower current limit
Root application point 12 if the root application point of 15%
is exceeded
if the value falls below the root
application point of 5%
Keyboard operation 2, 3, 5,
6
when the span to be adjusted is
larger than the maximum span
when the span to be adjusted
is smaller than the minimum
span
Normal operation Current exceeds the upper
saturation limit
Pressure exceeds the upper sensor
limit.
Current falls below the lower
saturation limit
Pressure falls below the lower
sensor limit.
6.4.6 Overflow range
Description
The output signal is divided into defined ranges:
Measuring range
Saturation limits
Fault current
The transmitter emits the output current according to the device variables selected as
primary variable (PV). The working range of the current lies between 4 mA and 20 mA.
Meaning
When the measurement limits are exceeded or not reached, the measured values are
correctly displayed in the overflow range.
A ticker is displayed in the lower line of the digital display showing the message UNDER or
OVER with respect to the selected unit. The possible overflow range can be adjusted via
HART communication. If either of the overflow limits are violated, the output current remain
constant. Violations of the measured value limits are displayed on the digital display with or
.

Note
The setting of the overflow range and the fault current range can be freely selected via
HART communication.

ITEM 1120, 1340, 1355
Operation
6.4 Digital display
Reference
NAMUR recommendation NE43 dated 03.02.2003
"Standardization of the signal level for the breakdown information of digital transmitters"
See also
Fault current (Page 109)
Setting the current limits (Page 110)
ITEM 1120, 1340, 1355
Operation
6.5 Local operation
6.5 Local operation
6.5.1 Local control elements
Introduction
The transmitter can be operated on-site using the buttons. Selectable modes can be used to
choose and execute the functions described in the table. The number of functions is limited if
the device does not have a digital display.
Control elements
6
5 4 3
2
1

Figure 6-5 Position of buttons and digital display
Digital display Connecting plug for the digital display
Mode button Increment button
Decrement button
Operating functions
NOTICE
Zero point calibration
For absolute pressure transmitters, the start of scale value is at vacuum.
A zero point calibration with transmitters which do not measure absolute pressure leads to
faulty settings.

ITEM 1120, 1340, 1355
Operation
6.5 Local operation
Table 6-4 Operating functions using buttons
Mode Button function Function
[M] [] [] [] and []
Display, explanations
Measured value The
modes
are
selected
here.
The current measured value is displayed as you
have adjusted it in the "Measured value display,
mode 13" function.
(only in "Pressure"
measuring mode)
2 Current
higher
Current
lower
Set to 4 mA Output current in mA
Full scale value
(only in "Pressure"
measuring mode)
3 Current
higher
Current
lower
Set to 20 mA Output current in mA
Electrical damping 4 Damping
higher
Damping
lower
Set to 0 Time constant T63 in seconds
Adjustment range: 0.0 s to 100.0 s
in the so-called blind
adjustment
5 Pressure
higher
Pressure
lower
Set start of
scale value to
0
Start of scale value in the selected pressure unit
Full scale value in
the so-called blind
adjustment
6 Pressure
higher
Pressure
lower
Set full scale
value to upper
measuring limit
Full scale value in the selected pressure unit
Zero point
calibration (position
correction)
7 Correctio
n value
higher
Correctio
n value
lower
execute Ventilate the transmitter for gauge pressure,
differential pressure, flow rate or level.
Evacuate the transmitter for absolute pressure
(< 0.1 of the measuring span).
(Start of scale value remains unaffected)
Measured value in pressure unit
Current transmitter 8 Current
higher
Current
lower
switch on constant output current in mA
"3.6"; "4", "12", "20" or "22.8"
Switch off using the [M] button.
Output current in
case of fault
9 Switch between lower
fault current and
upper fault current.
lower fault
current
selected output current possible: Fault current
limits adjusted by user
0 None
LA all locked
LO all locked except for start of scale value
LS all locked except for start of scale value
and full scale value
Button lock or
function lock
10 Switch between the
five functions

L Write protection
Operation via HART not possible.
lin linear
srlin square root extracting (linear up to the
application point)
sroff Square root extracting
(deactivated up to the application point)
Characteristic
curve
1)

11 Switch between the
four functions
linear
srli2 square root extracting (linear up to the
application point 10%)
ITEM 1120, 1340, 1355
Operation
6.5 Local operation
Mode Button function Function
[M] [] [] [] and []
Display, explanations
Application point of
the square root
extracting
characteristic curve
1)

12 Greater Smaller 10% flow rate Adjustment range of 5 to 15% flow rate.
Measured value
display
13 Select from three
options.
Display type (input value)
Output current in mA
Measured value in %
Unit 14 Select from the table
for measured value
display.
In each case,
the first value
from the table
of the physical
unit
Physical unit
1)
Not relevant for gauge and absolute pressure)
See also
Overview of operation (Page 55)
Operating functions through HART communication (Page 91)
6.5.2 Operation using buttons
Introduction
This overview informs you about the most important safety notes to be observed when
operating the pressure transmitter. Furthermore, the overview guides you in adjusting the
operating functions on site.
Condition
The keyboard must have been unlocked in order to operate the device using the buttons.
Procedure
In the default setting, the device is in the measured value display.
To adjust the operating functions, proceed as follows:
1. Loosen both the screws of the keyboard cover and lift it upwards.
2. Keep pressing the [M] button until the desired mode is displayed.
3. Keep pressing the [] or [] button until the desired value is displayed.
4. Press the [M] button.
Now you have saved the values and the device goes to the next mode.
5. Close the keyboard cover using the two screws.
ITEM 1120, 1340, 1355
Operation
6.5 Local operation

Note
The setting is saved and the measured values are automatically displayed again if more
than two minutes have passed after a button was pressed for the last time.
See also
Releasing key lock or function lock (Page 81)
6.5.3 Start of scale value/full scale value
6.5.3.1 Difference between setting and adjusting
Introduction
In "Pressure" measuring mode, you can set or adjust the start of scale value and full scale
value using the buttons. Modes 2 and 3 are used for this. Rising and falling characteristic
curves can be realized with appropriate use of the buttons. If the transmitter is not in
"Pressure" measuring mode, this mode is skipped in local operation.
Difference
The difference between setting and adjusting lies in the calculation.
Setting with reference pressure
Condition
Two reference pressures pr1 and pr2 are available. The reference pressures are initialized by
the process or generated by a pressure sensor.
When setting, a desired start of scale value or a full scale value is allocated to the standard
current values (4 mA or 20 mA). After setting, the measuring span entered on the type plate
may no longer correspond with the adjustment.
Depending on the series and measuring range, a maximum downscaling of 1:100 can be
achieved (measuring span ratio = r, turn down).

Note
Setting the start of scale value does not change the measuring span. Setting the full scale
value does not change the start of scale value.
The start of scale value should therefore be set first, then the full scale value.

The correlation between the measured pressure and the output current generated is linear.
The square root extracting characteristic curve for differential pressure transmitters is an
exception. Calculate the output current using the following formula.
ITEM 1120, 1340, 1355
Operation
6.5 Local operation
l =
p - MA
ME - MA
*
16 mA + 4 mA

Figure 6-6 Current calculation formula for setting

I Output current MAactual Old start of scale value
p Pressure MEactual Old full scale value
MA Start of scale value MAtarget New start of scale value
ME Full scale value MEtarget New full scale value
Example of setting with reference pressure

A Initial situation

B Setting start of scale value

C Setting full scale value
0 16
4 20
MA
actual
MA
target
ME
actual
0 2 16
16
18
4 18 20
MA
actual
MA
target
ME
target
0 2 11 14
4 16 20
p [bar]
l [mA]
p [bar]
l [mA]
p [bar]
l [mA]

Explanations for the example of setting with reference pressure

A The measuring range is from 0 to 16 bar. You are changing the start of scale value from
0 to 2 bar and the full scale value from 16 to 14 bar. The measuring span is then 12
bar.
B 2 bar process pressure is created.
Use the [M] button to set the transmitter to mode 2. To set the start of scale value,
press the [] and [] buttons simultaneously for 2 seconds.
If there is 2 bar input pressure, the transmitter produces an output current of 4 mA.
C 14 bar process pressure is created.
Use the [M] button to set the transmitter to mode 3. To set the full scale value, press the
[] and [] buttons simultaneously for 2 seconds.
D The output current can be calculated for any input pressure using the "current
calculation formula for setting".

ITEM 1120, 1340, 1355
Operation
6.5 Local operation

Note
If the value exceeds or falls below the preset measuring limits by more than 20% when
setting, the setting function is not carried out. The old value is retained in this case.
With a marked elevation of the zero point, the full scale value must therefore previously be
reduced such that it still lies within the permitted range after elevation of the zero point. This
setting function is only possible in "Pressure" measuring mode.

Adjusting with reference pressure
Condition:
The reference pressure, the adjusted start of scale value and adjusted full scale value are
known.
When adjusting, a start of scale value or a full scale value can be allocated to a desired
current value with the aid of a reference pressure. This function is particularly suitable when
the required pressures for the start of scale value and the full scale value are not available
After adjustment, the measuring range specified on the type plate may no longer correspond
with the setting.
Using the formulae below, the current to be set for the desired start of scale value and the
full scale value can be calculated.
To calculate the output currents when setting the start of scale value or the full scale value,
the reference pressure must be selected such that a value between 4 and 20 mA results for
the current.
l =
p - MA
ME - MA
*
16 mA + 4 mA

l
ME
=
p
ref
- MA
target
ME
target
- MA
target
*
16 mA + 4 mA

Figure 6-7 Current calculation formula for setting with reference pressure

I Output current MAactual Old start of scale value
IMA Current to be adjusted with MAtarget MEactual Old full scale value
IME Current to be adjusted with MEtarget MAtarget New start of scale value
p Pressure MEtarget New full scale value
pref Existing reference pressure
ITEM 1120, 1340, 1355
Operation
6.5 Local operation
Example of adjusting with reference pressure

A Initial situation

B Calculating start of scale
value

C Calculating full scale value
p
ref
MA
actual
MA
target
16
MA
actual
MA
target
ME
target
p [bar]
l [mA]
p [bar]
l [mA]
p [bar]
l [mA]
set
set
0 11 16
4 15 20
0 2 11
4 13 18
ME
lst
0 2 11 14 16
4 16 20

Explanations for the example of adjusting with reference pressure

bar.
A reference pressure of 11 bar is created.
B Use the [M] button to set the transmitter to mode 2.
The "Current calculation formula for adjusting with reference pressure" can be used to
calculate the current to be adjusted for the desired start of scale value IMA (13 mA at
2 bar) with the existing reference pressure. It can be adjusted with the [] or [] buttons
IMA.
C Use the [M] button to set the transmitter to mode 3.
The "Current calculation formula for adjusting" can be used to calculate the current to
be adjusted for the desired full scale value IME (16 mA at 14 bar) with the existing
reference pressure. It can be adjusted with the [] or [] buttons IM.

Note
If the preset measuring limits are exceeded or fallen below by more than 20% during
adjustment, the resulting current cannot be set above these limits.
reduced such that it still lies within the permitted range after elevation of the zero point.

See also
Unit (Page 86)
ITEM 1120, 1340, 1355
Operation
6.5 Local operation
6.5.3.2 Setting/adjusting the start of scale value
Introduction
Set or adjust the start of scale value of the pressure transmitter in mode 2.
You can also adjust the start of scale value or the full scale value separately as well as
adjust both these values one after the other.
Condition
You are familiar with the correct operation of the transmitter and the associated safety notes.
You have selected a reference pressure that corresponds to the start of scale value and is
within the permissible tolerance range.
The transmitter is in "Pressure" measuring mode.
Setting start of scale value
To set the output current of the start of scale value to 4 mA, proceed as follows:
1. Create the reference pressure.
2. Set mode 2.
3. Set the start of scale value to 4 mA.
4. Save with the [M] button.
Adjusting start of scale value
If you do not set the output current but constantly adjust it, you need to calculate the currents
to be adjusted mathematically.
To the adjust the output current of the start of scale value, proceed as follows:
2. Set mode 2.
3. Adjust the output current of the start of scale value to the calculated value.
Setting the start of scale value without a digital display
You have a device with a cover that does not have an inspection window and you wish to set
the start of scale value.
To set the output current of the start of scale value to 4 mA, proceed as follows:
2. Press the [] and [] buttons simultaneously.
The device has set the start of scale value to 4 mA.
3. When you release the buttons, the device saves the adjusted value automatically.
ITEM 1120, 1340, 1355
Operation
6.5 Local operation
Adjusting the start of scale value without a digital display
You have a device with a cover that does not have an inspection window and you do not
wish to set the start of scale value, but adjust it.
You will need an ammeter for this purpose.
To the adjust the output current of the start of scale value, proceed as follows:
1. Connect the ammeter to the test connector.
3. Adjust the output current of the start of scale value using the [] or [] button.
4. When you release the button, the device saves the adjusted value automatically.
6.5.3.3 Setting/adjusting the full scale value
Introduction
Set or adjust the full scale value of the pressure transmitter in mode 3.
You can also adjust the start of scale value or the full scale value separately as well as
adjust both these values one after the other.
Condition
You have selected a reference pressure that corresponds to the full scale value and is within
the permissible tolerance range.
The transmitter is in "Pressure" measuring mode.
Setting full scale value
To set the output current of the full scale value to 20 mA, proceed as follows:
2. Set mode 3.
3. Set the full scale value to 20 mA.
Adjusting full scale value
If you do not set the output current but constantly adjust it, you need to calculate the currents
to be adjusted mathematically.
To the adjust the output current of the full scale value, proceed as follows:
2. Set mode 3.
3. Adjust the output current of the full scale value to the calculated value.
ITEM 1120, 1340, 1355
Operation
6.5 Local operation
Setting the full scale value without a digital display
You have a device with a cover that does not have an inspection window and you wish to set
the full scale value.
To set the output current of the full scale value to 20 mA, proceed as follows:
2. Press and hold the [M] button.
3. Also press the [] and [] buttons simultaneously.
The device has set the full scale value to 20 mA.
4. When you release the buttons, the device saves the adjusted value automatically.
Adjusting the full scale value without a digital display
You have a device with a cover that does not have an inspection window and you do not
wish to set the full scale value, but adjust it continuously.
You will need an ammeter for this purpose.
To the adjust the output current of the full scale value, proceed as follows:
1. Connect the ammeter to the test connector.
3. Press and hold the [M] button.
4. Adjust the output current of the full scale value to the calculated value using the [] or []
button.
5. When you release the button, the device saves the adjusted value automatically.
6.5.4 Setting/adjusting electrical damping
Difference between setting and adjusting
You can set or adjust the time constant of electrical damping using the buttons. Setting
means that the time constant is automatically set to 0 seconds. Adjusting means that the
time constant is adjusted between 0 and 100 seconds using the steps of 0.1 seconds. This
electrical damping also has an effect on the built-in basic damping of the device.
Condition for "setting"
ITEM 1120, 1340, 1355
Operation
6.5 Local operation
Setting electrical damping
To set electrical damping to 0 seconds, proceed as follows:
1. Set mode 4.
Result
Electrical damping has been set to 0 seconds.
Condition for "adjusting"
The default setting of steps is an interval of 0.1 seconds. If you press the [] or [] button for
a longer time, the step is increased.
Adjusting electrical damping
To adjust electrical damping, proceed as follows:
1. Set mode 4.
2. Adjust the desired damping.
Result
Electrical damping has been set to the desired time constant.
6.5.5 Blind start of scale value/full scale value
6.5.5.1 Difference between setting/adjusting and blind setting/adjusting
Differences
In contrast to setting/adjusting with a reference pressure, you do not need a reference
pressure for blind setting/adjusting. You can adjust a value in the physical variable
"pressure" without a reference pressure, and an output current with a reference pressure.
Blind adjusting
First select the desired physical unit. Then, adjust two pressure values using the [] and []
buttons and save them in the device. These theoretical pressure values are allocated to the
standard current values 4 mA and 20 mA.
Depending on the series and measuring range, a maximum downscaling of 1:100 can be
achieved (measuring span ratio = r, turn down).
ITEM 1120, 1340, 1355
Operation
6.5 Local operation
The correlation between the measured pressure and the output current generated is linear.
The square root extracting characteristic curve for differential pressure transmitters is an
exception.
Example of blind adjusting

A Initial situation

B Blind adjustment of the start
of scale value

C Blind adjustment of the full
scale value
MA
actual
MA
target
ME
actual
MA
actual
MA
target
ME
target
p [bar]
l [mA]
p [bar]
l [mA]
p [bar]
l [mA]
0 16
4 20
0 2 16 18
20
4
18
0 2 14 16
4 20

I Output current p Pressure
MAactu
al
Old start of scale value MAtarget New start of scale value
MEactu
al
Old full scale value MEtarget New full scale value
Explanations for the blind adjusting example

bar.
In this example you create no pressure.
B Use the [M] button to switch the transmitter to mode 5. To adjust the start of scale value
to 2 bar, press one of the [] or [] buttons.
C Use the [M] button to switch the transmitter to mode 6. To adjust the full scale value to
14 bar, press one of the [] or [] buttons.

ITEM 1120, 1340, 1355
Operation
6.5 Local operation

Note
If the preset measuring limits are exceeded or fallen below by more than 20% during
adjustment, the resulting current cannot be set above these limits.

Setting without reference pressure
Blind setting resets the start of scale value to the lower sensor limit and the full scale value to
the upper sensor limit.

Note
If the value exceeds or falls below the preset measuring limits by more than 20% when
setting, the setting function is not carried out. The old value is retained in this case.

6.5.5.2 Blind setting of start of scale value
Introduction
Blind setting resets the start of scale value to the lower sensor limit.

Note
Changes in modes 5 and 6 have an exclusive effect on pressure scaling. This does not
affect the scaling for level or customized characteristic curve. Therefore, only measured
pressure values and pressure units are displayed in these modes.

Condition
You have not created any reference pressure and have selected a pressure unit.
Procedure
To the set the start of scale value blindly, proceed as follows:
1. Set mode 5.
2. Press the [] and [] buttons simultaneously for 2 seconds.
ITEM 1120, 1340, 1355
Operation
6.5 Local operation
6.5.5.3 Blind setting of full scale value
Introduction
Blind setting resets the full scale value to the upper sensor limit.

Note

Condition
Procedure
To the set the full scale value blindly, proceed as follows:
1. Set mode 6.
2. Press the [] and [] buttons simultaneously for 2 seconds.
6.5.5.4 Blind adjusting of the start of scale value
Introduction
In the case of blind adjustment, adjust the pressure value of the start of scale value
continuously and without a reference pressure.

Note

You can toggle between rising and falling characteristic curves.
Condition
ITEM 1120, 1340, 1355
Operation
6.5 Local operation
Procedure
To the adjust the pressure value of the start of scale value blindly, proceed as follows:
1. Set mode 5.
2. Adjust the pressure value of the start of scale value.
6.5.5.5 Blind adjustment of the full scale value
Introduction
In the case of blind adjustment, adjust the pressure value of the full scale value continuously
and without a reference pressure.

Note

You can toggle between rising and falling characteristic curves by swapping the start of scale
value and the full scale value.
Condition
Procedure
To the adjust the pressure value of the full scale value blindly, proceed as follows:
1. Set mode 6.
2. Adjust the pressure value of the full scale value.
6.5.6 Trimming the zero point
Introduction
The zero point is calibrated in mode 7. Zero point calibration corrects zero point errors
resulting from the installation position of the pressure transmitter. The device type
determines the way in which you proceed.
SIMATIC PDM or the HART communicator will display the total of all zero point corrections.
ITEM 1120, 1340, 1355
Operation
6.5 Local operation
Condition
Zero point calibration for gauge pressure transmitter
To calibrate the zero point, proceed as follows:
1. Pressurize the transmitter.
2. Set mode 7.
Zero point calibration for absolute pressure transmitter
Note
You need a reference pressure known to you which lies within the measuring limits.

To calibrate the zero point, proceed as follows:
2. Set mode 7.
3. Set the reference pressure on the digital display.
6.5.7 Current transmitter
Introduction
In mode 8, switch the pressure transmitter into the constant current operation. You can
connect an external current transmitter in the constant current operation. The current then no
longer corresponds to the process variable. The following output current can be adjusted
irrespective of the input pressure:
3.6 mA
4.0 mA
12.0 mA
20.0 mA
22.8 mA
You can use HART communication to adjust intermediate values.
ITEM 1120, 1340, 1355
Operation
6.5 Local operation
Procedure
To switch on the constant current operation, proceed as follows:
1. Set mode 8.
"Cur" in the digital display stands for current.
3. Select constant current.
Switching off the constant current operation
To switch off the constant current operation, proceed as follows:
Press the [M] button in mode 8.
6.5.8 Output current in case of fault
Introduction
When a fault occurs, the lower fault current is displayed in the basic setting. In mode 9, you
can choose between the output of the upper and lower fault current. The standard values
3.6 mA and 22.8 mA are set.
The standard values of the upper and lower fault current can be changed via HART
communication.
Condition
Procedure
To change the fault current, proceed as follows:
1. Set mode 9.
2. Select the fault current.

Note
If a current saturation interrupt is active, the setting of the output current may deviate from
your setting in the case of a fault.
Resetting fault current
To reset the fault current to the basic setting, proceed as follows:
Press the [] and [] buttons simultaneously.
ITEM 1120, 1340, 1355
Operation
6.5 Local operation
Fault causes
Fault currents may be triggered by:
FW alarm
HW alarm
Diagnostic interrupt
Sensor breakage
Measured value status BAD
Reference
6.5.9 buttons and function lock
Introduction
In mode 10, you can disable the functions that can be executed using buttons. Application
example for a lock is e.g. safeguarding the saved parameters.
Lock options
You have the following lock options on the pressure transmitter:
Table 6-5 Meaning of lock modes
Lock mode Meaning
0 The device can be operated by means of the keys and HART communication.
LA Keys on the transmitter are locked.
Exception:
Releasing key lock
The device can be operated by means of HART communication.
LO Keys on the transmitter are partially locked.
Exception:
Releasing key lock
LS Keys on the transmitter are partially locked.
Exception:
Releasing key lock
ITEM 1120, 1340, 1355
Operation
6.5 Local operation
Lock mode Meaning
L Write protection
Operation via keys and HART communication is blocked.
Exception:
Releasing key lock

Note
If you want to select the LO or LS lock, we recommend you first select the measured value
display of "Current" in "mA" or "%" in mode 13. Otherwise, a change in the output variable
using the [] and [] buttons is not detected.
If the blind cover is provided, the LS lock mode is effective, i.e. only the zero point and the
span can be changed. If you continuously operate the device with the blind cover, ensure
that the LS lock mode is constantly set.

Condition

Note
In the measured value display function, check whether the desired setting is displayed.

Procedure
To disable the buttons, proceed as follows:
1. Set mode 10.
2. Select the desired lock mode.
3. Confirm the lock mode with the [M] button.
6.5.10 Releasing key lock or function lock
Releasing key lock
WARNING
In the case of devices used for safety-relevant applications, only authorized personnel may
release the key lock, e.g. overflow protection.

To release a set key lock (LA, LO, LS) using buttons, proceed as follows:
Press the [M] button for 5 seconds.
ITEM 1120, 1340, 1355
Operation
6.5 Local operation
Releasing the write protection
To release a write protection for HART (L) using buttons, proceed as follows:
Press the [M] button for 5 seconds.
6.5.11 Flow rate measurement (only differential pressure)
Introduction
The characteristic curve representing the relationship between the output current and input
pressure can be adjusted in mode 11. Adjust the root application point in mode 12.
You can select the following characteristic curve types of the output current:
linear "lin": proportional to differential pressure
square root extracting "sroff": proportional to flow rate, deactivated up to the application
point
square root extracting "srlin": proportional to flow rate, linear up to the application point
square root extracting "srli2": proportional to flow rate, two-step linear up to the
application point
Variable application point
The output current for the "srlin" and "sroff" functions can be displayed linearly or set to zero
below the application point of the square root extracting characteristic curve.
Fixed application point
The "srli2" function has a permanently defined application point of 10%. The range up to this
point contains two linear characteristic curve sections. The first section ranges from the zero
point to 0.6% of the output value and 0.6% of the pressure value. The second section has a
higher gradient and it goes up to the root application point at 10% of the output value and 1%
of the pressure value. See the following figure for this purpose.
ITEM 1120, 1340, 1355
Operation
6.5 Local operation
Procedure
Proceed as follows to set or adjust the type of characteristic curve:
1. Set mode 11.
2. Select the type of characteristic curve.
To set the characteristic curve to "linear", press the [] and [] buttons simultaneously.
Proceed as follows to set or adjust the root application point: This procedure is not applicable
for "srli2":
1. Set mode 12.
2. Select an application point between 5 and 15%.
To set the application point to 10%, press the [] and [] buttons simultaneously.

Note
Mode 12 cannot be selected if the "linear" or "srli2" measuring mode has been adjusted in
mode 11.
If the square root extracting characteristic curve has been adjusted in mode 11 and if the
measured value display has been set to "Pressure" in mode 13, the root sign and the
differential pressure corresponding to the flow rate are displayed.

ITEM 1120, 1340, 1355
Operation
6.5 Local operation
100
80
60
40
20
0
0 20 40 60 80 100
square root
extracting
Linear
pressure
Pressure [%]
Output [%]

Characteristic curves and application point of square root
extracting characteristic curves
The dotted rectangle has
been magnified in the form
of the following
characteristic curves in
order to show the behavior
of characteristic curves.
Linear
pressure
20
15
10
5
0
0 1 2 3 4
lin

Characteristic curve "lin":
Adjustment range
for application
point
srlin
square root
extracting
linear
Application
point
20
15
10
5
0
0 1 2 3 4
l

Square root extracting characteristic curve
"srlin"
square root
extracting
Application
point
sroff
20
15
10
5
0
0 1 2 3 4

Characteristic curve "sroff"
square root
extracting
Application
point fixed
linear pressure
srli2
20
15
10
5
0,6
3 4
0,6

Characteristic curve "srli2"
ITEM 1120, 1340, 1355
Operation
6.5 Local operation
6.5.12 Measured value display
Introduction
In mode 13, adjust the following types of measured value display:
mA
%
Display of the selected measuring mode. See the following table.
Table 6-6 Display of measuring mode/device variables
Digital display DV Meaning
P 0 Pressure
t-SE 1 Sensor temperature
t-EL 2 Electronics temperature
P-UNC 3 Pressure (untrimmed)
LEVEL 4 Level
Vol 5 Volume
MASS 6 Mass
V-Flo 7 Volume of flow (not relevant for gauge and absolute pressure)
M-Flo 8 Mass flow rate (not relevant for gauge and absolute pressure)
CUSt 9 Users
Condition
Procedure
To select the display type, proceed as follows:
1. Set mode 13.
2. Select the measured value display.
See also
Measured value display (Page 112)
ITEM 1120, 1340, 1355
Operation
6.5 Local operation
6.5.13 Unit
Introduction
In mode 14, select the physical unit in which the measured value display of the device
should be shown.
Condition
You have already selected the desired measured value display in mode 13.
Procedure
To adjust the physical unit, proceed as follows:
1. Set mode 14.
2. Select a unit.
Press the [] and [] buttons simultaneously to set the unit to the first value in the
following table depending on the measuring mode set.
Instructions for selecting the unit
The unit is selected depending on the measurement type set. For example, only pressure
units are made available in "Pressure" measuring mode and only level unit are made
available in the "Level" measuring mode.
The displayed measured value is always converted into the new unit. When the display
capacity of the digital display is exceeded, "9.9.9.9.9" appears on the display.
The selected unit is visible on the display in the measuring mode only if you have
selected the display of a physical unit in mode 13. If you have not selected mode 13,
"mA" or "%" is displayed.
Units
Table 6-7 Units available for pressure
Pressure units Display
mbar mbar
bar bar
mm water column (20C / 68F) mmH2O
Inch water column (20C / 68F) inHG
Feet water column (20C / 68F) FTH2O
mm mercury column mm_HG
Inch mercury column in_HG
mm water column (4C / 39F) m4H2O
ITEM 1120, 1340, 1355
Operation
6.5 Local operation
Pressure units Display
Inch water column (4C / 39F) i4H2O
Psi PSi
Pa Pa
KPa KPa
MPa MPa
g/cm2 Gcm2
Kg/cm2 KGcm2
Torr TORR
ATM ATM

Table 6-8 Units available for volume
Volume unit Display
m3 m3
Liter L
Hectoliter Hl
US gallon Gal
British gallon in Gal
British barrel bbl
British barrel liquid bblli
Buschels buShl
yard3 Yd3
Feet3 FT3
inch3 in3
Standard l STdl
Standard m3 STdm3
Standard feet3 STFT3

Table 6-9 Units available for mass
Mass unit Display
Gram G
Kilogram KG
Ton T
Short ton STon
Long ton lTon
Pound lb
Ounce OZ

ITEM 1120, 1340, 1355
Operation
6.5 Local operation
Table 6-10 Units available for volume of flow
Unit for volume of flow Display
m3 / second m3/S
m3 / minute m3/M
m3 / hour m3/H
m3 / day m3/D
Liter / second L/S
Liter / minute L/M
Liter / hour L/H
Million liter / day ml/ D
Feet3 / second FT3/S
Feet3 / minute FT3/M
Feet3 / hour FT3/H
Feet3 / day FT3/D
Gallon / second Gal/S
Gallon / minute Gal/M
Gallon / hour Gal/H
Gallon / day Gal/D
Million gallon / day MGl/D
British gallon / second iGL/S
British gallon / minute iGL/M
British gallon / hour iGL/H
British gallon / day iGL/D
Standard m3 / hour Sm3/H
Standard l / hour STI/H
Standard feet3 / minute SFT3M
British barrel liquid / second bbl/S
British barrel liquid / minute bbl/M
British barrel liquid / hour bbl/H
British barrel liquid / day bbl/D

Table 6-11 Units available for mass flow rate
Mass flow rate unit Display
g / s G_S
g / min G_MIN
g / h G_H
Kg / s KG/S
Kg / min KG/M
Kg / h KG/H
Kg / d KG/D
T / min T/M
ITEM 1120, 1340, 1355
Operation
6.5 Local operation
Mass flow rate unit Display
T / h T/H
T / d T/D
Pound / s P/S
Pound / min lb/M
Pound / h lb/H
Pound / d lb/D
Short ton / min ShT/M
Short ton / h ShT/H
Short ton / d ShT/D
Long ton / h lT/H
Long ton / d lT/D

Table 6-12 Units available for level
Level unit Display
Feet FT
Inch inch
m m
cm cm
mm mm

Table 6-13 Units available for temperature
Temperature unit Display
Celsius / C
Fahrenheit / F
Kelvin K
Rankine R
See also
Selection of the physical unit (Page 113)
ITEM 1120, 1340, 1355
Operation
6.5 Local operation
ITEM 1120, 1340, 1355

Operating functions through HART
7
7.1 Operating functions through HART communication
Condition
You can operate the transmitter through HART communication. The following is required for
this purpose:
A HART communicator or PC software such as SIMATIC PDM.
A HART modem to connect a PC with the transmitter or a lead to connect a HART
communicator with the transmitter.
Introduction
The full functionality of the transmitter is available via HART communication. The HART
communicator and PC software are not supplied with the transmitter. How to connect and
operate a HART communicator or the PC software is described in separate operating
instructions or in the online help for both these tools.
Fundamental description
The input signal is provided in the form of digital information in the following variables
through HART communication:
Pressure
Level
Volume
Mass
Volume of flow
Mass flow rate
User programmable "characteristic curve"
As soon as you have set up the HART communication and the transmitter, you can adapt the
transmitter to your relevant measuring task. When doing so you are assisted by the
selectable measuring modes "Pressure", "Level", "Flow rate" and a user programmable
"Characteristic curve". One or more device variables are permanently allocated to each
measuring mode in order to execute corresponding measuring tasks.
ITEM 1120, 1340, 1355
7.2 Process tag data
See also
Overview of operation (Page 55)
7.2 Process tag data
You can store your process tag data in user definable fields. The following table contains
information about the structure of these fields and the format in which you can enter
information in these fields:
Table 7-1 Process tag data
Field Explanations
Tag designation Eight characters
Date Day:Month:Year
Description 16 characters
Message 32 characters
Works number Integer number
Tag designation long 32 characters
Freely definable material parameter 21 x 16 characters

7.3 Selecting the measuring modes
7.3.1 Overview of measuring modes
Overview
The transmitter can be set for the corresponding measuring task using a few parameters.
You can select the following measuring modes:
Pressure
Level
Flow rate
Users: user programmable characteristic curve
You can use the measuring mode selector to activate measuring modes "Level", "Flow rate"
and "User".
Selecting the device variables
One or more device variables are permanently allocated to each measuring mode. The
following device variables are always active and are therefore always displayed:
ITEM 1120, 1340, 1355
Pressure
Sensor temperature
Electronics temperature
Pressure (untrimmed)
The following device variables are activated only when the allocated measuring mode is
activated and parameterized simultaneously:
"Level", "Volume" and "Mass" are allocated to the "Level" measuring mode.
"Volume of flow" and "Mass flow rate" are allocated to the "Flow rate" measuring mode.
"User" is allocated to the "User" measuring mode.
The inactive device variables have the CONSTANT status.
7.3.2 Measuring mode selector
You can use this switch to toggle between measuring modes "Pressure", "Level", "Flow rate"
and a characteristic curve programmable by a "User".
If a measuring mode has been selected using the measuring mode selector, it has to be
configured. This does not mean that this block has an automatic effect on the current output
(4 to 20 mA). For that, you need to switch the corresponding device variable to the primary
variable (PV) using a so-called variable mapper.
7.3.3 Variable mapper
Introduction
In this transmitter, the dynamic variable that determines the behavior of current output is
always called the primary variable (PV). You need to use the variable mapper for a number
of purposes, including selecting which device variable is to be switched to PV. The variable
selected as PV using a PC program such as SIMATIC PDM or using the HART
Communicator is scaled once again in the analog output stage to a zero value and a limit
value. These two values then correspond to the current values 4 and 20 mA.
As soon as the PV is switched over using the variable mapper, the start of scale value and
full scale value in the analog output stage are preset to the limit values of the new device
variables. You can define these limit values within the individual block functions.
The dynamic variables "Primary", "Secondary", "Tertiary" and "Quarternary" (PV, SV, TV,
QV) can be interconnected with any active device variables. Various different measuring
mode examples are conceivable with a 4 bar pressure transmitter.
See also
ITEM 1120, 1340, 1355
7.3.4 Measuring mode "Pressure"
The "Pressure" measuring mode contains the "Sensor trim" function, and is always active
since it is the standard measuring mode. When the measuring mode selector is set to "Off",
further measuring variables are not derived from the "Pressure" measuring variable. Except
the first four variables, all other device variables are marked as inactive and have the
CONSTANT status. These four variables are mapped with dynamic variables PV, SV, TV
and QV by default.
Switching an inactive device variable to the primary variable (PV) generates an error
message since the variable currently does not have a valid measured value. This message
is displayed in SIMATIC PDM or the HART communicator.
QV
TV
SV
PV
(DV 0 . . . 9)
Sensor
Pressure
Sensor
temperature
Electronics
temperature
Lineari-
zation
Off
Measuring
mode
switch
Measuring modes
Pressure
Sensor trim
Level
Characteristic
curve
Users
Characteristic
curve
Flow rate
Characteristic
curve
Device
variables
Pressure
Sensor
temperature
Electronics
temperature
Pressure
(untrimmed)
Level
Volume
Volume of flow
Mass
Mass flow rate
Users
Variable
mapper
Dynamic variables
(DV standard setting)
Analog
output
LCD scale
MA, ME, unit
0
1
2
3
4
5
6
7
8
9
3, 2, 1, 0

Figure 7-1 Measuring mode "Pressure"

DV Device variable
MA Start of scale value
ME Full scale value
PV Primary variable
QV Quarternary variable
SV Secondary variable
TV Tertiary variable

ITEM 1120, 1340, 1355
7.3.5 Customized characteristic curve
Introduction
The customized "characteristic curve" is continuously active as an identical function in the
three following measuring modes "Level", "Flow rate" and "User". This means that the
customized "characteristic curve" always provides a result for the following function, thus
also influencing the measured value status of the affected device variables.
In the device, the characteristic curve vertices are only provided once in the EEPROM.
Therefore, if the measuring mode is changed, you will usually need to adjust the
characteristic curve accordingly.
The characteristic curve function expects at least two and at the most 30 characteristic curve
vertices as input parameters. Characteristic curve vertices are entered in pairs of values
x %;y %. The values for the x-coordinate are only accepted by the device when they run
monotonically. The y-coordinates, on the other hand, may also be non-monotonic. A warning
will however be issued by the configuring device, which you as the user have to recognize
and acknowledge. The output of the characteristic curve is not explicitly stored in a device
variable, but rather is directly interconnected with the input of the next function block in each
case. The pairs of values 0%;0% and 100%;100% are set as default values. In principle,
rising and falling characteristic curves can be configured. With regard to the device variable
status, rising characteristic curves are however preferred. Otherwise the meanings of HIGH
LIMIT and LOW LIMIT are swapped.
See also
7.3.6 Measuring mode "Level"
Description
Once you have configured the measuring mode "Level", the device variables "Level",
"Volume" and "Mass" are activated. They are all inferred from the measured pressure. The
"Level" block here represents a series of permanently interconnected functions which you
need to configure with appropriate parameters. Only then will you be given a meaningful
measured value for the three device variables.
ITEM 1120, 1340, 1355
QV
TV
SV
PV
Sensor
Pressure
Sensor
temperature
Electronic
temperature
Lineari-
zation
Off
Measuring
mode
switch
Measuring methods
Pressure
Sensor trim
Level
Characteristic
curve
User
Characteristic
curve
User
Characteristic
curve
Device
variables
Pressure
Sensor
temperature
Electronic
temperature
Pressure
(untrimmed)
Level
Volume
Volume of flow
Mass flow rate
Mass
User
Variable
mapper
Dynamic variables
(Selection)
Analog
output
LCD Scaling
MA, ME, unit
(DV 0 . . . 9)
0, 6, 5, 4
0
1
2
3
4
5
6
8
7
9

Figure 7-2 Measuring mode "Level"

DV Device variable
ME Full scale value
Functions of the "Level" block
The first function, "Input scaling, pressure", sets the pressure range used by the following
functions in all three blocks in the same way. Ideally, this range corresponds to the sensor
limits of the transmitter. In the following calculation examples, 0 and 4 bar are assumed for
these sensor limits for all blocks. You can however also set a downscaling, e.g. 1:2. The
downscaling of 1:2 means that 50% of the rated measuring range, here 2 bar, can control
the following characteristic curve 100%.
Use the "Output scaling, level" to set the measuring limits for the measuring mode "Level"
with a unit from the level range. Parameter settings in this example are 10 and 20 m. At
0 bar process pressure, 10 m is displayed in DV4 and 20 m is displayed at 2 bar. The values
for the start of scale value and the full scale value, which are effective for the analog output,
are configured in the "analog output" block.
In the calculation example, the two pairs of values 0%;0% and 100%;100% are configured
for the customized "characteristic curve". This is the default setting. The measured value
from the pressure scaling is transferred 1:1 in this example.

ITEM 1120, 1340, 1355
DV[0] (bar)
%
%
lnput scaling
Pressure
Calculation example:
MA = 0 bar, ME = 2 bar
p = 1 bar
MA = 0%;0%
ME = 100%;100%
Output = 50%
Characteristic
curve
Output scaling
Level (MA, ME)
MA = 10 m, ME = 20 m
L = 15 m
DV[4] level (m)
MA = 0 l, ME = 100 l
V = 50 l
Output scaling
Volume
DV[5] volume (l)
Output scaling
Mass
Density = 5 kg/l
m = 250 kg
DV[6] mass (kg)

Figure 7-3 Functions of the "Level" block

DV [x] Device variable x
L Level
m Mass
ME Full scale value
P Pressure
V Volume
Configure the "Output scaling, volume" with a unit from the volume range and the measuring
limits for the device variable "Volume". The characteristic curve output directly affects the
volume scaling input.
In the calculation example, for the measuring limits from 0 and 100 l, a volume of 50 l is
yielded for process pressure of 1 bar.
The "Level" parameter setting also still automatically activates the device variable for the
mass. If you have not yet configured a value for the density, the initial value of 1 kg/l is
preset. In the calculation example for the "Mass" device variable, a mass of 250 kg is derived
at a density of 5 kg/l.

Note
When the density changes, the measuring range limits have to be adjusted accordingly.

You can configure all parameter settings for the "Level" block in SIMATIC PDM or the HART
communicator. Activate the "Level" measuring mode for this purpose. For all settings, the
measuring limits may be exceeded by +/-20%. Values which lie above or below that will be
rejected by the device.
ITEM 1120, 1340, 1355
7.3.7 Measuring mode "Flow rate"
Description
When you activate the "Flow rate" measuring mode, only two other device variables are
active: Volume of flow and Mass flow rate. If another block was active earlier, the
corresponding device variables remain inactive and have the "CONSTANT" status. The
"Flow rate" block here represents a series of permanently interconnected functions which
you need to configure with appropriate parameters.
QV
TV
SV
PV
(DV 0 . . . 9)
Sensor
Pressure
Sensor
temperature
Electronics
temperature
Lineari-
zation
Off
Measuring
mode
switch
Measuring modes
Pressure
Sensor trim
Level
Characteristic
curve
Users
Characteristic
curve
Flow rate
Characteristic
curve
Device
variables
Pressure
Sensor
temperature
Electronics
temperature
Pressure
(untrimmed)
Level
Volume
Volume of flow
Mass
Mass flow rate
Users
Variable
mapper
Dynamic variables
(DV standard setting)
Analog
output
LCD scale
MA, ME, unit
0
1
2
3
4
5
6
7
8
9
3, 2, 1, 0

Figure 7-4 Measuring mode "Flow rate"

DV Device variable
ME Full scale value
Functions of the "Flow rate" block
The "Input scaling, pressure" function defines the pressure range of 0 to 2 bar that is
interpreted as 0 and 100% by the following square root extracting function. A process
pressure of 0.5 bar has been assumed in the following figure.
In the "Flow rate" measuring mode, a square root extracting characteristic curve "srlin2" is
plotted with a fixed root application point of 10%.
In the calculation example, the input value for the "square root extracting function" is
approximately 25% at a process pressure of 0.5 bar. The output value is approximately 50%.

ITEM 1120, 1340, 1355

Note
When using the "Flow rate" block, other square root extracting characteristic curves must be
deactivated if required.

DV[0] (bar)
lnput scaling
Pressure
Square root
extracting function
srlin2
MA = 0 bar, ME = 2 bar
p = 0.5 bar
MA = 0 l/s, ME = 1000 l/s
VF = 250 l/s
Root application point = 10%
input = 25%
output = 50%
MA = 0%; 0%
ME = 100%;50%
Output = 25%
Characteristic curve
Output scaling
Volume
DV[7] Volume of
flow(l/s)
Output scaling
Mass flow rate
Density = 4 kg/l
MF = 1000 kg/s
DV[8] Mass
flow rate (kg/s)
% %

Figure 7-5 Functions of the "Flow rate" block

DV [x] Device variable x MF Mass flow rate
MA Start of scale value p Pressure
ME Full scale value VF Volume of flow

In the calculation example, the two pairs of values 0%;0% and 100%;50 % are configured for
the customized "characteristic curve". This setting corresponds to a bisection of the input
value for all output values.
Configure the "Output scaling, volume of flow" with a unit from the volume of flow range and
the measuring limits for the device variable "Volume of flow". In the calculation example, 0 l/s
and 1000 l/s are defined as lower and upper measuring limits. The volume of flow is thus
250 l/s at a process pressure of 0.5 bar.
The "Mass flow rate" device variable is automatically activated when the "Flow rate" block is
configured. If you have not yet configured a value for the density, the initial value of 1 kg/l is
preset.
In the calculation example, a mass of 1000 kg/s is derived for the "Mass flow rate" device
variable at a value of 4 kg/l. The value of density entered is used only to calculate the mass
flow rate. The entered value of density has no effect on the diaphragm calculation that is to
be carried out by the user.
In SIMATIC PDM or the HART communicator, the "Flow rate" block is configured in an online
dialog box in an extremely compact manner. In this online dialog box, you can compile all
values in a menu and transfer them to the device collectively.
7.3.8 Measuring mode "User"
Description
The "User" measuring mode is the simplest of the measuring modes that you can select with
the measuring mode selector. Only one further device variable, "User", is activated in this
measuring mode in addition to the four standard device variables. The variables "Level",
ITEM 1120, 1340, 1355
"Volume", "Mass", "Volume of flow" and "Mass flow rate" are marked as inactive and are
given the status CONSTANT.
In the "User" measuring mode, you have an option to define a customized unit for output
scaling. This customized unit is, e.g. a specific quantity of liquid. This quantity of liquid
depends on the input process pressure.
Example: Fill the beverages in cans having a capacity of 0.33 l. You can now define a
customized unit "Can" that is exactly equal to 0.33 l. The quantity of "cans" depends on the
input process pressure.

Note
Permissible input values
All alphabetic a...z, A...Z and numeric 0...9 inputs are allowed for the customized unit. The
following characters are also allowed:
" $ / < > * , _ + - = @

QV
TV
SV
PV
(DV 0 . . . 9)
Sensor
Pressure
Sensor
temperature
Electronics
temperature
Lineari-
zation
Off
Measuring
mode
switch
Measuring modes
Pressure
Sensor trim
Level
Characteristic
curve
Level
Characteristic
curve
Users
Characteristic
curve
Device
variables
Pressure
Sensor
temperature
Electronics
temperature
Pressure
(untrimmed)
Level
Volume
Mass
Mass flow rate
Volume of flow
Users
Variable
mapper
Dynamic variables
(Selection)
Analog
output
LCD scale
MA, ME, unit
0
1
2
3
4
5
6
7
8
9
2, 1, 0, 9

Figure 7-6 Measuring mode "User"

DV Device variable MA Start of scale value
PV Primary variable ME Full scale value
Functions of the "User" block
The first function, "Input scaling, pressure", defines the pressure range which is used by the
customized characteristic curve. Ideally, this range corresponds to the sensor limits.
ITEM 1120, 1340, 1355
In the calculation example, 0 and 2 bar are assumed. This means that with process pressure
of 0.5 bar, there is a value of 25% on the characteristic curve.
DV[0] (bar)
DV[9]
%
%
p = bar
= 0 bar
lnput scaling
Pressure
0.5
MA = ME = 2 bar
MA = 0%;0%
ME = 100%;100%
Output = 25%
Characteristic Output scaling
User
MA = 0 vessels, ME = 1000 vessels
Output = 250 vessels
User
(vessels)

Figure 7-7 Functions of the "User" block

DV [x] Device variable x MA Start of scale value
p Pressure ME Full scale value
In the calculation example, the two pairs of values 0%;0% and 100%;100% are configured
for the customized "characteristic curve". Any curve shapes can be calculated with the help
of 30 characteristic curve vertices. These curve shapes can be stored in the device using
SIMATIC PDM or the HART communicator.
In the calculation example, the value at the input of the characteristic curve is transferred 1:1
to the output.
In the calculation example, a number of filled cans is set for the output scaling. You can
enter up to five characters for any given unit. Do not confuse this with the user-
programmable display unit of the "Analog output" block.
In the calculation example, you have a start of scale value of 0 cans and a full scale value of
1000 cans. At a process pressure of 0.5 bar, you get a value of 250 cans for the "User"
device variable.
See also
Analog output (Page 105)
7.3.9 Measured value status
Introduction
Every device variable is assigned a status byte to indicate the quality of the measured
values. This status byte can have the following values:
BAD
GOOD
MANUAL
UNCERTAIN
ITEM 1120, 1340, 1355
The following values are also possible:
CONSTANT
HIGH LIMIT
LOW LIMIT
A higher-level diagnosis program can display and analyze these states.
GOOD status
During smooth, uninterrupted operation, the measured value status of all active device
variables is GOOD.
BAD/CONSTANT status
All inactive device variables have CONSTANT/BAD status.
If a variable having the BAD status is an output value for calculation, the measured value is
BAD.
The basic measured values, namely pressure and temperatures, have the BAD status in the
following cases:
The analog-to-digital converter does not function.
Linearization values in the EEPROM are defective.
If the two end points of the customized characteristic curve are exceeded for the status of
the device variables of the following function.
UNCERTAIN status
If a pressure value exceeds or falls below the sensor limits of the device by more than 20%,
the corresponding measured value and the variables inferred from it are UNCERTAIN.
If the analog-to-digital converter for pressure control is over/underrange, the status is
UNCERTAIN.
HIGH LIMIT and LOW LIMIT
If the analog-to-digital converter is overrange, the HIGH LIMIT label is allocated. If the
analog-to-digital converter is underrange, the LOW LIMIT label is allocated.
Change in status
If the status of a device variable changes and it was right at the front of the sequence of
operations for a block, e.g. pressure, then all variables that are derived from it will take on
the same status. In the following example, the device variable "Pressure" has the BAD
status. Since the measuring mode selector is set to "USER", the device variable "User" is
also given the BAD status.
The reasons for changes in the status of a device variable are summarized in the table. If
there were several reasons for a change in status, MANUAL always has the highest priority.
BAD has the second highest and UNCERTAIN the third highest priority.
ITEM 1120, 1340, 1355
B
G
M
U
L
H
C
B
G
M
U
L
H
C
B
G
M
U
L
H
C
B
G
M
U
L
H
C
B
G
M
U
L
H
C
B
G
M
U
L
H
C
B
G
M
U
L
H
C
B
G
M
U
L
H
C
B
G
M
U
L
H
C
B
G
M
U
L
H
C
B
G
M
U
L
H
C
0
1
2
3
4
5
6
9
8
7
9 0, 1, 2,
Flow rate
Characteristic
curve
QV
TV
SV
PV
Status marking
= BAD
= GOOD
= MANUAL
= UNCERTAlN
= LOW LlMlTED
= HlGH LlMlTED
= CONSTANT
(DV 0 . . . 9)
Sensor
Pressure
Sensor
temperature
Electronics
temperature
Lineari-
zation
Off
Measuring
mode
switch
Measuring modes
Pressure
Sensor trim
Level
Characteristic
curve
Users
Characteristic
curve
Device
variables
Pressure
Sensor
temperature
Electronics
temperature
Pressure
(untrimmed)
Level
Volume
Mass
Users
Variable
mapper
Dynamic variables
(Selection)
Analog
output
LCD scale
MA, ME, unit
Volume of flow
Mass flow rate

Figure 7-8 Device status dependency


Table 7-2 Events which result in a change of status
DV Measuring
mode
BAD MANUAL UNCERTAIN CONSTANT HIGH LIMIT LOW LIMIT
0 Pressure DV3 = BAD,
fault in
linearization
When
DV0 is
simulated
DV3 = UNCERTAIN - DV3 =
HIGH LIMIT
DV3 =
LOW LIMIT
1 Sensor
temperature
DV2 = BAD,
analog-to-
digital converter
in
over/underrang
e, fault in
linearization
When
DV1 is
simulated
DV1 more than 20%
outside the sensor
limits
DV2 = UNCERTAIN
DV2 = MANUAL
- Analog-to-
digital
converter in
overrange
Analog-to-
digital
converter in
underrange
2 Electronics
temperature
Analog-to-
digital converter
in
over/underrang
e, fault in
linearization
When
DV2 is
simulated
DV2 more than 20%
outside the sensor
limits
- Analog-to-
digital
converter in
overrange
Analog-to-
digital
converter in
underrange
ITEM 1120, 1340, 1355
DV Measuring
mode
BAD MANUAL UNCERTAIN CONSTANT HIGH LIMIT LOW LIMIT
3 Pressure
(untrimmed)
Analog-to-
digital converter
in
over/underrang
e, DV1 sensor
breakage,
DV2 = BAD,
fault in
linearization
- Analog-to-digital
converter in
overrange/underran
ge, DV3 more than
20% outside the
sensor limits
DV2 = MANUAL
- Analog-to-
digital
converter in
overrange
Analog-to-
digital
converter in
underrange
4 Level If DV0 = BAD When
DV0 is
simulated
DV0= UNCERTAIN DV not
active
DV0 =
HIGH LIMIT
DV0 =
LOW LIMIT
5 Volume DV0 = BAD,
Characteristic
curve is faulty
When
DV0 is
simulated
DV0 = UNCERTAIN,
input value is
outside the specified
range
Characteristi
c curve is
faulty
DV not
active
DV4 =
HIGH LIMIT,
Characteristic
curve for
maximum
value with
gradient 0
DV4 =
LOW LIMIT,
Characteristic
curve for
minimum value
with gradient 0
6 Mass DV5 = BAD When
DV0 is
simulated
active,
DV5 =
CONSTANT
DV5 =
HIGH LIMIT
DV5 =
LOW LIMIT
7 Volume of flow
(not absolute
and gauge
pressure)
DV0 = BAD,
characteristic
curve is faulty
When
DV0 is
simulated
DV0 = UNCERTAIN,
input value is
range
Characteristi
c curve is
faulty,
DV not
active
DV4 =
HIGH LIMIT,
Characteristic
curve for
maximum
value with
gradient 0
DV4 =
LOW LIMIT,
Characteristic
curve for
minimum value
with gradient 0
8 Mass flow rate
(not absolute
and gauge
pressure)
DV5 = BAD When
DV0 is
simulated
active
DV5 =
CONSTANT
DV5 =
#HIGH LIMIT
DV5 =
LOW LIMIT
9 Users DV0 = BAD,
Characteristic
curve is faulty
When
DV0 is
simulated
DV0 = UNCERTAIN,
input value is
range
Characteristi
c curve is
faulty
DV not
active
DV0 =
HIGH LIMIT,
Characteristic
curve for
maximum
value with
gradient 0
DV0 =
LOW LIMIT,
Characteristic
curve for
minimum value
with gradient 0
If you use falling characteristic curves in the blocks, the meanings of HIGH LIMIT and LOW
LIMIT are swapped around.
If you mix falling and rising characteristic curves, the meanings will be swapped each time a
falling characteristic curve is run.
ITEM 1120, 1340, 1355
7.3.10 Analog output
Introduction
The "Analog output" block converts the value provided by the dynamic primary variable (PV)
into a current value of 4 to 20 mA. When you actuate the measuring mode selector, you
automatically define the start of scale value and the full scale value to the current values 4
and 20 mA, respectively. Limit values of corresponding device variables are used for scaling
the analog output by default. You have entered these limits when setting the parameters of
your measuring mode.
Example for measuring mode "Level"
This means that for a "Level" device variable as PV, 10 m corresponds to the value for 4 mA
and 20 m corresponds to the value for 20 mA. You can change this presetting again in the
"Analog output" block. This is done by restricting the range of the "Level" device variable for
scaling the output current to e.g. 12 to 18 m. This downscaling has no effect on the previous
block scaling. In this case, a current of 4 mA is output for a measured height of 12 m, and a
current of 20 mA for 18 m.
0
1
2
3
4
5
6
9
8
7
9 0, 1, 2,
Flow rate
Characteristic
curve
QV
TV
SV
PV
(DV 0 . . . 9)
Sensor
Pressure
Sensor
temperature
Electronics
temperature
Lineari-
zation
Off
Measuring
mode
switch
Measuring modes
Pressure
Sensor trim
Level
Characteristic
curve
Users
Characteristic
curve
Device
variables
Pressure
Sensor
temperature
Electronics
temperature
Pressure
(untrimmed)
MA=10 m,
ME=20 m Level
Volume
Mass
Users
Variable
mapper
Dynamic variables
(Selection)
Analog
output
LCD scale
MA, ME, unit
Volume of flow
Mass flow rate

Figure 7-9 "Analog output" scaling

ITEM 1120, 1340, 1355
Description of measuring mode "Level"
Primary Variable
%
p = 1 bar
sroff
srli
srli2
%
linear
PV level (m)
lnput scaling
(MA, ME)
MA = 12 m, ME = 18 m
Square root
extracting function
Square root
extracting function
Square root
extracting function
Output scaling
Current (4 to 20 mA)
Constant current

Figure 7-10 "Analog output" block

MA Start of scale value p Pressure
ME Full scale value PV Primary variable

Note
If, when setting the analog output, the values for the start of scale value zero and the full
scale value are more than 20% below or above the limit values of the set PV (set using the
variable mapper), the values will be rejected by the device. The values configured previously
are retained. Similarly, the span must not fall below the minimum.
Minimum span = ME - MA
The square root extracting function can only be selected in the "Pressure" measuring mode.
The "srlin2" square root extracting function is set as default in the "Flow rate" measuring
mode.

7.3.11 Scaling the digital display value
Introduction
You can freely scale the value shown in the digital display and allocate any unit of 5
characters to it. The scaling of the value is independent of the selection of the measuring
mode selector, the primary variable (PV) and the display unit defined. Use the "Digital
display settings" item in SIMATIC PDM or the HART communicator for this purpose.
The percent value of the PV is the basis for this scaling. This percent value is also used to
scale the current output. In SIMATIC PDM, this item is referred to as "Setting the PV output
scaling". After selecting the "Digital display settings" menu command, you must enter a start-
of-scale value, full scale value and a unit string.
This display option has the highest priority amongst all options. A switch over to %, mA or
any other unit is not possible in this status. You need to deactivate the LCD scaling again for
this purpose.
ITEM 1120, 1340, 1355
7.4 Setting zero point and limit point
Example
In the Level measuring mode, the start of scale value is assumed as 0 m and the full scale
value as 10 m in the example illustrated in the following picture. The value of 2 m is
displayed at a process pressure of 0.4 bar.
0
1
2
3
4
5
6
9
8
7
9 0, 1, 2,
Flow rate
Characteristic
curve
QV
TV
SV
PV
(DV 0 . . . 9)
Sensor
Pressure
Sensor
temperature
Electronics
temperature
Lineari-
zation
Off
Measuring
mode
switch
Measuring modes
Pressure
Sensor trim
Level
Characteristic
curve
Users
Characteristic
curve
Device
variables
Pressure
Sensor
temperature
Electronics
temperature
Pressure
(untrimmed)
Level
Volume
Mass
Users
Variable
mapper
Dynamic variables
(Selection)
Analog
output
LCD
scale
MA = 0 m
ME = 10 m
Volume of flow
Mass flow rate

Figure 7-11 Free LCD scaling


7.4 Setting zero point and limit point
You can set the zero point and the limit point using the SIMATIC PDM or HART
Communicator. You can use this function to realize rising or falling characteristic curves.
The pressure unit can be set separately for the display and for HART communication.
See also
Difference between setting and adjusting (Page 66)
ITEM 1120, 1340, 1355
7.5 Blind setting of zero point and limit point
7.5 Blind setting of zero point and limit point
The start of scale value and the full scale value can be set without creating a reference
pressure.
Both values can be selected as any point within the sensor limits.
The maximum downscaling is 1:100, depending on the series and the measuring range.
7.6 Zero point calibration (position correction)
Description
A zero point calibration is used to correct a zero point error resulting from the installation
position.
Procedure
Pressurize the device or evacuate it (at absolute pressure, < 0.1 of the measuring
span).
Perform the zero point calibration using SIMATIC PDM or the HART Communicator.
If you do not have a vacuum, perform a trimming of the lower sensor calibration point at a
known reference pressure.

CAUTION

For absolute pressure transmitters, the zero point is at vacuum. A zero point calibration
with a pressurized transmitter will lead to faulty settings!

Note
The effective measuring range is reduced by the amount of the upstream pressure.
Example:
With an upstream pressure of 100 mbar, the effective measuring range of a 1-bar
transmitter is reduced to a point between 0 and 0.9 bar.
See also
Trimming of the sensor trim point (Page 114)
ITEM 1120, 1340, 1355
7.7 Electrical damping
7.7 Electrical damping
Description
You can set the time constant of electrical damping to a point within a range from 0 to 100 s.
It always applies to the "Pressure" device variable (DV0) and thus to the measured values
derived from it.
7.8 Fast response mode
Description
This mode is only intended for special applications such as fast recognition of jumps in
pressure, e.g. pressure drop in the event of pipe breakage. The internal recording of
measured values is sped up at the cost of accuracy. From your point of view, an increased
low-frequency noise is caused for the measured value. For this reason, good accuracy can
only be achieved by setting the measuring span to the maximum.
7.9 Current sensor
Description
The transmitter can be switched to constant current operation for test purposes. In that case,
the current no longer corresponds to the process variable. A "C" appears in the mode display
of the digital display.
7.10 Fault current
Description
You can use this function to set the size of the lower (< 4 mA) and upper (> 20 mA) fault
current. Both signal a hardware/firmware fault, sensor breakage, or that the alarm limit has
been reached (diagnostic interrupt). In that case, ERROR appears in the digital display. You
can obtain a detailed guide to the display using SIMATIC PDM or the HART Communicator.
Reference
ITEM 1120, 1340, 1355
7.11 Setting the current limits
See also
Error display (Page 59)
Limit modules (Page 121)
7.11 Setting the current limits
Description
The level of the upper and lower fault current and the upper and lower saturation limits can
be freely selected within the preset limits of the current output signal.
The specified accuracy of the current output signal is only valid within the current limits 4 to
20 mA.
Measuring range
23
22,8
20,5
20
4,0
3,84
3,6
3,55
0 % 100 % p [%]
l
A
[mA]
1
4
5
3 7
6 2

Figure 7-12 Current limits

Linear control range
Lower saturation limit (default value)
Upper saturation limit (default value)
Lower fault current value (default value)
Upper fault current value (default value)
Recommended setting range for lower fault current range and lower control range limit
Recommended setting range for upper fault current range and upper control range limit

ITEM 1120, 1340, 1355
7.12 Key lock and write protection
7.12 Key lock and write protection
Introduction
You can use this function to lock the keys or activate write protection to safeguard the saved
parameters.
Lock options
You have the following lock options:
Table 7-3 Meaning of the HART lock modes
Lock mode Meaning
0 The device can be operated by means of the keys and HART communication.
LA Keys on the transmitter are locked.
Exception:
Releasing key lock
LO Keys on the transmitter are partially locked.
Exception:
Releasing key lock
LS Keys on the transmitter are partially locked.
Exception:
Releasing key lock
LL Write protection
You can now only release the lock using HART communication.
See also
buttons and function lock (Page 80)
Releasing key lock or function lock (Page 81)
ITEM 1120, 1340, 1355
7.13 Measured value display
7.13 Measured value display
Introduction
You can use this function to set one of three options for the device display:
Display in mA
Display in % (of the set measuring range)
Display in terms of a physical unit, e.g. bar, l, m3/ h etc.
Description
If the Primary Variable is mapped to the "Pressure" device variable, you can configure the
displayed pressure unit with an add-on, GAUGE (G) or ABS (A). The add-on has no effect
on the real measured value.
To do so, select the option Gauge or Absolute under the "Pressure display type" menu
command.
There are two options for the display:
If the pressure unit is < 5 characters, an A or a G is added at the end, respectively.
If the pressure unit is 5 characters, the letters GAUGE or ABS flash alternately with the
pressure unit.

Figure 7-13 Add-on with example GAUGE

Note
The change of the display with GAUGE or ABS does not change the physical pressure
used by the transmitter, rather only the nature of the display.
See also
Measured value display (Page 85)
ITEM 1120, 1340, 1355
7.14 Selection of the physical unit
7.14 Selection of the physical unit
Introduction
You can use this function to select a unit from a table with predefined units.
Description
The only units available will be those of the device variable that was mapped as the Primary
Variable (PV).
The unit can be set separately for the display and for HART communication. You can also
choose to link the setting of the two units.
See also
Unit (Page 86)
7.15 Bar graph
Description
You can use this to switch on the "Bar graph" function in the device display as an alternative
to the unit display. The "Bar graph" function is disabled in the factory state.
See also
Elements of the digital display (Page 57)
7.16 Sensor calibration
7.16.1 Sensor trim
Description
The sensor trim can be used to set the characteristic curve of the transmitter at two sensor
trim points. The results are then correct measured values at the sensor trim points. The
sensor trim points can be selected as any points within the nominal range.
Devices that are not turned down prior to delivery are trimmed at 0 bar and the upper limit of
the nominal range; devices that are turned down prior to delivery are trimmed at the lower
and upper limits of the set pressure measuring range.
ITEM 1120, 1340, 1355
7.16 Sensor calibration
Application examples
For a particular device that is not turned down (e.g. 63 bar), the typical measured value is
50 bar. To attain the highest possible accuracy for this value, set the upper sensor
calibration at 50 bar.
A 63-bar transmitter is turned down to 4 to 7 bar. You can attain the highest possible
accuracy by selecting 4 bar for the lower sensor calibration point and 7 bar for the upper.
A 250-mbar absolute pressure transmitter shows 25 mbar at 20 mbar (abs). A reference
pressure of 100 mbar is available. You can carry out zero point correction by performing
a lower sensor trim at 100 mbar.

Note
The accuracy of the test device should be at least three times as high as that of the
transmitter.
7.16.2 Trimming of the sensor trim point
Trimming the lower sensor trim point
The pressure at which the lower sensor trim is to be performed is applied at the transmitter.
Via SIMATIC PDM or the HART Communicator, you instruct the transmitter to accept this
pressure.
This represents an offset shift of the characteristic curve.
Trimming the upper sensor trim point
The pressure at which the upper sensor trim is to be performed is applied at the transmitter.
Via SIMATIC PDM or the HART Communicator, you instruct the transmitter to accept this
pressure.
A gradient correction is thereby applied to the characteristic curve. The lower sensor trim
point is not affected by this. The upper trim point needs to be greater than the lower trim
point.
ITEM 1120, 1340, 1355
7.17 Current sensor trim
Parallel displacement
Change of slope
Measured
pressure p
lower
balance point
upper
balance point
Set point pressure
1
2
1
2
A
B
C
A B:
B C:

Figure 7-14 Sensor calibration

A Output characteristic curve
B Characteristic curve after lower sensor trim
C Characteristic curve after upper sensor trim
7.17 Current sensor trim
Description
The current that is output by the transmitter can be trimmed independently of the pressure
measuring circuit. This function is designed for compensating inaccuracies in the processing
chain following the transmitter.
Example of an application
The current is to be measured as a voltage drop from 1 to 5 V at a resistance of 250 Ohm +/-
5%. To trim the tolerance of the resistance, set the current transmitter so that the voltage
drop at 4 mA is exactly 1 V and at 20 mA is exactly 5 V.
Trim at 4 mA:
Use the current transmitter trim menu option to instruct the transmitter to output 4 mA.
Read the measured value from the ammeter and enter it, via SIMATIC PDM for example.
The transmitter uses this value for offset correction of the current.
Trim at 20 mA:
Use the current transmitter trim menu option to instruct the transmitter to output 20 mA.
Read the measured value from the ammeter and enter it, via SIMATIC PDM for example.
ITEM 1120, 1340, 1355
7.18 Factory calibration
The transmitter uses this value for gradient correction of the current. The value for 4 mA
is not affected by this.

Note
If a multimeter is used, it must always be sufficiently accurate.
Parallelverschiebung
Measured
Current l
Nominal current l
Change of slope
1
2
1
2
A B:
l
2
l
1
4 mA 20 mA
B
C
B C:

Figure 7-15 Current transmitter trim

A Output characteristic curve
B Characteristic curve after current transmitter trim 4 mA
C Characteristic curve after current transmitter trim 20 mA
7.18 Factory calibration
Introduction
You can use factory calibration to reset the transmitter to the factory state.
Description
You can use the menu-guided interface of SIMATIC PDM or HART Communicator to select
the range of parameters to be reset:
1. Current trim
2. Sensor zero point calibration (position correction)
3. Pressure corrections (zero point calibration and sensor trim)
ITEM 1120, 1340, 1355
7.19 Static configuration data
4. All parameters relevant for the processing of measured values, such as zero point, limit
point, electrical damping, display unit, current trim, zero point calibration (position
correction), sensor trim, measuring speed, interrupt current limits, interrupt setting,
overflow ranges of current.
5. Variable mapper. This performs the following setting:
PV= Pressure, SV= Sensor temp., TV= Electronics temp., QV= Non-linearized pressure

PV Primary variable
7.19 Static configuration data
Description
A further menu command in the corresponding operating program allows you to read and
also write a series of sensor-specific material data. With the factory state, this data is pre-
allocated according to the particular device model. These values are not contained in the
"Factory calibration" function; in other words, changes in the device are permanently saved.
List of variable material parameters:
Flange type
Flange material
Remote seal type
Filling medium
O-ring material
Remote seal
Remote seal diaphragm material
Number of remote seals
Sensor filling medium
Sensor seal diaphragm material
Transmitter model
Housing material
Tube length
Process connection
Electrical connection
Material of pressure cap screws
Vent valve position
For a series of these material data items, you can enter any designation of your choice under
the option "Special". This applies to the following parameters:
ITEM 1120, 1340, 1355
7.20 Flow rate measurement (only differential pressure)
Process connection
Flange type
Pressure cap screws
O-ring material
Material of vent valve
Vent valve position
Remote seal type
Remote seal
Diaphragm material
Remote seal filling medium
You can use up to 16 characters for each entry.
7.20 Flow rate measurement (only differential pressure)
Description
For the "Differential pressure and flow rate" device version, you can select the characteristic
curve of output current as follows without actuating the measuring mode selector:
linear "lin": proportional to differential pressure
square root extracting "sroff": proportional to flow rate, deactivated up to the application
point
square root extracting "srlin": proportional to flow rate, linear up to the application point
square root extracting "srlin2": proportional to flow rate, two-step linear up to the
application point
Variable application point
The output current for the "srlin" and "sroff" functions can be displayed linearly or set to zero
below the application point of the square root extracting characteristic curve.
Fixed application point
The "srlin2" function has a permanently defined application point of 10%. The range up to
this point contains two linear characteristic curve sections. The first section ranges from the
zero point to 0.6% of the output value and 0.6% of the pressure value. The second section
has a higher gradient and it goes up to the root application point at 10% of the output value
and 1% of the pressure value.
See also
Flow rate measurement (only differential pressure) (Page 82)
ITEM 1120, 1340, 1355
7.21 Diagnostic functions
7.21.1 Overview
Description
HART communication allows you to activate and evaluate a wide range of diagnostic
functions from a central control room or onsite:
Calibration/service timer
Min/max indicator
Limit monitoring modules
Simulation of measured pressure and temperature values
Limit monitoring of all device variables
The diagnostics strategy employed for the transmitter incorporates a diagnostic warning and
a diagnostic interrupt for diagnostic functions for monitoring limit values, e.g. for monitoring
current saturation. This warning and interrupt can be configured:
Diagnostic warning: The device transmits via HART communication the diagnostic event
that has occurred. The current output value is unaffected. The message "Diagnostic
Warning" alternates with the unit on the display.
Diagnostic interrupt: The device goes into the fault current state. The message
"Diagnostic Warning" or "Diagnostic Alarm" appears on the display, along with the
message ERROR. In addition, the diagnostic event is made available via HART
communication.
In the default settings, all warnings and alarms are switched off. You can choose to set either
the diagnostic warning only or the diagnostic interrupt and warning. For HART
communication, use the HART Communicator or PC software such as SIMATIC PDM. To
see the steps required, refer to the attached table for operation of the HART Communicator
or the help functions in the SIMATIC PDM software.
7.21.2 Operating hours counter
Description
An operating hours counter can be read via HART communication for the electronics and
another for the sensor. For HART communication, use the HART Communicator or PC
software such as SIMATIC PDM. The counters are activated the first time the transmitter is
put into operation. If the device is separated from its power supply, the counter readings are
automatically stored in the non-volatile memories. That means that the current counter
readings can be accessed at the next restart. The operating hours counters cannot be reset.
ITEM 1120, 1340, 1355
7.21.3 Calibration timer and service timer
Description
To guarantee regular calibration of the electronics and for servicing work on the sensor, you
can fit a two-stage timer to each. After the first time period has elapsed, a calibration or
service warning will be issued. After a second time period, which can be configured as a time
differential, a diagnostic interrupt is reported and fault current is output.
To perform calibration work, you need to acknowledge warnings and interrupts. You can
then reset the timers and switch off the monitoring function. The calibration intervals for the
electronics are calculated using the following formula:
Calibration interval =
required accuracy probable total error
Stability/month

For operating/acknowledging the warnings and interrupts in SIMATIC PDM and via the
HART Communicator, the following applies:
As long as the warning/interrupt limit has not been reached, the following applies:
"Reset" resets the timer and starts again from count 0. Monitoring remains active.
"Acknowledge" has no effect; the timer continues running and monitoring remains active.
"Reset and deactivate" stops the timer, resets it, and deactivates monitoring.
When the warning/interrupt limit has been reached, the following applies:
"Acknowledge" resets the warning/interrupt message, but allows the timer to keep
running. In this state, a new interrupt or warning is not possible since the time limits have
already been exceeded.
"Reset" resets the warning/interrupt message and the timer. It acknowledges the interrupt
or warning at the same time. The timer immediately starts running again from zero and
will report again when the warning/interrupt limit is next reached. The next calibration
interval is therefore immediately active.
"Reset and deactivate W/I" resets the warning/interrupt message and the timer and
deactivates it.
7.21.4 Min/max indicator
Description
The measuring transmitter provides three min/max indicator pairs, which you can use to
monitor the three measured variables Pressure, Sensor temperature, and Electronics
temperature for negative and positive peak values. For each measured value, a resettable
min/max indicator saves the maximum and minimum peak values in long-term storage in the
two non-volatile memories. Consequently, the values are available even after the device is
restarted. The min/max indicators are also updated during a simulation.
ITEM 1120, 1340, 1355
P
r
e
s
s
u
r
e

c
u
r
v
e
Upper drag indicator point
Lower drag indicator point
p
t

Figure 7-16 Basic representation of min/max indicators

p Pressure t Time
7.21.5 Limit modules
Introduction
The diagnostic functions of this device give you an option to monitor the measured values in
programmable limits. If the limits are not adhered to, the device sends a warning through
HART communication or notifies a higher-level instance about an analog fault current.
Monitoring of current saturation
You can monitor the current output in the saturation range using a simple limit module. This
limit module is configured and activated via HART communication. For HART
communication, use a HART communicator or PC software such as SIMATIC PDM.
You need to set two time periods to configure the limit module:
The first time period specifies how long the current output is allowed to be in saturation
before an interrupt is triggered and the device outputs its set fault current. This first time
period is the response time.
The second time period specifies the duration of the interrupt. This second time period is the
stop time.
Different outputs of the fault current corresponding to the set response and stop times are
shown in the following example.
ITEM 1120, 1340, 1355
Configuring the direction of fault current
The current value is proportional to pressure within the saturation limits. When the saturation
limits are exceeded, the direction of fault current can however vary from the direction of
saturation. The upper or the lower fault current is displayed depending on the parameter
settings of the direction of fault current.
You can configure the direction of fault current for a current saturation interrupt depending on
your requirements. The following settings are possible under the current saturation menu:

Active interrupt value The applicable settings are those under the current interrupt
type menu command.
Inverse interrupt value The applicable settings are the inverse settings under the
current interrupt type menu command.
Saturated interrupt value The fault current is output in the direction of current saturation.
Inverse saturated
interrupt value
The fault current is output in the opposite direction to current
saturation.

The difference between different settings is evident in examples 3 and 4 in the following
figure. Example 3 shows the direction of fault current with the "Saturated current value"
setting. Example 4 shows the direction of fault current with the "Active upper interrupt value"
setting.
Example
The configured saturation limits in the following figures are 3.8 mA and 20.5 mA.
Example 1: the response time starts at t1. At t1, current reaches the configured saturation
limit of 20.5 mA for the first time. At t2, the response time ends. The stop time begins and the
interrupt is triggered. Time t3 is the configured end of the stop time. At t3, the interrupt is
immediately revoked even if the current then drops below the saturation limit again.
Example 2: the duration of the current saturation is shorter than the response time (t1, t2). In
that case, the device does not go into "fault current" state.
Example 3: the current drops below the lower saturation limit only for a short time. The fault
current is not switched off until after the end of the stop time (t3). The direction of fault current
corresponds to the "Saturated interrupt value" setting. The fault current is output in the
direction of current saturation.
Example 4: the current drops below the lower saturation limit only for a short time. The fault
current is not switched off until after the end of the stop time (t3). The direction of fault current
corresponds to the "Active upper interrupt value" setting. The upper fault current is outputted
although the direction of current saturation is downward.

ITEM 1120, 1340, 1355
7.22 Simulation
Time [s]
Example 1 Example 2 Example 3 Example 4
upper
Fault current
lower
Fault current
l [mA]
20,5
3,8
p
p
max
p
min
t
1
t
2
t
3
t
3
t
3
t
2
t
2
t
2
t
1
t
1
t
1

Figure 7-17 Four examples of saturation monitoring
See also
Fault current (Page 109)
7.22 Simulation
7.22.1 Overview of simulation
Description
With the "Simulation" diagnostic function, you can receive and process simulated
measurement data onsite or in the control room without having process pressure or a
temperature value. This allows you to run individual process sequences in the "cold" state
and thus simulate process states. In addition, if you inject simulation values you can test the
line routing from the control room to the individual transmitter.
The value to be simulated can be provided as a fixed value or in the form of a ramp function.
Simulation of pressure and temperature values is handled in the same way in terms of
parameter settings and function, so the following will only deal with the general simulation
procedures "Fixed value" and "Ramp function".
ITEM 1120, 1340, 1355
7.22 Simulation
For reasons of safety, all simulation data are held only in the non-volatile user memory. This
means that when the device is restarted any simulation which may be active will be shut
down. You can simulate the pressure and both temperature values. It should be noted here
that changing the temperatures by simulation will have no effect on the measured pressure
value.
A
D
D
A
HART
HART
Communicator
C
Measurement
Process value
4.20 mA
Sensor
T electr.
Values
T sensor
Fixed value
Values P
Ramp
Values
T electr.
l
Constant
Simulate
Sensor
p
Sensor
T

Figure 7-18 Block diagram of simulation
7.22.2 Simulation as fixed value
Description
Taking the physical unit into account you can set a fixed simulation value for all three
possible simulation paths. You can simulate the pressure value and both temperature values
simultaneously. While pressure simulation is activated, the transmitter will not react to
changes in the process pressure. The output value for the current adjusts itself in
accordance with the preset pressure value. Simulation of the temperature values has no
effect on the current output. It can only be observed via HART communication.
7.22.3 Simulation with a ramp function
Description
In addition to the adjustable fixed values for all three simulation paths, you can, as a second
option, also configure one ramp function in each case. Adjustable lower and upper values
together determine the limits between which the simulation values with a rising or falling
ITEM 1120, 1340, 1355
7.23 Limit monitor
tendency can move. The step width can be calculated with the step number, which is also
adjustable. You can specify the rate of rise of the ramp via the duration of the individual ramp
steps.
lncrement =
Upper range value Lower range value
Number of steps

7.23 Limit monitor
Description
You can activate up to three limit monitors in order to monitor any of the device variables.
The limit monitor monitors a value at an upper or lower limit value. If this limit is violated it
sends a diagnostic warning or a diagnostic interrupt. Select the "Limit Monitor" menu
command in SIMATIC PDM or in the HART communicator. You can program the following
values for each of the three limit monitors:
Table 7-4 Parameter of the limit monitor
Monitoring variable You will be shown a list of the active device variables. This list is
independent of the measuring mode selected.
Limit monitoring: warning / interrupt Select whether a warning or a warning plus an interrupt should be
triggered when a limit is violated.
Limit monitoring: upper / lower Specify here whether a device variable monitors the upper limit, the
lower limit, or both limits.
Upper limit value Upper limit value in the unit of the device variable.
Lower limit value Lower limit value in the unit of the device variable.
Hysteresis Operating point for chatter suppression in the case of small pressure
changes.
Response time The time which must pass after the limit is violated before this violation
is registered.
Stop time The time for which a limit interrupt or warning will always be sustained
even when the event which triggered it is no longer present.

ITEM 1120, 1340, 1355
7.23 Limit monitor
20,5
[s]
Fault
current
Min. stop time:
Time
Response time:
3,8
l [mA]
DVmax
DVmin
DV 0...9

Figure 7-19 Trip levels for the limit monitor
You can count the limit violations for each limit monitor by activating an event counter that
provides separate, cumulative totals of upper and lower limit violations. A diagnostic warning
and / or a diagnostic interrupt can be issued once a certain number of violations is reached,
a number which you can also program. You can program the following values for the event
counter:
Table 7-5 Parameters of the event counter
Event counter: upper limit Select here whether a warning or a warning plus an interrupt should be
triggered when the comparison value is exceeded.
Event counter: lower limit Select here whether a warning or a warning plus an interrupt should be
triggered when the comparison value is not met.
Comparison value: upper limit Specify here the number of overflows at which a warning or a warning
plus an interrupt should be triggered.
Comparison value: upper limit Specify here the number of underflows at which a warning or a warning
plus an interrupt should be triggered.
Limit monitoring, warning/interrupt: upper limit Select whether a warning or a warning plus an interrupt should be
triggered when the event counter upper limit is violated.
Limit monitoring, warning/interrupt: lower limit Select whether a warning or a warning plus an interrupt should be
triggered when the event counter lower limit is violated.
Reset event counter upper limit Here you can reset the upper limit counter to zero. A new event is not
possible until the counter has been reset.
Reset event counter lower limit Here you can reset the lower limit counter to zero. A new event is not
possible until the counter has been reset.
Warning/interrupt acknowledgement Here you can acknowledge each warning or interrupt separately.

ITEM 1120, 1340, 1355
7.23 Limit monitor
DV 0...9 (current)
Limit max. [unit DV]
Limit min. [unit DV]
Hysteresis [unit DV]
Response time [s] Enable comparator
Stop time [s]
Enable max./min./both/off
Warning active
Warning active below
Warning above active
Warning and alarm above active
Warning and alarm active
Warning/alarm acknowledgement
Max./min. trigger
lnput
Event
Event
Count
Comparison value above
Warning and alarm below active
Warning/alarm acknowledgement
Reset counter above/below
Event counter
Event counter below
Event counter above

Figure 7-20 Limit monitor and event counter
Messages from the limit monitor and from the event counter can be acknowledged
separately. Resetting the event counter starts a new monitoring interval.
ITEM 1120, 1340, 1355
7.23 Limit monitor
ITEM 1120, 1340, 1355

Functional safety
8
8.1 General safety instructions
8.1.1 Safety-instrumented system
This chapter describes the functional safety in general and not specific to a device. The
devices in the examples are selected as representative examples. The device-specific
information follows in the next chapter.
Description
The sensor, logic unit/control system and final controlling element combine to form a safety-
instrumented system, which executes a safety function.
4...20 mA
Sensor
4...20 mA
SF < 3.6 mA
Transducer
Final controlling
element
Valve with actuator
and positioner
Control system
PLC

Figure 8-1 Example of a safety-instrumented system
SF Failure signal
ITEM 1120, 1340, 1355
Functional safety
8.1 General safety instructions
Functioning of the system as shown in the example
The transmitter generates a process-specific analog signal. The downstream control system
monitors this signal to ensure that it does not fall below or exceed a set limit value. In case of
a fault, the control system generates a failure signal of < 3.6 mA or > 22 mA for the
connected positioner, which switches the associated valve to the specified safety position.
8.1.2 Safety Integrity Level (SIL)
The international standard IEC 61508 defines four discrete Safety Integrity Levels (SIL) from
SIL 1 to SIL 4. Each level corresponds to the probability range for the failure of a safety
function.
Description
The following table shows the dependency of the SIL on the "average probability of
dangerous failures of a safety function of the entire safety-instrumented system" (PFDAVG)
The table deals with "Low demand mode", i.e. the safety function is required a maximum of
once per year on average.
Table 8-1 Safety Integrity Level
SIL Interval
4 10
-5
PFDAVG < 10
-4

3 10
-4
PFDAVG < 10
-3

2 10
-3
PFDAVG < 10
-2

1 10
-2
PFDAVG < 10
-1

The "average probability of dangerous failures of the entire safety-instrumented system"
(PFDAVG) is normally split between the three sub-systems in the following figure.

Sensor
e. g. pressure,
temperature etc.
Control system
or logic unit
e. g.
PLC
PFDAVG component < 35 % < 15 % < 50%
Final controlling
element
e. g. valve with actuator
and positioner

Figure 8-2 Example of PFD distribution
The following table shows the achievable Safety Integrity Level (SIL) for the entire safety-
instrumented system for type B subsystems depending on the safe failure fraction (SFF) and
the hardware fault tolerance (HFT). Type B subsystems include analog transmitters and
shut-off valves without complex components, e.g. microprocessors (also see IEC 61508,
Section 2).

HFT SFF
0 1 (0)
1)
2 (1)
1)

< 60 % Not permitted SIL 1 SIL 2
ITEM 1120, 1340, 1355
Functional safety
8.2 Device-specific safety instructions
HFT
60 to 90 % SIL 1 SIL 2 SIL 3
90 to 99 % SIL 2 SIL 3 SIL 4
> 99 % SIL 3 SIL 4 SIL 4
1)
As per IEC 61511-1, Section 11.4.4
According to IEC 61511-1, Section 11.4.4, the hardware fault tolerance (HFT) can be
reduced by one (values in brackets) for sensors and final controlling elements with complex
components if the following conditions are applicable for the device:
The device is proven-in-use.
The user can configure only the process-related parameters, e.g. control range, signal
direction in case of a fault, limiting values, etc.
The configuration level of the firmware is blocked against unauthorized operation.
The function requires SIL of less than 4.
The device fulfills these conditions.
See also
Safety characteristics (Page 134)
8.2.1 Safety function
Safety function for pressure transmitters
Measuring pressures is the safety function for SITRANS P. It is applicable for output current
from 4 to 20 mA and ensures an accuracy of 2% of the measured value in this range. The
safety function ensures that the diagnosis function responds within 4 seconds in the worst
case scenario.

WARNING
The binding settings and conditions are listed in the "Settings" and "Safety characteristics"
sections.
These conditions must be met in order to fulfil the safety function.

The calculated Mean Time Between Failures (MTBF) for the SITRANS P pressure
transmitter is approximately 400 years.
ITEM 1120, 1340, 1355
Functional safety
See also
Safety characteristics (Page 134)
8.2.2 Requirements
Requirements
Functional safety has the following requirements:
Functional safety to SIL 2 under IEC 61508 or IEC 61511-1, from firmware version FW:
from 11/02/03
Explosion protection for corresponding versions
Electromagnetic compatibility in compliance with EN 61326
8.2.3 Settings
The following settings must be adhered to after installing and commissioning as per the
Operating Instructions:
Operation/configuration
While operating/configuring, ensure that the technical data of the pressure transmitter are
adhered to in their respective version.
Checking the safety function
We recommend that:
You check the status for warnings and alarms.
You check the measurement value limits.
You simulate different current values.
You check the measuring accuracy that must be in the range of 2% for the safety
function.
You check the zero point, e.g. in a pressure-less state, for gauge and differential
pressure.
You check the zero point, e.g. with a defined pressure, for absolute pressure.
Protection against configuration changes
After parameterizing/commissioning:
1. Set the lock mode in Mode 10 to write protection "L".
Operation via keys and HART communication is blocked.
2. Protect the keys from unintended change in the parameters, e.g. by lead-sealing.
ITEM 1120, 1340, 1355
Functional safety
8.2.4 Behavior in case of faults
Repairs
Defective devices should be sent in to the repair department with details of the fault and the
cause. When ordering replacement devices, please specify the serial number of the original
device. The serial number can be found on the rating plate.
The address of the responsible SIEMENS repair center, contacts, spare parts lists, etc. can
be found on the Internet.
See also
Services & Support (http://www.siemens.com/automation/services&support)
Partner (http://www.automation.siemens.com/partner)
8.2.5 Maintenance/Checking
Interval
We recommend that the functioning of the pressure transmitter be checked at regular
intervals of one year.
Checking the safety function
We recommend that:
You check the status for warnings and alarms.
You check the measurement value limits.
You simulate different current values.
You check the measuring accuracy that must be in the range of 2% for the safety
function.
You check the zero point, e.g. in a pressure-less state, for gauge and differential
pressure.
You check the zero point, e.g. with a defined pressure, for absolute pressure.
Checking safety
You should regularly check the safety function of the entire safety circuit in line with IEC
61508/61511. The testing intervals are determined during the calculation for each individual
safety circuit in a system (PFDAVG).
Electronics
The safety function of the transmitter is ensured only with the electronics delivered by the
factory. It cannot be replaced.
ITEM 1120, 1340, 1355
Functional safety
8.2.6 Safety characteristics
The safety characteristics necessary for using the system are listed in the "SIL declaration of
conformity". These values apply under the following conditions:
The SITRANS P pressure transmitter is only used in applications with a low demand rate
for the safety function (low demand mode).
Communication with the HART protocol is used only for the following:
Device configuration
Reading diagnostic values
However, it is not used for operations critical to safety. In particular, the trace function
must not be activated in safety related operation.
The safety-related parameters/settings have been entered by local operation or HART
communication before commencing safety-instrumented operation. They are checked on
the local display.
(see "Settings" section)
The safety function test is concluded successfully.
The transmitter is blocked against unwanted and unauthorized changes/operation.
The current signal of 4 to 20 mA of the transmitter is evaluated by a safe system.
The calculation of fault rates is based on a Mean Time To Repair (MTTR) of eight hours.
See also
Settings (Page 132)
ITEM 1120, 1340, 1355

Commissioning
9
9.1 Safety notes for commissioning

WARNING
"explosion-proof" type of protection

WARNING
Hazardous areas
If the transmitters are to be used as category 1/2 operational resources, please observe the
type examination certificates or the test certifications applicable in your country.

WARNING
Incorrect or improper use of the shut-off modules can lead to serious physical injuries or
considerable damage to property.

WARNING
Using toxic substances
The transmitter should not be depressurized if toxic substances are being used.

WARNING
Intrinsically safe circuits
With intrinsically-safe circuits, use only certified ammeters appropriate for the transmitter.
"Intrinsically safe"
If a non-conforming supply unit is used, the "fail-safe" type of protection will no longer be
effective and the approval certification will be invalid.

ITEM 1120, 1340, 1355
Commissioning
9.2 Notes on commissioning
WARNING
Laying of cables
Connect the devices that are operated in hazardous areas as per the stipulations applicable
in your country, e.g. for Ex "d" and "nA", permanent cables must be laid.

WARNING
Devices with the common approval "Intrinsically safe" and "Flameproof"
The following is applicable for devices with the common approval "Intrinsically safe" and
"Flameproof" (EEx ia and EEx d):
The type of protection that is not suitable must be permanently defaced on the type plate
before commissioning.

NOTICE
Before commissioning, check the basic parameters.
Due to changes in the operating functions, the display and the measurement output could
be set such that the actual process pressure is not reproduced.

9.2 Notes on commissioning

Note
In order to obtain stable measured values, the transmitter must be allowed to warm up for at
least 5 minutes after the power supply is switched on.
The order data must match with the values given on the type plate. The transmitter is in
operation as soon as the power supply is switched on.
The following cases of commissioning can be taken as the typical examples. Changing the
arrangements specified here may be practical depending on the system configuration.

9.3 Introduction to commissioning
Following commissioning, the transmitter is immediately ready for use.
To obtain stable measured values, the transmitter needs to be allowed to warm up for five
minutes or so after the power supply is switched on.
The measuring span which can be set corresponds to the information on the nameplate.
Even in the case of a customer-specific setting configured in the factory, the zero point and
the limit point will appear on the nameplate.
If need be, you can change the parameters by simple user operations on the device even
during commissioning.
ITEM 1120, 1340, 1355
Commissioning
9.4 Gauge pressure, absolute pressure from the differential pressure series and absolute pressure from the gauge pressur
9.4 Gauge pressure, absolute pressure from the differential pressure
series and absolute pressure from the gauge pressure series
9.4.1 Commissioning for gases
Overview
Usual arrangement Special arrangement
1
2
3
4
5
6

1
2
3
4
5
6
7
8
9

Measuring gases above the pressure
tapping point
Measuring gases below the pressure
tapping point

Shut-off module
Shut-off valve to process
Shut-off valve for test connection or for bleed screw
Pressure line
Shut-off valve
Shut-off valve (optional)
ITEM 1120, 1340, 1355
Commissioning
9.4 Gauge pressure, absolute pressure from the differential pressure series and absolute pressure from the
gauge pressure series
Condensation vessel (optional)
Drain valve
Condition
All valves are closed.
Procedure
To commission the transmitter for gases, proceed as follows:
1. Open the shut-off valve for the test connection .
2. Via the test connection of the shut-off module , apply the pressure corresponding to the
start of scale value to the pressure transmitter .
3. Check the start of scale value.
4. If the start of scale value differs from the value desired, correct it.
5. Close the shut-off valve for the test connection ..
6. Open the shut-off valve at the pressure tapping point.
7. Open the shut-off valve for the process .
9.4.2 Commissioning with steam or liquid
Overview
1
2
3
4
5
6
7
8

Figure 9-1 Measuring steam

ITEM 1120, 1340, 1355
Commissioning
9.5 Differential pressure and flow rate
Shut-off module
Shut-off valve to process
Shut-off valve for test connection or for bleed screw
Pressure line
Shut-off valve
Drain valve
Compensation vessel (steam only)
Condition
Procedure
To commission the transmitter for steam or liquid, proceed as follows:
1. Open the shut-off valve for the test connection .
2. Via the test connection of the shut-off module , apply the pressure corresponding to the
start of scale value to the pressure transmitter .
3. Check the start of scale value.
4. If the start of scale value differs from the value desired, correct it.
5. Close the shut-off valve for the test connection .
6. Open the shut-off valve at the pressure tapping point.
7. Open the shut-off valve for the process .
9.5.1 Safety notes for commissioning with differential pressure and flow rate

WARNING
Ensure that the locking screw and/or the vent valve are connected and adequately fixed.
Ensure that the valves are operated correctly and properly.
If the lock screws are missing or are not sufficiently tight, and/or if the valves are operated
incorrectly or improperly, it could lead to serious physical injuries or considerable damage
to property.

ITEM 1120, 1340, 1355
Commissioning
WARNING
Hot mediums
In the case of hot mediums, the individual operational steps should be carried out one after
the other. Otherwise, it could lead to excessive heating, thus causing damage to the valves
and the transmitter.

9.5.2 Commissioning in gaseous environments
Overview

9
6 6
5 5
4
1
2
3

6 6
7
8
5 5
8
4
1
2
3
7
9

Transmitter above the differential
pressure transducer
Transmitter below the
differential pressure transducer

ITEM 1120, 1340, 1355
Commissioning

Stabilizing valve
, Differential pressure valves
Differential pressure lines
Shut-off valves
Blowout valves
Condensation vessels (optional)
Differential pressure transducer
Condition
All shut-off valves are closed.
Procedure
To commission the transmitter for gases, proceed as follows:
1. Open both the shut-off valves at the pressure tapping point.
2. Open the stabilizing valve .
3. Open the differential pressure valve ( or ).
4. Check and if required correct the zero point when the start of scale value is 0 mbar
(4 mA).
5. Close the stabilizing valve .
6. Open the other differential pressure valve ( or ).
ITEM 1120, 1340, 1355
Commissioning
9.5.3 Commissioning for liquids
Overview

1
2
3 4 5 5
7 7
6 6
9

1
2
3 4 5 5
6 6 9
7
7
8 8
10 10

Transmitter below the differential
pressure transducer
Transmitter above the
differential pressure transducer

Stabilizing valve
Shut-off valves
Blowout valves
Gas collector vessels (optional)
Vent valves
ITEM 1120, 1340, 1355
Commissioning
Condition
Procedure
WARNING
The transmitter should not be depressurized if toxic substances are being used.

To commission the transmitter with liquids, proceed as follows:
3. In the case of Transmitter below the differential pressure transducer Open both the
blowout valves one after the other until the air-free liquid emerges.
In the case of a transmitter above the differential pressure transducer, open both the vent
valves one after the other until the liquid emerges.
4. Close both the blowout valves or vent valves .
5. Open the differential pressure valve and the vent valve at the plus chamber of the
transmitter until the liquid emerges.
6. Close the vent valve.
7. Open the vent valve at the minus chamber of the transmitter until the liquid emerges.
8. Close the differential pressure valve .
9. Open the differential pressure valve until the liquid emerges and then close it.
10. Close the vent valve at the minus chamber of the transmitter .
11. Open the differential pressure valve by rotating it in half a turn.
12. Check and if required correct the zero point in case of start of scale value 0 bar (4 mA).
14. Open the differential pressure valves ( and ) completely.
ITEM 1120, 1340, 1355
Commissioning
9.5.4 Commissioning with vapor
Overview
7
5 5
7
8
10 9
6 6
4 3
1
2
6
8

Figure 9-2 Measuring steam

Stabilizing valve
Shut-off valves
Blowout valves
Condensate pots
Insulation

ITEM 1120, 1340, 1355
Commissioning
Condition
Procedure
CAUTION
The measuring result is error-free only if the differential pressure lines have equally high
condensate columns with the same temperature. The zero calibration must be repeated if
required if these conditions are fulfilled. If the shut-off valves and the differential pressure
valves are open at the same time and the stabilizing valve is opened, there is a
possibility of the transmitter being damaged due to the streaming vapor.

To commission the transmitter for vapor, proceed as follows:
3. Wait till the vapor in the differential pressure lines and in the condensate pots
condenses.
4. Open the differential pressure valve and the vent valve at the plus chamber of the
transmitter till the air-free condensate.
5. Close the vent valve.
6. Open the vent valve at the minus chamber of the transmitter till the air-free condensate
goes out.
7. Close the differential pressure valve .
8. Open the differential pressure valve till the air-free condensate goes out and then
close it.
9. Close the vent valve at the minus chamber .
10. Open the differential pressure valve by rotating it in half a turn.
11. Check and if required correct the zero point in case of start of scale value 0 bar (4 mA).
13. Open the differential pressure valve and completely.
ITEM 1120, 1340, 1355
Commissioning
ITEM 1120, 1340, 1355

10
10.1 Notes for servicing

Note
Depending on the use of the device and certain empirical values, determine a maintenance
interval for the tests to be carried out repeatedly.
The maintenance interval is influenced by the corrosion resistance depending on the site of
use.

Note
Checking the gaskets
Check the gaskets of the pressure transmitter at regular intervals. Grease or replace the
gaskets if required.

10.2 Display in case of a fault
Check the start of scale value of the device from time to time.
Differentiate between the following in case of a fault:
The internal self test has detected a fault, e.g. sensor break, hardware fault/Firmware
fault.
Displays:
Digital display: "ERROR" display and ticker with an error text
Analog output: Factory setting: Failure current 3.6 or 22.8 mA
Or depending on the parameterization
HART: detailed error breakdown for display in the HART communicator or SIMATIC
PDM
Grave hardware faults, the processor is not functioning.
Displays:
Digital display: no defined display
Analog output: failure current < 3.6 mA
In case of defect, you can replace the electronic unit by following the warning notes and the
provided instruction manual.
ITEM 1120, 1340, 1355
10.3 Modular structure
See also
Modular structure (Page 148)
Error display (Page 59)
10.3 Modular structure
Safety note
NOTICE
The structure of this device is modular. You can thus replace different parts with original
spare parts. When replacing components, always adhere to the notes provided with the
components to be replaced.
This is especially applicable for devices that are used in hazardous areas.

Related
Both the individual components "Measuring cell" and "Electronics" always have a non-
volatile memory (EEPROM). Every EEPROM has a data structure that is permanently
allocated to the measuring cel, or the electronics. Measuring cell data (e.g.: measuring
range, measuring cell material, oil filling) are stored in the EEPROM of the measuring cell.
Data of the electronics (e.g.: downscaling, electrical additional damping) is located in the
EEPROM of the electronics. It is thus ensured that the data that is relevant for the remaining
components is retained when replacing the electronic unit.
Before starting the replacement work, you have the following setting options via HART:
After replacement, the common measuring range settings from the measuring cell or from
the electronic unit are adopted.
A standard parameterization is carried out.
The measuring accuracy in the specified measuring limits with a 1:1 downscaling can be
reduced by the temperature error in unfavorable cases.
In the course of further technical development, it is possible to implement advanced
functions in the measuring cell or the electronic unit. This is indicated by modified Firmware
statuses (FW). The Firmware status does not have an effect on the replaceability. The scope
of functions however is limited to the functioning of the older components.
If a combination of certain Firmware statuses of measuring cell and electronic unit is not
possible due to technical reasons, the device identifies this status and goes into the "Fault
current" status. This information is provided via the HART interface.
ITEM 1120, 1340, 1355
10.4 Notes for servicing of the remote seal
The remote seal measuring system usually does not need servicing.
If the mediums are contaminated, viscous or crystallized, it could be necessary to clean the
diaphragm from time to time. Use only a soft brush and a suitable solvent to remove the
deposits from the diaphragm. Do not use corrosive cleaning agents. Prevent the diaphragm
from getting damaged due to sharp-edged tools.
ITEM 1120, 1340, 1355
ITEM 1120, 1340, 1355

Technical data
11
11.1 Overview of technical data
Introduction
The following overview of technical data provides you with a quick and easy access to
relevant data and characteristic numbers.
Remember that the tables partially contain the data of the three communication types HART,
PROFIBUS and FoundationFieldbus. This data deviates in many cases. Therefore, adhere
to the communication type used by you when using the technical data.
Contents of the chapter
Input point (Page 152)
Output (Page 157)
Measuring accuracy (Page 158)
Operating conditions (Page 164)
Construction (Page 167)
Display, keyboard and auxiliary power (Page 171)
Certificates and approvals (Page 172)
HART communication (Page 173)
ITEM 1120, 1340, 1355
Technical data
11.2 Input point
11.2 Input point

DS III input with PMC connection
HART PROFIBUS PA or Foundation Fieldbus
Measured variable Gauge pressure
Measuring
range
Maximum
permissible
operating
pressure
Maximum
permissible
test
pressure
Measuring
span
Maximum
permissible
operating
pressure
Maximum
permissible
test pressure
0.01 1 bar g
(0.15
14.5 psi g)
1)

4 bar g
(58 psi g)
6 bar g
(87 psi g)
1 bar g
(14.5 psi g)
1)

4 bar g
(58 psi g)
6 bar g
(87 psi g)
0.04 4 bar g
(0.58
58 psi g)
7 bar g
(102 psi g)
10 bar g
(145 psi g)
4 bar g
(58 psi g)
7 bar g
(102 psi g)
10 bar g
(145 psi g)
Measuring span
(continuously adjustable)
or measuring range, max
permissible operating
pressure and max.
permissible test pressure
0.16
16 bar g (2.3
232 psi g)
21 bar g
(305 psi g)
32 bar g
(464 psi g)
16 bar g
(232 psi g)
21 bar g
(305 psi g)
32 bar g
(464 psi g)
Lower measuring limit
Measuring cell with
silicon oil filling
2)

100 mbar a (1.45 psi a)
Measuring cell with
inert liquid
2)

100 mbar a (1.45 psi a)
Measuring cell with
neobee
2)

30 mbar a (0.44 psi a)
Upper measuring limit 100 % of the max. measuring range 100% of maximum measuring span
1)
1 bar g (14.5 psi g) only in PMC-Style Standard, not in Minibolt
2)
For PMC-Style Minibolt, the measuring span should not be less than 500 mbar

Gauge pressure input
Measuring
range
Maximum
permissible
operating
pressure
Maximum
permissible
test
pressure
Measuring
span
Maximum
permissible
operating
pressure
Maximum
permissible
test pressure
0.01 1 bar g
(0.15
14.5 psi g)
4 bar g
(58 psi g)
6 bar g
(87 psi g)
1 bar g
(14.5 psi g)
4 bar g
(58 psi g)
6 bar g
(87 psi g)
0.04 4 bar g
(0.58
58 psi g)
7 bar g
(102 psi g)
10 bar g
(145 psi g)
4 bar g
(58 psi g)
7 bar g
(102 psi g)
10 bar g
(145 psi g)
Measuring span
pressure (as per
97/23/EC pressure device
guideline) and max.
(as per DIN 16086) (for
oxygen measurement
max. 160 bar)
0.16
16 bar g (2.3
232 psi g)
21 bar g
(305 psi g)
32 bar g
(464 psi g)
16 bar g
(232 psi g)
21 bar g
(305 psi g)
32 bar g
(464 psi g)
ITEM 1120, 1340, 1355
Technical data
11.2 Input point
Gauge pressure input
0.63 63 bar
g (9.1
914 psi g)
67 bar g
(972 psi g)
100 bar g
(1450 psi g)
63 bar g
(914 psi g)
67 bar g
(972 psi g)
100 bar g
(1450 psi g)
1.6
160 bar g (23
2321 psi g)
167 bar g
(2422 psi g)
250 bar g
(3626 psi g)
160 bar g
(2321 psi g)
167 bar g
(2422 psi g)
250 bar g
(3626 psi g)
4 400 bar g
(58
5802 psi g)
400 bar g
(5802 psi g)
600 bar g
(8702 psi g)
400 bar g
(5802 psi g)
400 bar g
(5802 psi g)
600 bar g
(8702 psi g)
Measuring cell with
silicon oil filling
Measuring cell with
inert liquid
Upper measuring limit 100 % of the max. measuring range (for
oxygen measurement max. 160 bar g
(2321 psi g))
100 % of the max. measuring span (for oxygen
measurement max. 160 bar g (2321 psi g))
Start of scale value between the measuring limits (continuously adjustable)

gauge pressure input, with flush mounted diaphragm
Measuring
range
Maximum
permissible
operating
pressure
Maximum
permissible
test
pressure
Measuring
span
Maximum
permissible
operating
pressure
Maximum
permissible
test pressure
8
250 mbar g
(0.12
3.6 psi g)
4 bar g
(58 psi g)
6 bar g
(87 psi g)
250 mbar g
(3.6 psi g)
4 bar g
(58 psi g)
6 bar g
(87 psi g)
0.01 1 bar g
(0.15
14.5 psi g)
4 bar g
(58 psi g)
6 bar g
(87 psi g)
1 bar g
(14.5 psi g)
4 bar g
(58 psi g)
6 bar g
(87 psi g)
0.04 4 bar g
(0.58
58 psi g)
7 bar g
(102 psi g)
10 bar g
(145 psi g)
4 bar g
(58 psi g)
7 bar g
(102 psi g)
10 bar g
(145 psi g)
0.16
16 bar g (2.3
232 psi g)
21 bar g
(305 psi g)
32 bar g
(464 psi g)
16 bar g
(232 psi g)
21 bar g
(305 psi g)
32 bar g
(464 psi g)
Measuring span
pressure and max.
0.6 63 bar g
(9.1
914 psi g)
67 bar g
(972 psi g)
100 bar g
(1450 psi g)
63 bar g
(914 psi g)
67 bar g
(972 psi g)
100 bar g
(1450 psi g)
Measuring cell with
silicon oil filling
100 mbar a (1.45 psi a)
ITEM 1120, 1340, 1355
Technical data
11.2 Input point
gauge pressure input, with flush mounted diaphragm
Measuring cell with
inert liquid
100 mbar a (1.45 psi a)
Measuring cell with
neobee

Absolute pressure input (from the gauge pressure series)
Measured variable Absolute pressure
Measuring
range
Maximum
permissible
operating
pressure
Maximum
permissible
test
pressure
Measuring
span
Maximum
permissible
operating
pressure
Maximum
permissible
test pressure
8.3
250 mbar a
(0.12
3.6 psi a)
1.5 bar a
(21.8 psi a)
6 bar a
(87 psi a)
250 mbar a
(3.6 psi a)
1.5 bar a
(21.8 psi a)
6 bar a
(87 psi a)
43
1300 mbar a
(0.62
18.9 psi a)
2.6 bar a
(37.7 psi a)
10 bar a
(145 psi a)
1.3 bar a
(18.9 psi a)
2.6 bar a
(37.7 psi a)
10 bar a
(145 psi a)
160
5000 bar a
(2.32
72.5 psi a)
10 bar a
(145 psi a)
30 bar a
(435 psi a)
5 bar a
(72.5 psi a)
10 bar a
(145 psi a)
30 bar a
(435 psi a)
Measuring span
pressure (as per
97/23/EC pressure device
guideline) and max.
(as per DIN 16086)
1 30 bar a
(14.5
435 psi a)
45 bar a
(653 psi a)
100 bar a
(1450 psi a)
3 bar a
(435 psi a)
45 bar a
(653 psi a)
100 bar a
(1450 psi a)
Measuring cell with
silicon oil filling
0 mbar a (0 psi a)
Measuring cell with
inert liquid
0 mbar a (0 psi a)
for process
temperature -20C <
60C (-4F <
+140F)
for process
temperature 60C <
100C (max.
85C for measuring
cell 30 bar) (140F <
212F (max.
185F for measuring
cell 435 psi))
30 mbar a + 20 mbar a ( - 60C)/C
(0.44 psi a + 0.29 mbar a ( - 108F)/F)
ITEM 1120, 1340, 1355
Technical data
11.2 Input point
Absolute pressure input (from the gauge pressure series)
(2321 psi g))

Absolute pressure input (from the differential pressure series)
Measured variable Absolute pressure
Measuring range Overload limits Measuring span Overload limits
8.3 250 mbar a
(0.12 3.6 psi a)
32 bar a (464 psi a) 250 mbar a
(3.6 psi a)
32 bar a (464 psi a)
43 1300 mbar a
(0.62 18.9 psi a)
32 bar a (464 psi a) 1300 mbar a
(18.9 psi a)
32 bar a (464 psi a)
160 5000 bar a
(2.32 72.5 psi a)
32 bar a (464 psi a) 5 bar a (72.5 psi a) 32 bar a (464 psi a)
1 30 bar a
(14.5 435 psi a)
160 bar a (2320 psi a) 30 bar a (435 psi a) 160 bar a (2320 psi a)
Measuring span
or measuring range and
max permissible
operating pressure (as
per 97/23/EC pressure
device guideline)
5.3 100 bar a
(76.9 1450 psi a)
160 bar a (2320 psi a)
(for connection thread
M10 and
7
/16-20 UNF
in the pressure caps)
100 bar a
(1450 psi a)
160 bar a (2320 psi a)
(for connection thread
M10 and
7
/16-20 UNF in
the pressure caps)
Measuring cell with
silicon oil filling
0 mbar a (0 psi a)
Measuring cell with
inert liquid

for process
temperature -20C <
60C (-4F <
+140F)
for process
temperature 60C <
100C (max.
85C for measuring
212F (max.
185F for measuring
cell 435 psi))
30 mbar a + 20 mbar a ( - 60C)/C
(0.44 psi a + 0.29 mbar a ( - 108F)/F)
(2321 psi g))

ITEM 1120, 1340, 1355
Technical data
11.2 Input point
Differential pressure and flow rate input
Measured variable Differential pressure and flow rate
Measuring range Maximum
permissible
operating pressure
Measuring span Maximum permissible
operating pressure
1 20 mbar (0.4015
8.031 inH2O)
32 bar (464 psi) 20 mbar
(8.031 inH2O)
32 bar a (464 psi)
1 60 mbar (0.4015
24.09 inH2O)
60 mbar
(24.09 inH2O)
2.5 250 mbar
(1.004 100.4 inH2O)
250 mbar
(100.4 inH2O)
6 600 mbar
(2.409 240.9 inH2O)
600 mbar
(240.9 inH2O)
16 1600 mbar
(6.424 642.4 inH2O)
1600 mbar
(642.4 inH2O)
50 5000 mbar
(20.08 2008 inH2O)
5 bar
(2008 inH2O)
0.3 30 bar (4.35
435 psi)
160 bar (2320 psi)
30 bar
(435 psi)
160 bar (2320 psi)
2.5 250 mbar
(1.004 100.4 inH2O)
250 mbar
(100.4 inH2O)
6 600 mbar
(2.409 240.9 inH2O)
600 mbar
(240.9 inH2O)
16 1600 mbar
(6.424 642.4 inH2O)
1600 mbar
(642.4 inH2O)
50 5000 mbar
(20.08 2008 inH2O)
5 bar
(2008 inH2O)
Measuring span
max permissible
device guideline)
0.3 30 bar (4.35
435 psi)
420 bar (6091 psi)
30 bar
(435 psi)
420 bar (6091 psi)
Measuring cell with
silicon oil filling
-100% of the max. measuring range (-33% for measuring cell (435 psi)) or 30 mbar a
(0.44 psi a)
Measuring cell with
inert liquid

for process
temperature -20C <
60C (-4F <
+140F)
-100% of the max. measuring range (-33% for measuring cell (435 psi)) or 30 mbar a
(0.44 psi a)
for process
temperature 60C <
100C (max.
85C for measuring
212F (max.
185F for measuring
cell 435 psi))
-100% of the max. measuring range (-33% for measuring cell (435 psi))
30 mbar a + 20 mbar a ( - 60C)/C
(0.44 psi a + 0.29 mbar a ( - 108F)/F)
ITEM 1120, 1340, 1355
Technical data
11.3 Output
Differential pressure and flow rate input
(2321 psi g))

Level input
Measured variable Level
Measuring range Maximum permissible
operating pressure
Measuring span Maximum permissible
operating pressure
25 250 mbar
(0.36 3.63 psi)
250 mbar
(3.63 psi)
25 600 mbar
(0.36 8.7 %)
600 mbar (8.7 %)
53 1600 mbar
(0.77 23.2 psi)
1600 mbar
(23.2 psi)
Measuring span
max permissible
device guideline)
160 5000 mbar
(2.32 72.5 psi)
see the mounting
flange
5 bar
(72.5 psi)
see the mounting flange
Measuring cell with
silicon oil filling
-100% of the max. measuring range or 30 mbar a (0.44 psi a) depending on the mounting
flange
Measuring cell with
inert liquid
-100% of the max. measuring range or 30 mbar a (0.44 psi a) depending on the mounting
flange
Start of scale value between the measuring limits continuously adjustable
11.3 Output

Output
Output signal 4 20 mA Digital PROFIBUS-PA or
Foundation Fieldbus signal
Lower limit (continuously
adjustable)
3.55 mA, set to 3.84 mA in the factory
Upper limit (continuously
adjustable)
23 mA, set to 20.5 mA or optionally
22.0 mA in the factory

Ripple (without HART
communication)
ISS 0.5 % of the max. output current
settable time constants (T63) 0 100 s, in steps of 0.1 s
set to 0.1 s in the factory
0 100 s, in steps of 0.1 s
set to 0.1 s in the factory
ITEM 1120, 1340, 1355
Technical data
11.4 Measuring accuracy
Output
Current transmitter 3.55 23 mA
Failure signal 3.55 23 mA
Load Resistor R []
UH - 10,5 V
23 mA
R =

Without HART communication
UH Power supply in V
With HART communication
HART communicator R =230 500
SIMATIC PDM R =230 1100
Characteristic curve Linearly increasing or linearly decreasing
Linear increase or decrease or square root extracting increasing (only for
DS III differential pressure and flow rate)
Bus physics IEC 61158-2
Polarity-independent Yes

Measuring accuracy (as per EN 60770-1) DS III with PMC connection
Reference conditions Rising characteristic curve
Start of scale value 0 bar
Seal diaphragm: stainless steel
Measuring cell with silicon oil filling
Room temperature 25C (77F)
Measuring span ratio r
r = maximum measuring span or set
measuring span

Measurement deviation with cut-off
point setting, including hysteresis and
repeatability.

Linear characteristic curve 0.075 %
r 10 (0.0029 r + 0.071) %
10 < r 30 (0.0045 r + 0.071) %
30 < r 100 *) (0.005 r + 0.05) %
Repeatability Included in the measuring deviation
Hysteresis Included in the measuring deviation
Settling time T63 without electrical
damping
approx. 0.2 s
ITEM 1120, 1340, 1355
Technical data
Measuring accuracy (as per EN 60770-1) DS III with PMC connection
Long-term drift at 30C (54F) In 5 years
(0.25 r) %
In 5 years
0.25 %
Effect of the ambient temperature
(double values for measuring cell
20 mbar g (0.29 psi g))
As percentage
at -10 +60C (14 140F) (0.1 r + 0.1) % 0.3 %
at -40 -10C and
+60 +85C
(-40 14F and 140 185F)
(0.1 r + 0.15) % per 10 K 0.25 % per 10 K
Process temperature influence In pressure per temperature change
Temperature difference between
process temperature and ambient
temperature
3 mbar per 10 K (0.04 psi per 10 K)
Influence of mounting position In pressure per change in angle
0.1 mbar g (0.00145 psi g) per 10 inclination
correction via zero offset
Power supply influence In percent per change in voltage
0.005 % per 1 V

Measuring value resolution 3 10-5 from the nominal measuring
span
*) not for 4 bar PMC Minibolt

Measuring accuracy (as per EN 60770-1) gauge pressure
Rising characteristic curve
Reference conditions
measuring span

repeatability.

r 10 (0.0029 r + 0.071) %
10 < r 30 (0.0045 r + 0.071) %
30 < r 100 (0.005 r + 0.05) %
Repeatability Included in the measuring deviation
Hysteresis Included in the measuring deviation
damping
approx. 0.2 s
(0.25 r) %
In 5 years
0.25 %
ITEM 1120, 1340, 1355
Technical data
Measuring accuracy (as per EN 60770-1) gauge pressure
20 mbar g (0.29 psi g))
As percentage
at -10 +60C (14 140F) (0.1 r + 0.1) % 0.3 %
at -40 -10C and
+60 +85C
(-40 14F and 140 185F)
(0.1 r + 0.15) % per 10 K 0.25 % per 10 K
Influence of mounting position 0.05 mbar g (0.000725 psi g) per 10 inclination
correction via zero offset
0.005 % per 1 V

Measuring value resolution 3 10
-5
from the nominal measuring
span

Gauge pressure measuring accuracy, with flush mounted diaphragm
measuring span

repeatability.

r 10 (0.0029 r + 0.071) %
10 < r 30 (0.0045 r + 0.071) %
30 < r 100 (0.005 r + 0.05) %
damping
approx. 0.2 s
(0.25 r) %
In 5 years
0.25 %
20 mbar g (0.29 psi g))
As percentage
at -10 +60C (14 140F) (0.1 r + 0.2) % 0.3 %
at -40 -10C and
+60 +85C
(-40 14F and 140 185F)
(0.1 r + 0.15) % per 10 K 0.25 % per 10 K
Process temperature influence In pressure per temperature change
ITEM 1120, 1340, 1355
Technical data
Gauge pressure measuring accuracy, with flush mounted diaphragm
Temperature difference between
process temperature and ambient
temperature
3 mbar per 10 K (0.04 psi per 10 K)
Influence of mounting position In pressure per change in angle
0.4 mbar (0.006 psi) per 10 inclination
Correction via zero offset
0.005 % per 1 V

-5
span

Absolute pressure measuring accuracy (from gauge and differential pressure series)
measuring span

repeatability.

r 10 0.1 %
10 < r 30 0.2 %
damping
approx. 0.2 s
Long-term drift at 30C (54F) per year (0.1 r) % per year 0.1 %
20 mbar g (0.29 psi g))
As percentage
at -10 +60C (14 140F) (0.1 r + 0.2) % 0.3 %
at -40 -10C and
+60 +85C
(-40 14F and 140 185F)
(0.1 r + 0.15) % per 10 K 0.25 % per 10 K
Influence of mounting position In pressure per change of angle
for absolute pressure (from the gauge pressure series): 0.05 mbar
(0.000725 psi) per 10 inclination
for absolute pressure (from the differential pressure series): 0.7 mbar
(0.001015 psi) per 10 inclination
0.005 % per 1 V

ITEM 1120, 1340, 1355
Technical data
Absolute pressure measuring accuracy (from gauge and differential pressure series)
-5
span

Differential pressure and flow rate measuring accuracy
measuring span

repeatability.

Linear characteristic curve 0.075
r 10 (0.0029 r + 0.071) %
10 < r 30 (0.0045 r + 0.071) %
30 < r 100 (0.005 r + 0.05) %
Square root extracting characteristic
curve (flow rate > 50%)
0.1 %
r 10 0.1 %
10 < r 30 0.2 %
square root extracting characteristic
curve (flow rate 25 50%)
0.2 %
r 10 0.2 %
10 < r 30 0.4 %
damping
approx. 0.2 s
approx 0.3 s for measuring cell 20 and 60 mbar (0.29 and 0.87 psi)
Long-term drift at 30C (54F) (0.25 r) % per five years
static pressure max. 70 bar g
(1015 psi g)
0.25 % per five years
(1015 psi g)
Measuring cell 20 mbar (0.29 psi) (0.2 r) % per year 0.2 % per year
20 mbar g (0.29 psi g))
As percentage
At -10 +60C (14 140F) (0.08 r + 0.1) % 0.3 %
At -40 -10C and
+60 +85C
(-40 14F and 140 185F)
(0.1 r + 0.15) % per 10 K 0.25 % per 10 K
Effect of static pressure
At the start of scale value (0.15 r) % per 100 bar (1450 psi) 0.15% per 100 bar (1450 psi)
ITEM 1120, 1340, 1355
Technical data
Differential pressure and flow rate measuring accuracy
Measuring cell 20 mbar
(0.29 psi)
(0.15 r) % per 32 bar (464 psi) 0.15% per 32 bar (464 psi)
On the measuring span 0.2 % per 100 bar (1450 psi)
(0.29 psi)
0.2 % per 32 bar (464 psi)
Influence of mounting position In pressure per change of angle
0.7 mbar (0.001015 psi) per 10 inclination
0.005 % per 1 V

-5
span

Level measuring accuracy
measuring span

repeatability.

Linear characteristic curve 0.075
r 10 0.15 %
10 < r 30 0.3 %
30 < r 100 (0.0075 r + 0.075) %
damping
approx. 0.2 s
Long-term drift at 30C (54F) (0.25 r) % per five years
(1015 psi g)
0.25 % per five years
(1015 psi g)
Ambient temperature influence As percentage
At -10 +60C (14 140F)
(0.4 instead of 0.2 at 10 < r 30)

Measuring cell
250 mbar (3.63 psi)
(0.5 r + 0.2) % 0.7 %
Measuring cell
600 mbar (8.7 psi)
(0.3 r + 0.2) % 0.5 %
Measuring cell 1.6 and 5 bar
(23.2 and 72.5 psi)
(0.25 r + 0.2) % 0.45 %
ITEM 1120, 1340, 1355
Technical data
11.5 Operating conditions
Level measuring accuracy
At -40 -10C and
+60 +85C
(-40 14F and 140 185F)
(double values for 10 < r 30)

Measuring cell
250 mbar (3.63 psi)
(0.25 r + 0.15) %/10 K
( (0.25 r + 0.15) %/18F)
0.4 %/10 K
( 0.4 %/18F)
Measuring cell
600 mbar (8.7 psi)
(0.15 r + 0.15) %/10 K
( (0.15 r + 0.15) %/18F)
0.3 %/10 K
( 0.3 %/18F)
(23.2 and 72.5 psi)
(0.12 r + 0.15) %/10 K
( (0.12 r + 0.15) %/18F)
0.27 %/10 K
( 0.27 %/18F)
Effect of static pressure
At the start of scale value
(0.29 psi)
(0.3 r) % per nominal pressure 0.3 % per nominal pressure
Measuring cell
600 mbar (8.7 psi)
(23.2 and 72.5 psi)
On the measuring span (0.1 r) % per nominal pressure 0.1 % per nominal pressure
Influence of mounting position depending on the fill fluid in the mounting flange
0.005 % per 1 V

-5
span

Rated conditions DS III with PMC connection
Installation conditions
Ambient temperature
Note Observe the temperature class in hazardous areas.
Measuring cell with silicon oil
filling
-20 +85C (-4 185F)
Digital display -30 +85C (-22 185F)
Storage temperature -50 +85C (-58 185F)
Climate class
Condensation permitted
Degree of protection (as per
EN 60529)
IP65
Electromagnetic Compatibility
Interference emission and
interference immunity
As per EN 61326 and NAMUR NE 21
ITEM 1120, 1340, 1355
Technical data
Rated conditions DS III with PMC connection
Medium conditions
Process temperature -20 +100C (-4 +212F)

Rated conditions for gauge pressure and absolute pressure (from the gauge pressure series)
Installation instruction Process connection vertically downward
Ambient conditions
Ambient temperature
filling
--40 +100C (-40 212F)
Measuring cell with inert liquid -20 +100C (-40 212F)
Climate class
Condensation Permitted
EN 60529)
IP65
Medium conditions
Process temperature
filling
-40 +100C (-40 212F)
in conjunction with dust
explosion protection
-20 +60C (-4 140F)

Gauge pressure rated conditions, with flush mounted diaphragm
Ambient temperature
filling
-40 +85C (-40 185F)
Measuring cell with neobee -10 +85C (+14 185F)
Climate class
Condensation permitted
Degree of protection
In accordance with EN 60 529
IP65, IP68
ITEM 1120, 1340, 1355
Technical data
Gauge pressure rated conditions, with flush mounted diaphragm
Medium conditions
Process temperature
filling
-40 +150C (-40 302F)
-40 +200C (-40 392F) with temperature decoupler
-10 +250C (+14 482F) with temperature decoupler
Measuring cell with neobee -10 +150C (+14 302F)

Rated conditions for absolute pressure (from the differential pressure series), differential pressure and flow rate
Installation instruction any
Ambient conditions
Ambient temperature
filling
-40 +100C (-40 212F)
Measuring cell
30 bar (435 psi)
-40 +85C (-40 +185F)
for flow rate: -20 +85C (-4 +185F)
Measuring cell with neobee -20 +100C (-4 212F)
Climate class
EN 60529)
IP65
Medium conditions
Process temperature
filling
-40 +100C (-40 212F)
Measuring cell
30 bar (435 psi)
-40 +85C (-40 +185F)
for flow rate: -20 +85C (-4 +185F)
Measuring cell
30 bar (435 psi)
-40 +85C (-40 +185F)
for flow rate: -20 +85C (-4 +185F)
In conjunction with dust
explosion protection
-20 +60C (-4 +140F)
ITEM 1120, 1340, 1355
Technical data
11.6 Construction

Rated conditions for level
Installation instruction specified through the flange
Ambient conditions
Ambient temperature
Note Observe the allocation of the max. permissible operating temperature to the max.
permissible operating pressure of the relevant flange connection.
filling
-40 +100C (-40 212F)
Climate class
EN 60529)
IP65
Medium conditions
Process temperature
filling
Plus side: see the mounting flange
Minus side: -40 +100C (-40 +212F)
11.6 Construction

DS III construction with PMC connection
Weight approx 1.5 kg (3.3 lb)
Material
Wetted parts materials
Gasket (standard) PTFE flat gasket
O-ring (minibolt) FPM (Viton)
FFPM or NBR (optional)
Non-wetted parts materials
Electronics housing Non-copper aluminum die casting GD-AlSi 12 or stainless steel precision
casting, mat. no. 1.4408
Lacquer on polyester base
Type plate made of stainless steel
Mounting bracket Steel, zinc plated and yellow chrome plated or stainless steel
Measuring cell filling Silicone oil
Neobee M20
Inert liquid
ITEM 1120, 1340, 1355
Technical data
11.6 Construction
DS III construction with PMC connection
Process connection
Standard Flush mounted
1
1
/2''
PMC Standard design
Minibolt Flush mounted
1''
PMC Minibolt design
Electrical connection Cable inlet using the following screwed joints:
Pg 13.5 (adapter)
M20 x 1.5
-14 NPT
Han 7D/Han 8U plug connector
M12 connector

Construction for gauge pressure and absolute pressure (from the gauge pressure series)
Weight approx 1.5 kg (3.3 lb)
Material
Connection pins Stainless steel, mat. no. 1.4404/316L or Hastelloy C4, mat. no. 2.4610
Oval flange Stainless steel, mat. no. 1.4404/316L
Seal diaphragm Stainless steel, material no. 1.4404/316L or Hastelloy C276, material no. 2.4819
Neobee M20
Inert liquid
(max. 160 bar g (2320 psi g) for oxygen measurement)
Process connection Connection pin G
1
/2A as per DIN EN 837-1; female thread
1
/2-14 NPT or oval
flange (PN 160 (MWP 2320 psi g)) with fastening screw thread M10 as per
DIN 19213 or
7
/16-20 UNF as per EN 61518
Electrical connection Screw terminals
Cable inlet using the following screwed joints:
Pg 13.5 (adapter)
M20 x 1.5
-14 NPT or Han 7D/Han 8U plug connector
M12 connector

Construction for gauge pressure, with flush mounted diaphragm
Weight approx. 1.5 13.5 kg (3.3 30 lb)
Material
ITEM 1120, 1340, 1355
Technical data
11.6 Construction
Construction for gauge pressure, with flush mounted diaphragm
Process connection Stainless steel, mat. no. 1.4404/316L
Seal diaphragm Stainless steel, mat. no. 1.4404/316L
Neobee M20
Inert liquid
Process connection Flanges as per EN and ASME
F&B and pharma flange
Bioconnect/Biocontrol
PMC style
Electrical connection Cable inlet using the following screwed joints:
Pg 13.5 (adapter)
M20x1.5
-14 NPT
Han 7D/Han 8U plug connector
M12 connector

Construction for absolute pressure (from the gauge pressure series), differential pressure and flow rate
Weight approx. 4.5 kg (9.9 lb)
Material
Seal diaphragm Stainless steel, mat. no. 1.4404/316L, Hastelloy C276, mat. no. 2.4819, Monel,
mat. no. 2.4360, tantalum or gold
Pressure caps and locking
screw
Stainless steel, mat. no. 1.4408 to PN 160, mat. no. 1.4571/316Ti for PN 420,
Hastelloy C4, 2.4610 or Monel, mat. no. 2.4360
O-ring FPM (Viton) or optionally: PTFE, FEP, FEPM and NBR
Pressure cap screws Steel, zinc plated and yellow chrome plated or stainless steel
Neobee M20
Inert liquid
(max. 160 bar g (2320 psi g) for oxygen measurement)
ITEM 1120, 1340, 1355
Technical data
11.6 Construction
Construction for absolute pressure (from the gauge pressure series), differential pressure and flow rate
Process connection Female thread
1
/4-18 NPT and flat connection with fastening screw thread M10 as
per DIN 19213 (M12 for PN 420 (MWP 6092 psi)) or
7
/16-20 UNF as per EN 61518
Pg 13.5 (adapter)
M20 x 1.5
M12 connector

Construction for level
Weight
as per EN (pressure transmitter
with mounting flange, without
tube)
approx 11 13 kg (24.2 28.7 lb)
as per ASME (pressure
transmitter with mounting flange,
without tube)
approx 11 18 kg (24.2 39.7 lb)
Material
Plus side
Seal diaphragm on the
mounting flange
Stainless steel, mat. no. 1.4404/316L, Monel 400, mat. no. 2.4360, Hastelloy B2,
mat. no. 2.4617, Hastelloy C276, mat. no. 2.4819, Hastelloy C4, mat. no. 2.4610,
tantalum, PTFE, ECTFE
Sealing surface smooth as per EN 1092-1, form B1 or ASME B16.5 RF 125 250 AA for stainless
steel 316L, EN 2092-1 form B2 or ASME B16.5 RFSF for the remaining materials
Sealing material in the pressure
caps

for standard applications Viton
for underpressure
applications on the mounting
flange
Copper
Minus side
Seal diaphragm Stainless steel, mat. no. 1.4404/316L
Pressure caps and locking
screws
Stainless steel, mat. no. 1.4408
O-ring FPM (Viton)
Pressure cap screws Steel, zinc plated and yellow chrome plated or stainless steel
Mounting flange fill fluid Silicon oil or a different design
Process connection
Plus side Flange as per EN and ASME
ITEM 1120, 1340, 1355
Technical data
11.7 Display, keyboard and auxiliary power
Construction for level
Minus side Female thread
1
/4-18 NPT and flat connection with fastening screw thread M10 as
per DIN 19213 (M12 for PN 420 (MWP 6092 psi)) or
7
/16-20 UNF as per EN 61518
Pg 13.5 (adapter)
M20 x 1.5
M12 connector
11.7 Display, keyboard and auxiliary power

Display and user interface
Keys 3 for on-site programming directly at the device
Digital display Installed
Cover with inspection window (optional)

Auxiliary power UH
Terminal voltage at transmitter DC 10.5 V 45 V
In the case of intrinsically safe
operation 10.5 V 30 V DC

Ripple USS 0.2 V (47 125 Hz)
Noise Ueff 1.2 V (0.5 10 Hz)
Auxiliary power Bus-powered
Separate supply voltage Not necessary
Bus voltage
Not 9 32 V
For intrinsically safe operation 9 24 V
Current consumption
Max. basic current 12.5 mA
Starting current basic current Yes
Max. current in event of fault 15.5 mA
Error shut-down electronics (FDE)
present
Yes

ITEM 1120, 1340, 1355
Technical data
11.8 Certificates and approvals
11.8 Certificates and approvals

Certificates and approvals
Classification according to Pressure
Equipment Directive (PED 97/23/EC)
for gases of Fluid Group 1 and liquids of Fluid Group 1; meets requirements of
Article 3 Para. 3 (good engineering practice)
only for flow rate:
for gases of Fluid Group 1 and liquids of Fluid Group 1; fulfills the basic safety
requirements as per article 3, Para 1 (appendix 1); classified as category III,
module H conformity evaluation by TV Nord
Water, waste water In preparation
Explosion protection
Intrinsic safety "i" PTB 99 ATEX 2122
Identifier II
1
/2 G EEx ia/ib IIB/IIC T6
Permissible ambient temperature -40 +85C (-40 +185F) temperature class T4
-40 +70C (-40 +158F) temperature class T5
Connection To a certified intrinsically safe circuit
with the max. values:
Ui = 30 V, Ii = 100 mA,
Pi = 750 mW, Ri = 300
FISCO supply unit
Ui = 17.5 V, Ii = 380 mA, Pi = 5.32 W
Linear barrier
Ui = 24 V, Ii = 250 mA, Pi = 1.2 W
Effective inner capacitance: Ci = 6 nF Ci = 1.1 nF
Effective inner inductance: Li = 0.4 mH Li = 7 H
Flameproof enclosure
encapsulation "d"
PTB 99 ATEX 1160
Identifier II
1
/2 G EEx d IIC T4/T6
Permissible ambient temperature -40 +85C (-40 +185F) temperature class T4
Connection To a circuit with the operating values:
UH = DC 10.5 45 V
To a circuit with the operating values:
UH = DC 9 32 V
Dust explosion protection for Zone
20
PTB 01 ATEX 2055
Identifier II 1 D IP65 T 120C, II 1/2 D IP65 T 120C
Permissible ambient temperature -40 ... +85 C (-40 ... +185 F)
max. surface temperature 120C (248F)
Connection To a certified intrinsically safe circuit
with the max. values:
Ui = 30 V, Ii = 100 mA,
Pi = 750 mW, Ri = 300
FISCO supply unit
Ui = 17.5 V, Ii = 380 mA, Pi = 5.32 W
Dust explosion protection for Zone
21/22
PTB 01 ATEX 2055
Identifier II 2 D IP65 T 120C
Connection To a circuit with the operating values:
UH = DC 10.5 45 V; Pmax = 1.2 W
To a circuit with the operating values:
UH = DC 9 32 V; Pmax = 1.2 W
ITEM 1120, 1340, 1355
Technical data
11.9 HART communication
Certificates and approvals
Type of protection "n" (Zone 2) TV 01 ATEX 1696 X
Identifier II 3 G EEx nA L IIC T4/T5/T6
only for gauge pressure, with flush mounted diaphragm:
II 3 G EEx nL IIC T4/T5/T6
Connection "nA" Un = 45 V n = 32 V
Connection "nL" Un = 45 V FISCO supply unit
Ui = 32 V, Ii = 515 mA, Pi = 5.25 W
Explosion protection in accordance
with FM
Certificate of Compliance 3008490
Designation (XP/DIP) or IS; NI; S CL I, DIV 1, GP ABCD T4 ... T6; CL II, DIV 1, GP EFG; CL III; CL I, ZN 0/1 AEx ia
IIC T4 ... T6; CL I, DIV 2, GP ABCD T4 ... T6; CL II, DIV 2, GP FG; CL III
Permissible ambient temperature Ta = T4: -40 ... +85C (-40 ... +185F)
Ta = T5: -40 ... +70C (-40 ... +158F)
Ta = T6: -40 ... +60C (-40 ... +140F)
Entity parameters As per "control drawing"
A5E00072770A:
Ui = 30 V, Ii = 100 mA,
Pi = 750 mW, Ri = 300 ,
Ci = 6 nF, Li = 0.4 mH
As per "control drawing"
A5E00072770A:
Umax = 17.5 V, Imax = 380 mA,
Pmax = 5.32 W,
Cmax = 6 nF, Lmax = 0.4 mH
Explosion protection as per CSA Certificate of Compliance 1153651
Designation (XP/DIP) or (IS) CL I, DIV 1, GP ABCD T4 ... T6; CL II, DIV 1, GP EFG; CL III; ia IIC T4 ... T6:
CL I, DIV 2, GP ABCD T4 ... T6; CL II, DIV 2, GP FG; CL III
Permissible ambient temperature Ta = T4: -40 ... +85C (-40 ... +185F)
Ta = T5: -40 ... +70C (-40 ... +158F)
Ta = T6: -40 ... +60C (-40 ... +140F)
Entity parameters As per "control drawing" A5E00072770A:
Ui = 30 V, Ii = 100 mA, Pi = 750 mW, Ri = 300 ,
Li = 0.4 mH, Ci = 6 nF

HART communication
Load for a
HART communicator connection 230 1100
HART modem 230 500
Cable 2-wire, shielded: 3.0 km (1.86 miles), multi-
wired, shielded: 1.5 km (0.93 miles)
Protocol HART Version 5.x
ITEM 1120, 1340, 1355
Technical data
HART communication
PC/laptop requirements IBM-compatible, user memory > 32 MB,
hard disk > 70 MB, depending on the type of
modem: RS 232 interface or USB connection,
VGA graphic
Software for computer SIMATIC PDM

ITEM 1120, 1340, 1355

Dimension drawings
12
12.1 SITRANS P, DS III series for gauge pressure and absolute pressure
from the gauge pressure series
50
1.97
28
1.1
69
2.7
15
0.6
138
5.4
69
0.6
2
0
0
.
8
5
0
1
.
9
7
1
1
7
4
.
6
6
8
2
.
7
7
2
2
.
8
8
0
3
.
1
5
approx.96(3.78)
approx.96(1.2)
100
3.94
6
.
7
1
7
1
3
6
,
5
1
.
4
4
2
3
7
9
.
3
105
4.1
1
2
0
4
.
7
1
2
3
4
5
4
6
7
8
123
4.8
1)
min.-77
min. 3.0
5)
1)
4)

Figure 12-1 Pressure transmitter SITRANS P, DS III HART series for absolute pressure, from gauge
pressure series, dimensions in mm (inch)

Electronic side, digital display (greater design length for cover with inspection window)
Process connection:

1
/2-14 NPT,
Connection pin G
1
/2A or
Oval flange
Connection side
Electrical connection:
Screwed point Pg 13,5 (adapter)
2)3)
,
Screwed point M20 x 1,5
3),

Screwed point
1
/2-14 NPT
Han 7D/Han 8U
2)3)
plug connector
M12 connector
Protective cap of the operating buttons
Blanking plug
ITEM 1120, 1340, 1355
Dimension drawings
12.2 SITRANS P, DS III series for differential pressure, flow rate and absolute pressure from the differential
pressure series
Screw cover - lock bracket (only for "explosion-proof" type of protection, not shown in the
drawing)
Mounting bracket (optional)
1)
Take additional 20 mm (0.79 inch) thread length into account
2)
Not with "Explosion-proof" type of protection
3)
Not for "FM + CSA [is + XP]" type of protection
4)
For Pg 13,5 with adapter approx 45 mm (1.77 inch)
5)
Minimum distance when rotating

12.2 SITRANS P, DS III series for differential pressure, flow rate and
absolute pressure from the differential pressure series
S
p
a
c
e

f
o
r

r
o
t
a
t
i
o
n

o
f

h
o
u
s
i
n
g
1
2
3
4 5
6
7
8
9
10
11
12
15
0.6
138
5.4
50
1.97
72
2.83
105
4.1
1
3
4
5
.
2
7
1
1
7
4
.
6
5
0
1
.
9
7
2
0
0
.
8
8
0
3
.
1
5
69
2.7
77
3
100
3.94 approx.30(1.2)
52
2.05
approx. 96(3.78)
68
2.7
120
4.7
9
6
3
.
8
a
p
p
r
o
x
.

2
6
1
(
1
0
.
3
)
1
9
8
7
.
8
1)
1) 6
)
4)
7)

Figure 12-2 Pressure transmitter SITRANS P, DS III HART series for differential pressure and flow rate, dimensions in mm
(inch)

Connection side
2)3)
,
3),

Screwed point
1
/2-14 NPT
Han 7D/Han 8U
2)3)
plug connector
M12 connector
ITEM 1120, 1340, 1355
Dimension drawings
12.2 SITRANS P, DS III series for differential pressure, flow rate and absolute pressure from the differential pressure serie
Blanking plug
drawing)
Mounting bracket (optional)
2)3)
,
3),

Screwed point
1
/2-14 NPT or
Han 7D/Han 8U
2)3)
plug connector
Lateral ventilation for gas measurement (addition H02)
Sealing plug, with valve (optional)
Lateral ventilation for liquid measurement
Process connection:
1
/4-18 NPT (EN 61518)
1)
2)
3)
4)
92 mm (3.62 inch) minimum distance for rotating the pointer
5)
S
p
a
c
e

f
o
r

r
o
t
a
t
i
o
n

o
f

h
o
u
s
i
n
g
1
2
3
4 5
6
3
7
8
7
15
0.6
138
5.4
50
1.97
1
1
7
4
.
6
5
0
1
.
9
7
2
0
0
.
8
8
0
3
.
1
5
3
100
3.94
approx.30(1.2)
1)
1)
6
)
4)
77
67
2.64
5)
8)
approx. 96(3.8)
a
p
p
r
o
x
.

8
5
(
3
.
4
)
a
p
p
r
o
x
.

2
1
7
(
8
.
5
)
7
)
approx. 84,6(3.3)

Figure 12-3 Pressure transmitter SITRANS P, DS III HART series for differential pressure and flow
rate with caps for vertical differential pressure lines, dimensions in mm (inch)

Connection side
2)3)
,
3),

Screwed point
1
/2-14 NPT or
Han 7D/Han 8U
2)3)
plug connector
Blanking plug
ITEM 1120, 1340, 1355
Dimension drawings
12.2 SITRANS P, DS III series for differential pressure, flow rate and absolute pressure from the differential
pressure series
drawing)
Sealing plug, with valve (optional)
Process connection:
1
/4-18 NPT (EN 61518)
1)
2)
3)
4)
5)
74 mm (2.9 inch) for PN 420 (MWP 6092 psi)
6)
7)
8)

ITEM 1120, 1340, 1355
Dimension drawings
12.3 SITRANS P, DS III series for level
12.3 SITRANS P, DS III series for level
1
2
3
4
4
5
6
7
8
9 10
Space for rotation
of housing
approx.
30(1.2)
185
8.28
100
3.94
54
2.1
108
4.25
approx.96(3.7)
n x d
2
b
f
L
d
5
d
4
k D
1
6
5
6
.
5
138
5.4
50
1.97
69
2.72
15
0.6
77
3.3
4)
5)
1)
1)
1)

Figure 12-4 Pressure transmitter SITRANS P, DS III HART series for level, including mounting flange, dimensions in mm
(inch)

2)3)
,
3),

Screwed point
1
/2-14 NPT
Han 7D/Han 8U
2)3)
plug connector
M12 connector
Blanking plug
Connection side
Sealing plug with valve (optional)
drawing)
Process connection: Minus side
1
/4-18 NPT (EN 61518)
1)
2)
ITEM 1120, 1340, 1355
Dimension drawings
12.4 SITRANS P, DS III series (flush mounted)
3)
4)
5)

4
1
3
2
5
6
7
15 138
15
60 50
2
0
5
0
8
0
H
2
=
c
a
.

5
5
H
1
=
c
a
.

1
3
0
77 [92]
4)
1)
1)
ca. 30 160
0.59
2.36 1.97
0.59
5.43
0
.
7
9
1
.
9
7
H
1
=
c
a
.

5
.
1
2
3
.
1
5
H
2
=
c
a
.

2
.
1
7
3.03 [3.62]
4)
ca. 1.18 6.3

Figure 12-5 SITRANS P DS III (flush mounted)

Electronics side, "digital display" option Protective caps for buttons
Connection side, "analog display" option Blanking plug
Cable gland Screw cover - lock bracket, only for flameproof
encapsulation, not shown in the dimension drawings
Process connection
1)
Take additional 20 mm (approx.) thread length into account
4)
Minimum distance for turning without display and [ ] with display
The screen consists of a SITRANS P DS III with an example flange. On this screen, the
height is divided into H1 and H2.

H1 Height of the device up to a defined cut
H2 Height of the flange up to this defined cut
In the flange dimensions, only the height H2 is specified.
ITEM 1120, 1340, 1355
Dimension drawings
12.4.1 Note 3A and EHDG

Note
The SITRANS P, DS III series is approved by "EHEDG". The SITRANS P300 is approved by
"EHEDG" and "3A" for example.
The same flanges and flush mounted connections are used for both the pressure
transmitters. The connections for both the abovementioned approvals are thus specified.
Since the SITRANS P, DS III series transmitter is not approved by "3A", the connections
marked with "3A" are not applicable for the SITRANS P, DS III series.

12.4.2 Connections as per EN and ASME
Flange as per EN

EN 1092-1
DN PN D H2
25 40 115 mm (4.5'')
25 100 140 mm (5.5'')
40 40 150 mm (5.9'')
40 100 170 mm (6.7'')
50 16 165 mm (6.5'')
50 40 165 mm (6.5'')
80 16 200 mm (7.9'')

H
2
D
80 40 200 mm (7.9'')
Approx. 52 mm (2'')
Threaded connections

G2" as per DIN 3852
DN PN D H2
D
H
2

2'' 63 78 mm (3.1'') Approx. 52 mm (2'')
ITEM 1120, 1340, 1355
Dimension drawings
Flanges as per ASME

ASME B 16.5
DN CLASS D H2
1'' 150 110 mm (4.3'')
1'' 300 125 mm (4.9'')
1 1/2'' 150 130 mm (5.1'')
1 1/2'' 300 155 mm (6.1'')
2'' 150 150 mm (5.9'')
2'' 300 165 mm (6.5'')
3'' 150 190 mm (7.5'')
3'' 300 210 mm (8.1'')
4'' 150 230 mm (9.1'')

D
H
2

4'' 300 255 mm (10.0'')
Approx. 52 mm (2'')
12.4.3 F&B and pharma flange
Connections as per DIN

DIN 11851
DN PN D H2
25 40 63 mm (2.5'')
32 40 70 mm (2.8'')
40 40 78 mm (3.1'')
50 25 92 mm (3.6'')

D
H
2

80 25 127 mm (5'')
Approx. 52 mm (2'')
Approvals 3A
1)

1) If the transmitter is approved by 3A, use only 3A-approved sealing rings.

DIN 11864-1
DN PN D H2
25 40 52 mm (2'')
40 40 65 mm (2.6'')
50 40 78 mm (3.1'')

D
H
2

100 40 130 mm (5.1'')
Approx. 52 mm (2'')
Approvals 3A, EHEDG

ITEM 1120, 1340, 1355
Dimension drawings

DIN 11864-2
DN PN D H2
25 40 70 mm (2.8'')
40 40 82 mm (3.2'')
50 40 94 mm (3.7'')

D
H
2
100 40 159 mm (6.3'')
Approx. 52 mm (2'')
Approvals 3A, EHEDG

DIN 11864-3
DN PN D H2
25 40 50.5 mm (2'')
40 40 64 mm (2.5'')
50 40 77.5 mm (3.1'')

D
H
2

100 40 130 mm (5.1'')
Approx. 52 mm (2'')
Approvals 3A, EHEDG

Tri-Clamp as per DIN 32676
DN PN D H2
20 16 34 mm (1.3'')
25 16 50.5 mm (2'')
32 16 50.5 mm (2'')
40 16 50.5 mm (2'')
50 16 64 mm (2.5'')
65 10 91 mm (3.6'')
80 10 106 mm (4.2'')

D
H
2

100 40 119 mm (4.7'')
Approx. 52 mm (2'')
Approvals 3A
Other connections

Varivent
connector
DN PN D H2
25-32 40 66 mm (2.6'')
D
H
2

40-125 40 84 mm (3.3'')
Approx. 52 mm (2'')
Approvals 3A, EHEDG
ITEM 1120, 1340, 1355
Dimension drawings
Bioconnect
TM
connector

Bioconnect
TM
screwed joint
DN PN D H2
25 16 55 mm (2.2'')
50 16 82 mm (3.2'')

H
2
D
100 16 145 mm (5.7'')
Approx. 52 mm (2'')
Approvals 3A, EHEDG

Bioconnect
TM
flange connector
DN PN D H2
25 16 85 mm (3.3'')
50 16 110 mm (4.3'')

D
H
2

100 16 175 mm (6.9'')
Approx. 52 mm (2'')
Approvals 3A, EHEDG

Bioconnect
TM
clamp connector
DN PN D H2
25 16 50.4 mm (1.9'')
40 16 64 mm (2.5'')
50 16 77.4 mm (3'')
65 10 90.9 mm (3.6'')
80 10 106 mm (4.2'')

D
H
2

100 10 119 mm (4.7'')
Approx. 52 mm (2'')
Approvals 3A, EHEDG
Other connections

Biocontrol
TM
connector
DN PN D H2
50 16 90 mm (3.5'')
65 16 120 mm (4.7'')

H
2
D
80 16 140 mm (5.5'')
Approx. 52 mm (2'')
Approvals 3A, EHEDG

ITEM 1120, 1340, 1355
Dimension drawings

Connect S
TM
flanged joint
DN PN D H2
25 16 97 mm (3.8'')
32 16 105 mm (4.1'')
40 16 115 mm (4.5'')
50 16 125 mm (4.9'')
65 10 145 mm (5.7'')
80 10 155 mm (6.1'')

H
2
D
100 10 180 mm (7.1'')
Approx. 52 mm (2'')
Approvals 3A, EHEDG

12.4.4 PMC Style
Connections for the paper industry

PMC Style Standard
DN PN D H2
40.4 mm (1.6'') Approx. 52 mm (2'')
D
H
2

M44x1.25 cap nut

PMC-Style Minibolt
DN PN D H2
H
2
D
26.3 mm (1'') Approx. 52 mm (2'')

ITEM 1120, 1340, 1355
Dimension drawings
12.4.5 Special connections
Tank connection

TG52/50 and TG52/150
DN PN D H2
TG52/50
25 40 63 mm (2.5'') Approx. 63 mm (2.5'')
TG52/150

D
H
2

25 40 63 mm (2.5'') Approx. 170 mm (6.7'')

ITEM 1120, 1340, 1355

13
13.1 Order data
In order to ensure that the ordering data you are using is not outdated, the latest ordering
data is always available on the Internet:
See also
Catalog process instrumentation (http://www.siemens.com/processinstrumentation/catalogs)

Selection and order data Order no.
CD "sitrans p - pressure transmitters" with documentation in
German/English/French/Spanish/Italian, etc.
A5E00090345
HART modem
With serial interface RS232 7MF4997-1DA
1) D)

With USB interface 7MF4997-1DB
1) D)

Weld-in support for PMC connection
For DS III and P300 series
PMC Style Standard: Thread 1" 7MF4997-2HA
PMC-Style Minibolt: flush mounted 1" 7MF4997-2HB
Gaskets for PMC connection, (1 set = 5 pieces)
PTFE gasket for PMC Style Standard: Thread 1" 7MF4997-2HC
Viton gasket for PMC Style Minibolt: flush mounted 1" 7MF4997-2HD
Weld-in adapter for PMC connection
For connection of weld-in support delay during welding for:
PMC Style Standard: Thread 1" 7MF4997-2HE
PMC-Style Minibolt: flush mounted 1" 7MF4997-2HF

Mounting bracket and fastening parts
For DS III, DS III PA and DS III FF series
For gauge pressure transmitter (7MF403.-.....-..C.)
For transmitter for absolute pressure (7MF423.-.....-..C.)
Made of steel 7MF4997-1AB
Made of stainless steel 7MF4997-1AH
ITEM 1120, 1340, 1355
13.1 Order data
For gauge pressure transmitter (7MF403.-.....-..A., -..B. and -..D.)
For transmitter for absolute pressure (7MF423.-.....-..A., -..B. and -
..D.)

Made of steel 7MF4997-1AC
Made of stainless steel 7MF4997-1AJ
Differential pressure transmitter with flange thread
Made of steel
For thread M10 (7MF433.-... and 7MF443.-...) 7MF4997-1AD
For thread M12 (7MF453.-...) 7MF4997-1AE
Made of stainless steel
For thread M10 (7MF433.-... and 7MF443.-...) 7MF4997-1AK
For thread M12 (7MF453.-...) 7MF4997-1AL
Differential and absolute transmitter with
flange thread 7/16-20 UNF
(7MF433.-..., 7MF443.-... and 7MF453.-...)

Made of steel 7MF4997-1AF
Made of stainless steel 7MF4997-1AM
Cover
Made of aluminum die casting, including gasket
Without inspection window 7MF4997-1BB
With inspection window 7MF4997-1BE
Made of stainless steel, including gasket
Without inspection window 7MF4997-1BC
With inspection window 7MF4997-1BF
Analog display
Scale 0 ... 100% 7MF4997-1BN
Customer-specific scale division as per the plain text
specifications
7MF4997-1BP-Z
Y20: ................
Digital display
Including the fastening material 7MF4997-1BR
not labelled (five pieces) 7MF4997-1CA
labelled (one piece)
Specifications as per Y01 or Y02, Y15 and Y16
(refer to SITRANS P transmitter)
7MF4997-1CB-Z
Y..: ................
ITEM 1120, 1340, 1355
13.1 Order data
Fastening screws, 50 pieces for:
Earthing and connecting terminals
Digital display
7MF4997-1CD
Locking screws, (1 set = 2 pieces) for pressure cap
Made of stainless steel 7MF4997-1CG
Made of Hastelloy 7MF4997-1CH
Vent valves, complete (1 set = 2 pieces)
Made of stainless steel 7MF4997-1CP
Made of Hastelloy 7MF4997-1CQ
Electronic
For DS III series 7MF4997-1DK
For DS III PA series 7MF4997-1DL
For DS III FF series 7MF4997-1DM
Network card
For DS III series 7MF4997-1DN
For DS III PA and DS III FF series 7MF4997-1DP
Sealing rings for pressure caps off
FPM (Viton) 7MF4997-2DA
PTFE (Teflon) 7MF4997-2DB
FEP (with silicon core, suitable for food) 7MF4997-2DC
FFPM (Kalrez, Compound 4079) 7MF4997-2DD
NBR (Buna N) 7MF4997-2DE

1)
Available from stock
D)
Subject to export regulations AL: N, ECCN, EAR99H

ITEM 1120, 1340, 1355
13.2 Order data for SIMATIC PDM

SIMATIC PDM Single Point
SIMATIC PDM Single Point V6.0 6ES7 658-3HX06-0YA5
for operating and parameterizing one field device at a time,
Communication via PROFIBUS DP/PA or HART modem, incl. 1
TAG,
neither functional nor expandable via TAGOption/PowerPack
in five languages (German, English, French, Italian and Spanish),
can be run on Windows 2000 Professional or
Windows XP Professional
Floating License for one user
Delivery form:
License Key Disk, Emergency Key Disk, Certificate of License,
Terms and Conditions;
2 CDs with SIMATIC PDM V6.0 and Device Library and an
additional Microsoft ServicePacks and Tools DVD

SIMATIC PDM Basic
SIMATIC PDM Basic V6.0
for operating and parameterizing field devices and components,
communication via
PROFIBUS DP/PA, HARTModem/Interface, RS 232,
Modbus, SIREC-Bus, SIPART DR, incl. 4 TAGs
Delivery form:

Floating License for one user 6ES7 658-3AX06-0YA5
Rental License for 50 hours 6ES7 658-3AX06-0YA6
Functional options for SIMATIC PDM V6.0
Integration in STEP 7 / SIMATIC PCS 7
required only when the integration of SIMATIC PDM in HW Config
is to be used
Delivery form:
Terms and Conditions

Floating License for one user 6ES7 658-3BX06-2YB5
Routing via S7-400
ITEM 1120, 1340, 1355
Delivery form:

Floating License for one user 6ES7 658-3CX06-2YB5
Communication via Standard HART-Multiplexer
Delivery form:

Floating License for one user 6ES7 658-3EX06-2YB5
TAG options/ PowerPacks
SIMATIC PDM TAG-Option
for TAG expansion, in addition to SIMATIC PDM Basic V6.0
Delivery form:
License Key Disk, Certificate of License, Terms and Conditions

up to 128 TAGs 6ES7 658-3XA06-2YB5
up to 512 TAGs 6ES7 658-3XB06-2YB5
up to 1,024 TAGs 6ES7 658-3XC06-2YB5
up to 2,048 TAGs 6ES7 658-3XD06-2YB5
SIMATIC PDM PowerPack
for subsequent TAG expansion of all SIMATIC PDM product
configurations V6.0
Delivery form:
License Key Disk, Certificate of License, Terms and Conditions

from 128 TAGs to 512 TAGs 6ES7 658-3XB06-2YD5
from 512 TAGs to 1.024 TAGs 6ES7 658-3XC06-2YD5
from 1,024 TAGs to 2,048 TAGs 6ES7 658-3XD06-2YD5
from 2.048 TAGs to TAGs unlimited 6ES7 658-3XH06-2YD5
ITEM 1120, 1340, 1355
Pre-defined SIMATIC PDM V6.0 product configurations for special applications
SIMATIC PDM Service V6.0 6ES7 658-3JX06-0YA5
Complete pack for stand-alone users in the service, with:
Option "128 TAGs"
Windows XP Professional, Floating License for one user
Delivery form:

SIMATIC PDM S7 V6.0 6ES7 658-3KX06-0YA5
Complete pack for use in an SIMATIC S7 project planning
environment, with
Option "Integration in STEP 7/PCS 7"
Option "128 TAGs"
Delivery form:

SIMATIC PDM PCS 7 V6.0 6ES7 658-3LX06-0YA5
Complete pack for integration in the engineering toolset of the
SIMATIC PCS 7 engineering system
Floating License for one user, with
SIMATIC PDM Basic
Option "Integration in STEP 7 / PCS 7"
Option "Routing via S7-400"
Option "128 TAGs"
Delivery form:

Demo-software
SIMATIC PDM Demo V6.0 6ES7 658-3GX06-0YC8
ITEM 1120, 1340, 1355
without online communication and memory functionality
Delivery form:

SIMATIC PDM Upgrade/Update Service
SIMATIC PDM Upgrade from V5.x to V6.0 6ES7 651-5CX06-0YE5
for all product versions and combinations
Delivery form:

SIMATIC PDM Software Update Service 6ES7 658-3XX00-0YL8
One-year subscription with automatic extension
Condition: current software version

Plug-in line for PROFIBUS 6ES7 901-4BD00-0XA0
designed with two 9-pin Sub-D connectors; max. transmission
rate 12 Mbit/s; 3 m

ITEM 1120, 1340, 1355
ITEM 1120, 1340, 1355

Appendix
A
A.1 Certifications
The certifications are enclosed as a loose collection of operating instructions or on CD..
A.2 Literature and standards

No. Standard Description
/1/ IEC 61508
Section 1-7
Functional safety of following systems:
Safety-instrumented
Electrical
Electronic
Programmable
Target group:
Manufacturers and suppliers of equipment
/2/ IEC 61511
Section 1-3
Functional safety - Safety systems for the process industry
Target group:
Planners, constructors and users

ITEM 1120, 1340, 1355
Appendix
A.3 SIL Declaration of Conformity

ITEM 1120, 1340, 1355
Appendix

ITEM 1120, 1340, 1355
Appendix

ITEM 1120, 1340, 1355
Appendix
A.4 exida proven in use

ITEM 1120, 1340, 1355
Appendix

ITEM 1120, 1340, 1355
Appendix

ITEM 1120, 1340, 1355
Appendix

ITEM 1120, 1340, 1355
Appendix
A.5 Overview of HART operating structure
The following overview applies to the HART communicator operating structure.
2 Online 1 (PV meas) *)
2 (PV) status
3 Module type
4 Identification 1 Operation Unit 1 Tag
2 Long Tag --> M **)
3 Descriptor
4 Message
5 Date
2 Device 1 Manufacturer
2 Model
3 Device identification
4 Distributor
5 MLFB Order Number 1 MLFB Order No --> M
6 Measurement type
7 Fabrication-No
8 Final asembly number
9 Sensor serial number
10 Revisions 1 Universal rev.
2 Field device rev.
3 Software rev.
4 Hardware rev.
3 Basic Parameters 1 Pressure unit
2 LSL (Lower Sensor Limit)
3 USL (Upper Sensor Limit)
4 Minimum Span
5 LRV (Lower Range Value)
6 URV (Upper Range Value))
7 Pressure damping
8 Pressure xfer function xfer = transfer
5 Config Inp/Outp 1 Quick-Setup & Meas. 1 PV, Current, Status 1 (PV meas) *)
2 AO (analogue output)
3 (PV) % range
4 Status see ---> 6 Diagnosis/Service
5 Measurement type
2 Meas.Val. & Status 1 Pressure Values 1 Pressure
2 Pres status
3 Untrimmed pressure
4 Untrimmed pres status
2 Temperature Values 1 Sens-Temp
2 Sens-Temp status
3 Electr-Temp
4 Electr-Temp status
3 Level, Vol, Mass Values 1 Level
(shown if valid items) 2 Level status
3 Volume
4 Volume status
5 Mass
6 Mass status
4 Vol-, Mass- & Flow 1 Vol-Flow
(shown if valid items) 2 Vol-Flow status
3 Mass-Flow
4 Mass-Flow status
5 Appl & Stat 1 Customer
(shown if valid items) 2 Customer Status
3 Quick-Setup 1 Tag
2 Ext TAG --> M
3 PV is
4 (PV) unit
5 Position correction 1 Position corr --> M
6 LRV
7 URV
8 Pressure damping
9 Pressure xfer function
2 Input 1 Config Pres/Temp 1 Pressure sensor 1 Pressure
2 Untrimmed pres
3 Pressure units 1 Pres abs/rel
2 Pressure unit
3 Untrimmed pres unit
2 Temperature sensor 1 Sens-Temp
2 Electr-Temp
3 Temp units 1 Sens-Temp unit
2 Electr-Temp unit
3 Pres units see --> 1 Pressure sensor
4 Temp units see --> 1 Temperature sensor
2 Display Process Variables 1 Prozess variables 1 (PV measurement)
2 (PV) %rnge
3 A O
4 (SV measurement)
5 (TV measurement)
6 (QV measurement)
3 Meas Switch/Mapper 1 measurement
2 PV is
3 SV is
4 TV is
5 QV is
6 (measurement) config 1 Input scaling 1 Pres abs/rel
e.g. Level 2 Pressure unit
3 Input LRV
4 Input URV
2 Level scaling 1 Level unit
e.g. Level scaling 2 Level LRV
3 Level URV to be continued
ITEM 1120, 1340, 1355
Appendix
3 Volume scaling 1 Volume unit
2 Vol LRV
3 Vol URV
2 Density unit
3 Density
3 Mass unit
e.g. Flow
e.g. Level
6 (measurement) config
continuance
3 Meas Switch/Mapper
continuance
2 Input
continuance
5 Config Inp/Outp
continuance
2 Pressure unit
3 Input LRV
4 Input URV
2 Flow scaling 1 Vol flow unit
2 Vol flow LRV
3 Vol flow URV
2 Density unit
3 Density
3 Mass flow unit
e.g. Customer 2 Pressure unit
3 Input LRV
4 Input URV
3 Customer scaling 1 Cust unit (5 Ch)
2 Cust LRV
3 Cust URV
7 Unser linearization 1 Special Curve status --> only if meas not pres
if Level, Flow or Customer 2 No curve points
this is valid - otherwise not 3 Setup special char --> M
4 Display special char --> M
4 Meas.Limits & Span 1 Module range
2 Active Device Variables 1 Pressure 1 Pressure unit
2 Pres USL
3 Pres LSL
4 Trimpoint sum
5 Pres min.span
2 Sens-Temp 1 Sens-Temp unit
2 Sens-Temp USL
3 Sens-Temp LSL
4 Sens-Temp min.span
3 Electr-Temp 1 Electr-Temp unit
2 Electr-Temp USL
3 Electr-Temp LSL
4 Electr-Temp min.span
4 Untrimmed Pres 1 Untrimmed Pres unit
2 Untrimmed Pres USL
3 Untrimmed Pres LSL
4 Untr Pres min.span
additional if measurement 5 Level 1 Level unit
is mapped to level 2 Level USL
3 Level LSL
4 Level min.span
additional if measurement 6 Volume 1 Volume unit
is mapped to level 2 Volume USL
3 Volume LSL
4 Volume min.span
additional if measurement 7 Mass 1 Mass unit
is mapped to level 2 Mass USL
3 Mass LSL
4 Mass min.span
additional if measurement 5 Vol-Flow 1 Vol-Flow unit
is mapped to flow 2 Vol-Flow USL
3 Vol-Flow LSL
4 Vol-Flow min.span
additional if measurement 6 Mass-Flow 1 Mass-Flow unit
is mapped to flow 2 Mass-Flow USL
3 Mass-Flow LSL
4 Mass-Flow min.span
additional if measurement 5 Customer 1 (PV) unit
is mapped to customer 2 Customer USL
3 Customer LSL
4 Customer min. span
3 Output 1 Analog output 1 Analog output
2 Percent range
3 Zero and Span 1 Zero/Span set 1 Apply values >1
4 Pres xfer function 2 Out Scaling PV >2
5 Startpoint square root
>1 Out Scaling PV 1 Unit
2 LRV
3 URV
4 LSL
5 USL
>2 Apply values 1 Apply values --> M
6 Current Limits 1 Lower AO Limit
2 Upper AO Limit
7 Alarms 1 AO Alarm Type
2 Alarm LRV
3 Alarm URV
2 Sensor trim points 1 Lower sensor trim point
2 Upper sensor trim point
3 HART output 1 Polling address
2 Num request preambles
3 Num response preambles
4 Local meter 1 Meter type
2 Unit tracking
3 Local Display unit to be continued
ITEM 1120, 1340, 1355
Appendix
4 LCD Settings 1 LCD Scaling, if On: 2 LCD Unit
5 Bargraph 3 LCD LRV
4 LCD URV
6 Access Control 1 Lokal keys control mode
2 Write protect
3 Set write protect --> M
5 Mech. Construction
4 Local Meter
1 No of electronic changes
Mech = mechanical 2 Design 1 Sensor 1 Fill fluid
2 Isolation material
3 O ring material
4 Module range
2 Remote Seal 1 Number remote seal (RS)
2 RS type
3 RS isolator material
4 RS fill fluid
5 Extension length
6 Extension type
7 Capillar length
3 Process Connection 1 Process Connection
2 DrainVent / plug mat
3 DrainVent / plug pos
4 Process flange bolt
5 Flange type
6 Flange material
4 Electronic Connection 1 Electr housing material
2 Electr connection
7 Diagnosis/Service 1 Status 1 Status summary
2 Extended device status
3 Simulation status
4 Hardw/Firmw status 1 Status group 2
2 Status group 3
3 Status group 4
4 Status group 5
5 Diag Alarm Status 1 Status group 15
2 Status group 16
6 Diag Warn Status 1 Status group 19
2 Status group 20
2 Device 1 Selftest/Reset 1 Selftest --> M
2 Display Test --> M
3 Master reset --> M
4 Changes Config 1 Config changed counter
2 Sensor trim 1 Restore mfgr trims --> M mfgr = manufacturer
2 Sensor trim 1 Sensor trim points 1 Lower sensor trim point
2 Upper sensor trim point
2 Sensor trim 1 Pres zero trim--> M
2 Lower sensor trim --> M
3 Upper sensor trim --> M
3 Trimpoint summary
3 Trim analog output 1 D/A trim --> M
2 Scaled D/A trim --> M
4 Position correction 1 Position corr --> M
3 Simulation/Test 1 Loop test --> M Simulation AO
2 Inputs --> M Simulation Fixed / Ramp
4 Access Control 1 Local keys control mode
2 Write protect
3 Set write protect --> M
3 Diagnostic settings 1 W/A time unit W/A = warning/alarm
2 Calib interval 1 Calib status
2 W/A acknowledge --> M
3 Calib timer 1 Calib time
2 Reset timer --> M
4 Calib warning
5 Calib alarm
6 W/A activation
3 Service interval 1 Service status
2 W/A acknowledge --> M
3 Service timer 1 Service time
2 Reset timer --> M
4 Service warning
5 Service alarm
6 W/A activation
4 AO saturation 1 AO alarm type
2 Saturation alarm
3 Alarm duration
4 Alarm activation
5 Limiter setup 1 Display limiter --> M
2 Setup limiter --> M
3 Limiter status --> M
4 Limiter: Ack W/A --> M Ack = acknowledge
5 CmpCnt: Ack W/A --> M CmpCnt =
6 Reset counter. --> M Comparation Counter
4 View 1 Operating hours 1 Operating hours Electr
2 Operating hours Sensor
3 Min/Max pointer 1 Pressure pointer 1 Pres max
2 Pres min
3 Reset pointer --> M
2 Electr-Temp pointer 1 Electr-Temp max
2 Electr- Temp min
3 Sens-Temp pointer 1 Sens-Temp max
2 Sens-Temp min
6 Certif & Approv 1 Explos. Protection
Certif = Certification
Explos = Explosion
Approv = Approval
continuance
5 Config Inp/Outp
continuance

ITEM 1120, 1340, 1355
Appendix
A.6 Pressure equipment directive
The monitoring of the design, dimensioning, testing and manufacture to ensure it is in
accordance with Module H (comprehensive quality assurance) by TV North as the
appointed body.
General
The pressure equipment directive 97/23/EC applies to the align-
ment of the statutory orders of the European member states for
pressure equipment. Such equipment in the sense of the direc-
tive includes vessels, pipelines and accessories with a maxi-
mum permissible pressure of more than 0.5 bar above atmos-
pheric.
The pressure equipment directive can be used starting Novem-
ber 29, 1999, and is compulsory starting May 29, 2002.
Division according to the danger potential
Equipment is divided in line with the pressure equipment direc-
tive according to the danger potential (medium/pressure/vo-
lume/nominal diameter) into the categories I to IV or Article 3 Pa-
ragraph 3.
The following criteria are decisive for assessment of the danger
potential, and are also shown in Diagrams 1 to 4 and 6 to 9:
Fuelled pressure equipment or equipment heated in another
manner are shown separately in Diagram 5.
Note:
Liquids according to Article 3 are those liquids whose steam
pressure is not more than 0.5 bar above standard atmospheric
pressure (1013 mbar) at the maximum permissible temperature.
Division of media (liquid/gaseous) into the fluid groups
Fluids are divided according to Article 9 into the following fluid
groups:
Conformity rating
Pressure equipment of categories I to IV must comply with the
safety requirements of the directive and be assigned the CE
symbol.
They must comply with a conformity rating procedure according
to Appendix III of the directive.
Pressure equipment according to Article 3 Paragraph 3 must be
designed and manufactured in agreement with the sound engi-
neering practice SEP applying in a member country, and must
not be assigned a CE symbol (CE symbols from other directives
are not affected).
Siemens has carried out a conformity rating, assigned a CE sym-
bol, and issued a declaration of conformity for its products (pro-
viding the equipment is not within the context of Article 3
Paragraph 3).
Supervision of the design, dimensioning, testing and manufac-
ture is carried out according to module H (comprehensive qual-
ity assurance).
Notes:
Equipment designed for media with a high danger potential
(e.g. gases of fluid group 1) may also be used for media with
a lower danger potential (e.g. gases of fluid group 2, or liquids
of fluid groups 1 and 2).
The pressure equipment directive according to Article 1 Para-
graph 1 does not apply to equipment such as e.g. mobile off-
shore plants, ships, aircraft, water supply and waste water net-
works, nuclear plants, rockets and pipelines outside industrial
plants.
Fluid group Group 1 or 2
Aggregate state Liquid or gaseous
Type of pressurized equipment
- Vessel
- Pipeline
Product of pressure and volume
(PS * V [barL])
Nominal diameter, pressure or
product of pressure and nominal
diameter (PS * DN)
The maximum permissible temperature for the used liquids
is the maximum process temperature which can occur, as
defined by the user. This must be within the limits defined for
the equipment.
Group 1
Potentially
explosive
R phrases:
e.g.: 2, 3 (1, 4,
5, 6, 9, 16, 18,
19, 44)
Highly toxic
R phrases:
e.g.: 26, 27, 28,
39 (32)
Highly
flammable
R phrases:
e.g.: 12 (17)
Toxic
R phrases:
e.g.: 23, 24, 25
(29, 31)
Readily
flammable
R phrases:
e.g.: 11, 15, 17
(10, 30)
Fire
stimulating
R phrases:
e.g.: 7, 8, 9
(14, 15, 19)
Flammable if the maximum permissible temperature is above the flash
point.
Group 2
All fluids not belonging to Group 1.
Also applies to fluids which are e.g. dangerous to the environment, cor-
rosive, dangerous to health, irritant or carcinogenic (if not highly toxic).

Figure A-1 Pressure equipment directive, sheet 1
ITEM 1120, 1340, 1355
Appendix
Diagrams
Gases of fluid group 1
Vessels according to Article 3 Number 1.1 Letter a) First dash
Exception: unstable gases belonging to Categories I and II
must be included in Category III.
Vessels according to Article 3 Number 1.1 Letter a) Second
dash
Exception: fire extinguishers and bottles for breathing appara-
tus: at least Category III.
Liquids of fluid group 1
Vessels according to Article 3 Number 1.1 Letter b) First dash
Vessels according to Article 3 Number 1.1 Letter b) Second
dash
Exception: modules for producing warm water
Fuelled pressure equipment or equipment heated in another
manner above 110 C and liable to overheating.
Vessel according to Article 3 Number 1.2
Exception: pressure cooker, test procedure at least according
to Category III.

ITEM 1120, 1340, 1355
Appendix
Pipelines according to Article 3 Number 1.3 Letter a) First dash
Exception: unstable gases belonging to Categories I and II
must be included in Category III.
Pipelines according to Article 3 Number 1.3 Letter a) Second
dash
Exception: liquids at temperatures > 350 C belonging to Cat-
egory II must be included in Category III.
Pipelines according to Article 3 Number 1.3 Letter b) First dash
Pipelines according to Article 3 Number 1.3 Letter b) Second
dash

ITEM 1120, 1340, 1355

B
Table B-1 Variables
Abbreviation In full Meaning
PV Primary variable

Table B-2 Units
bar a bar absolute Unit of pressure for absolute pressure
bar g bar gauge Unit of pressure for gauge pressure
lb Pfund (engl.: Pound) Unit of weight
psi a psi absolute Unit of pressure for absolute pressure
psi g psi gauge Unit of pressure for gauge pressure

Table B-3 Other abbreviations
PED Pressure equipment directive
HART Highway Addressable Remote
Transducer
Standard protocol for the transmission of information between field
device and automation system
ME Full scale value
NFPA National Fire Protection
Association

F&B Food and beverage industry
PDM Engl.: Process Device Manager

ITEM 1120, 1340, 1355
B.1 Functional safety
B.1 Functional safety

Abbreviation Full term in English Meaning
FIT Failure in Time Frequency of failure
Number of faults withing 10
9
hours
HFT Hardware Fault Tolerance Hardware fault tolerance:
Capability of a function unit to continue executing a required
function in the presence of faults or deviations.
MooN "M out of N" voting Classification and description of the safety-instrumented system
in terms of redundancy and the selection procedures used.
A safety-instrumented system or part that consists of "N"
independent channels. The channels are connected to each
other in such a way that "M" channels are in each case
sufficient for the device to perform the safety instrumented
function.
Example:
Pressure measurement: 1oo2 architecture. A safety-
instrumented system decides that a specified pressure limit has
been exceeded if one out of two pressure sensors reaches this
limit. In a 1oo1 architecture, there is only one pressure sensor.
MTBF Mean Time Between Failures Average period between two failures
MTTR Mean Time To Restoration Average period between the occurrence of a fault in a device or
system and restoration of functionality
PFD Probability of Failure on Demand Probability of dangerous failures of a safety function on demand
PFDAVG Average Probability of Failure on
Demand
Average probability of dangerous failures of a safety function on
demand
SFF Safe Failure Fraction Proportion of safe failures:
Proportion of failures without the potential to bring the safety-
instrumented system into a dangerous or non-permissible
functional status.
SIL Safety Integrity Level The international standard IEC 61508 defines four discrete
Safety Integrity Levels (SIL 1 to SIL 4). Each level corresponds
to a range of probability for failure of a safety function. The
higher the Safety Integrity Level of the safety-instrumented
system, the lower the probability that it will not execute the
required safety functions.
SIS Safety Instrumented System A safety-instrumented system (SIS) executes the safety
functions that are required to achieve or maintain a safe status
in a system. It consists of a sensor, logic unit/control system
and final controlling element.
TI Test Interval Testing interval of the protective function

ITEM 1120, 1340, 1355

Glossary
ATEX
ATEX is an abbreviation of the French term "Atmosphre explosible" (potentially explosive
atmosphere). ATEX stands for both EC directives in the area of explosion protection: ATEX
product directive 94/9/EC and ATEX operating directive 1999/92/EC.
Auxiliary power supply
Auxiliary power supply refers to an electrical supply or reference voltage which some
electrical circuits require apart from the standard supply. The auxiliary power supply can, for
example, be specially stabilized, have a particular level or polarity and/or other properties
which are important for the correct functioning of switch components.
Auxiliary voltage
Auxiliary power supply
Dangerous failure
Failure with the potential to bring the safety-instrumented system into a dangerous or non-
functional status.
EEPROM
EEPROM (Electrically Erasable Programmable Read-Only Memory): a non-volatile,
electronic memory module.
EEPROMs are often used where individual bytes of data (e.g. configuration data or runtime
meters) change over time and must be stored safely in the event of a mains power failure.
Fail-safe
The capability of a control to maintain the safe state of the controlled device, e.g. machine,
process, or to bring the device to a safe state even when faults/failures occur.
Failure/Fault
Failure:
A resource is no longer capable of executing a required function.
Fault:
Undesired state of a resource indicated by the incapability of executing a required function.
ITEM 1120, 1340, 1355
Glossary

Fault
Failure/Fault
Fault tolerance
Fault tolerance N means that a device can execute the intended task even when N faults
exist. The device fails to execute the intended function in case of N+1 faults.
Final controlling element
Converter that converts electrical signals into mechanical or other non-electrical variables.
Firmware
Firmware (FW) is software, which is embedded in a chip in electronic devices unlike
software that is stored on hard disks, CD ROMs or other media. These days, firmware is
mostly stored in a flash memory or EEPROM.
Firmware usually contains the elementary functions for controlling the device, as well as
input and output routines.
Frequency shift keying
Frequency shift keying in a simple form of modulation in which the digital values 0 and 1 are
represented by two different frequencies.
Frequency Shift Keying (FSK)
Frequency shift keying
HART
HART (Highway Addressable Remote Transducer) is a standardized, widely used
communications system used to structure industrial fieldbusses. The communications
system provides digital communications for multiple participants (field devices) via a
common databus. HART is based especially on the equally widely used 4/20 mA standard
for the transfer of analog sensor signals. The cabling from existing older systems can be
used directly and both systems operated in parallel.
HART specifies several protocol levels in the OSI model. It facilitates the transfer of process
and diagnostics data and control signals between field devices and high-level control
systems. Standardized parameter sets can be used for the manufacture-independent
operation of all HART devices.
Typical applications include transmitters for measuring mechanical and electrical
dimensions.
Non-volatile memory
EEPROM
ITEM 1120, 1340, 1355
Glossary

Risk
The combination of probability of a damage occurring and its magnitude.
Safety function
Defined function executed by a safety-instrumented system with the objective of achieving or
maintaining a safe system status taking into account a defined dangerous occurrence.
Example:
Limit pressure monitoring
Safety Instrumented Function
SIF
Safety Integrity Level
SIL
Safety-instrumented system
A safety-instrumented system executes the safety functions that are required to achieve or
maintain a safe status in a system. It consists of a sensor, logic unit/control system and final
controlling element.
Example:
A safety-instrumented system is made up of a pressure transmitter, a limit signal sensor and
a control valve.
Sensor
Converter that converts mechanical or other non-electrical variables into electrical signals.
SIF
A part/function of a safety-instrumented system that reduces the risk of a dangerous failure
occurring.
SIL
The international standard IEC 61508 defines four discrete Safety Integrity Levels (SIL) from
SIL 1 to SIL 4. Each level corresponds to the probability range for the failure of a safety
function. The higher the SIL of the safety-instrumented system, the higher probability that the
required safety function will work.
The achievable SIL is determined by the following safety characteristics:
Average probability of dangerous failure of a safety function in case of demand (PFDAVG)
Hardware fault tolerance (HFT)
Safe failure fractions (SFF)
ITEM 1120, 1340, 1355
Glossary

srli2
srlin2
srlin2
"srli2" or "srlin2" is a type of square root extracting characteristic curve for the output current.
This characteristic curve type is proportional to the flow rate, linear in two levels up to the
application point and has a pre-defined application point of 10%.
"srli2" or "srlin2" are synonymous and technically, there is no difference in them. The
abbreviation "srli2" is used in sections that refer to the on-site operation of the pressure
transmitter. The reason for this abbreviation is that the digital display of the pressure
transmitter is restricted to five characters. The abbreviation "srlin2" is used for HART
operation.
ITEM 1120, 1340, 1355

Index
A
Acknowledgement, 120
Ambient temperature, 164, 165, 166, 167
Influence, 159, 160, 161, 162, 163
Analog output, 105
Analog output block, 105
Analog output stage, 93
Arrow display, 60
Assembly
At electrostatic risk, 12
B
Bar graph, 113
Basic variables, 55
Blind adjustment, 108
Bridge output voltage, 22, 23, 24
C
Calibration
Current transmitter, 115
Sensor, 113
Calibration interval, 120
Calibration timer, 120
Certificate, 195
Certification, 195
Characteristic curve
lin, 82
srli2, 82
srlin, 82
sroff, 82
characteristics
Safety, 134
Checking, 133
Commissioning, 136
Configuration data, 117
Connector
M12, 52
Constant current operation, 78, 109
Control system, 129
Correct usage, 11
Current limit, 110
Current transmitter, 78, 109
D
Device variable, 61, 101
DV, 94
Device view, 18
Diagnostic interrupt, 109, 119
Diagnostic warning, 119
Differential pressure, 16, 17, 82, 118
Display of unit, 58
Downscaling, 66
DV
Device variable, 94
Dynamic variable (DV), 93
E
Electrical damping, 109
Electromagnetic Compatibility, 164, 165, 166, 167
Compatibility, 132
Electronics, 133
Electrostatic Sensitive Devices (ESD), 12
EMC, 164, 165, 166, 167
Error display, 59
F
Factory calibration, 116
Failure current, 109
Failure signal, 129
Fast recording of measured values, 109
Fast Response Mode, 109
Fill liquid, 22, 24, 25
Final controlling element, 129
Firmware, 9
Firmware version
Safety Integrity Level, 132
Flameproof enclosure, 12
Flange, 24, 35
Full scale value
Set, 66
Function chart, 26
ITEM 1120, 1340, 1355
Index

H
Han plug, 52
HART
Modem, 15
HART communicator, 91
Hazardous area, 11
History, 9
I
Input scaling, 96, 98, 101
Install
Remote seal, 38
Installation, 31, 32
Intrinsic safety, 12
K
Keyboard lock, 80
L
L (level), 97
LCD scaling, 106
Level, 17
Limit monitor, 125
lin, 82, 118
Load, 158
M
M12 connector, 52
MA
Start of scale value, 94
Maintenance, 133
Mapper, 93, (Also see: Variable mapper)
Mass, 95, 97
ME
Full scale value, 94
Mean Time Between Failures, 131
Measured value display, 65
Measured value display, 85
Measured value status, 102
Measuring accuracy, 132
Measuring cell
Absolute pressure, 26
Differential pressure and flow rate, 23
Gauge pressure, 22
Level, 24
Measuring mode, 66, 92, 94, 98
Measuring mode selector, 93, 94
Measuring span, 66
Message
OVER, 61
UNDER, 61
Modular structure, 148
More information, 10
Mounting bracket, 32
Mounting flange, 24
MTTR, 134
O
Operating structure, 203
operation
Local, 65
Output scaling, 96, 101
Output scaling, 99
P
Pair of min/max pointer, 120
Pairs of values, 99, 101
PED, 206
Plug
Han, 52
Position correction, 77
Precautions, 11
Pressure equipment directive
Conformity evaluation, 206
Diagrams, 207, 208
Hazard potential, 206
Pressure simulation, 124
Pressure unit, 113
Primary variable, 61
Process connection, 17
Product information on the Internet, 10
PV
Primary variable, 94
Q
Qualified personnel, 13
QV
Quarternary variable, 94
R
Ramp function, 123, 125
Remote seal
ITEM 1120, 1340, 1355
Index

Description, 28
Install, 38
Maintenance, 149
Response time, 121
Root application point, 83, 98
S
Safety
Checking, 133
Safety function, 131
Checking, 132, 133
Safety Integrity Level, 132
Saturation limit, 110
Sensor, 129
sensor calibration, 113
Service timer, 120
Settings, 132
Shut-off valve, 139, 141, 143, 144, 145
Signal range, 61
Simulation, 120, 123
srli2, 82
srlin, 82, 118
srlin2, 118
sroff, 82, 118
Stabilizing valve, 141, 143, 145
Set, 66
Stop time, 121
Structure, 17
SV
Secondary variable, 94
T
Tank connection, 186
Technical data, 132
Test certification, 11
Trim
Lower sensor calibration, 114
Upper sensor calibration, 114
Turning range, 46
TV
Tertiary variable, 94
Type of protection
Flameproof enclosure, 12
Intrinsic safety, 12
Limited energy nL (zone 2), 12
Non-sparking nA (zone 2), 12
V
Variable mapper, 93
Vent valve, 117, 143, 145
Volume, 97
W
Working reliability regulation, 11
worldwide
Contact person, 10
Worldwide contact person, 10
Write protection, 80, 132
Z
Zero point calibration, 77, 108
Zone 2, 12
ITEM 1120, 1340, 1355
SITRANS P measuring instruments for pressure
Transmitters for gage, absolute and differential pressure, flow and level
DS III series
for gage pressure
2/66
Siemens FI 01 2007
2
Selection and Ordering data Order No.
SITRANS P pressure transmitters for gage
pressure, series DS III HART
7 MF 4 0 3 3 -
77777 - 7777
Measuring cell filling Measuring cell
cleaning
Silicone oil Standard } 1
Inert liquid
1)
Grease-free 3
Span
0.01 ... 1 bar g (0.15 ... 14.5 psi g) } B
0.04 ... 4 bar g (0.58 ... 58 psi g) } C
0.16 ... 16 bar g (2.32 ... 232 psi g) } D
0.63 ... 63 bar g (9.14 ... 914 psi g) } E
1.6 ... 160 bar g (23.2 ... 2320 psi g) } F
4.0 ... 400 bar g (58.0 ... 5802 psi g) } G
Seal diaphragm Process connection
Stainless steel Stainless steel } A
Hastelloy Stainless steel B
Hastelloy Hastelloy C
Version as diaphragm seal
2)

3)
Y
Process connection
Connection shank GA to EN 837-1 } 0
Female thread -14 NPT 1
Oval flange made of stainless steel,
max. span 160 bar g (2320 psi g)
- Mounting thread
7
/
16
-20 UNF to EN 61518 2
- Mounting thread M10 to DIN 19213 3
Housing made of die-cast aluminium } 0
Housing stainless steel precision casting
4)
3
Version
Standard version 1
International version, English label inscriptions,
documentation in 5 languages on CD
} 2
Without A
With ATEX, Type of protection:
- "Intrinsic safety (EEx ia)" B
- "Explosion-proof (EEx d)"
5)
D
- "Intrinsic safety and explosion-proof enclosure
(EEx ia + EEx d)"
6)
P
- "n (Zone 2)" E
- "Intrinsic safety, explosion-proof enclosure and
dust explosion protection (EEx ia + EEx d +
Zone 1D/2D)"
6)
} R
With FM + CSA, Type of protection:
- "Intrinsic safety and explosion-proof
(is + xp)"
5)
NC
Electrical connection / cable entry
Screwed gland Pg 13.5 (adapter)
7)
A
Screwed gland M20x1.5 } B
Screwed gland -14 NPT C
Han 7D plug (plastic housing) incl. mating
connector
7)
D
M12 connector (metall)
8)
F
Display
Without (digital indicator hidden, setting: mA) } 1
With visible digital indicator, setting: mA
6
with customer-specific digital indicator
(setting as specified, Order code "Y21" or "Y22"
required)
7
}Available ex stock
Power supply units see "SITRANS I power supply units and isolation
amplifiers".
Included in delivery of the device:
Brief instructions (Leporello)
CD-ROM with detailed documentation
1)
For oxygen application, add Order code E10.
2)
When the manufactures certificate M (calibration certificate) has to be
ordered for transmitters with diaphragm seals, it is recommended only to
order this certificate exclusively with the diaphragm seals. The measuring
accuracy of the total combination is certified here.
3)
Whe the acceptance test certificate 3.1 for transmitters with direct-con-
nected diaphragm seals is ordered, this certificate must also be ordered
with the corresponding seals.
4)
Not together with Electrical connection Screwed gland Pg 13.5 and
Han7D plug.
5)
Without cable gland, with blanking plug
6)
With enclosed cable gland EEx ia and blanking plug
7)
Not together with type of protection "Explosion-proof"
8)
Cannot be used together with the following types of protection:
"Explosion-proof" and "Intrinsic safety and explosion-proof"
TID
1355
ITEM: 1120,1340, 1355

DS III series
for gage pressure
2/68
Siemens FI 01 2007
2
Selection and Ordering data Order code
Further designs
Add "-Z" to Order No. and specify Order
code.
HART PA FF
Pressure transmitter with mounting
bracket made of:
Steel A01 9 9 9
Stainless steel A02 9 9 9
Plug
Han 7D (metal, gray) A30 9
Han 8U (instead of Han 7D) A31 9
Cable sockets for M12 connectors (metal) A50 9 9 9
Rating plate inscription
(instead of German)
English B11 9 9 9
French B12 9 9 9
Spanish B13 9 9 9
Italian B14 9 9 9
English rating plate B21 9 9 9
Pressure units in inH
2
O or psi
Manufacturer's test certificate M
(calibration certificate)
1)
1)
C11 9 9 9
To DIN 55350, Part 18 and to ISO 8402
Acceptance test certificate
2)
2)
C12 9 9 9
To EN 10204-3.1
Factory certificate C14 9 9 9
To EN 10204-2.2
"Functional Safety (SIL)" certificate C20 9
Setting of upper limit of output signal to
22.0 mA
D05 9
Manufacturer's declaration acc. to NACE D07 9 9 9
Type of protection IP68 D12 9 9 9
(not together with 7D/
Han 8U plug, cable gland Pg 13.5)
Digital indicator alongside the input keys D27 9 9 9
(only together with the devices 7MF4033-
. .. .0-. A.6 or -.A. 7-Z, Y21 or Y22 + Y01)
Supplied with oval flange D37 9 9 9
(1 item), PTFE packing and screws in thread
of oval flange
Use in or on zone 1D/2D E01 9 9 9
(only together with type of protection
"Intrinsic safety (EEx ia)")
Use on zone 0 E02 9 9 9
Oxygen application E10 9 9 9
(max. 160 bar g (2320 psi g) for oxygen
measurement and inert liquid)
Explosion-proof "Intrinsic safety" to
INMETRO (Brazil)
E25 9 9 9
(only for transmitter 7MF4...-.....-.B..)
NEPSI (China)
E55 9 9 9
Explosion protection "Explosion-proof" to
NEPSI (China)
E56 9 9 9
(only for transmitter 7MF4...-.....-.D..)
Explosion-proof "Zone 2" to NEPSI (China) E57 9 9 9
(only for transmitter 7MF4...-.....-.E..)
Additional data
code.
HART PA FF
Measuring range to be set Y01 9
Specify in plain text (max. 5 digits):
Y01: ... up to ... mbar, bar, kPa, MPa, psi
Measuring point number (TAG No.) Y15 9 9 9
Max. 16 characters, specify in plain text:
Y15: ...........................................
Measuring point text Y16 9 9 9
Y16: ...........................................
Entry of HART address (TAG) Y17 9
Y17: ...........................................
Setting of pressure indication in pressure
units
Y21 9 9 9
Specify in plain text (standard setting: mA):
Y21: mbar, bar, kPa, MPa, psi, ...
Note:
The following pressure units can be selected:
bar, mbar, mm H
2
O
*)
, inH
2
O
*)
, ftH
2
O
*)
,
mmHG, inHG, psi, Pa, kPa, MPa, g/cm
2
,
kg/cm
2
, Torr, ATM oder %
*) ref. temperature 20 C
Setting of pressure indication in
non-pressure units
Y22 +
Y01
9
Specify in plain text:
Y22: ..... up to ..... l/min, m
3
/h, m, USgpm, ...
(specification of measuring range in
pressure units "Y01" is essential, unit with
max. 5 characters)
Preset bus address Y25 9
Y25: .....................
Only "Y01", "Y21", "Y22", "Y25" and "D05" can be factory preset
9 = available
Ordering example
Item line: 7MF4033-1EA00-1AA7-Z
B line: A01 + Y01 + Y21
C line: Y01: 10 ... 20 bar (145 ... 290 psi)
C line: Y21: bar (psi)
ITEM: 1120,1340, 1355

DS III series
for differential pressure and flow
2/101
Siemens FI 01 2007
2
SITRANS P pressure transmitters for differen-
tial pressure and flow, Series DS III HART
PN 32/160 (MWP 464/2320 psi)
7 MF 4 4 3 3 -
77777 - 7777
Measuring cell filling Measuring cell
cleaning
Silicone oil Standard } 1
Inert liquid
1)
Grease-free 3
Span
PN 32 (MWP 464 psi)
1 ... 20 mbar
2)
(0.4015 ... 8.03 inH
2
O) } B
PN 160 (MWP 2320 psi)
1 ... 60 mbar (0.4015 ... 24.09 inH
2
O) } C
2.5 ... 250 mbar (1.004 ... 100.4 inH
2
O) } D
6 ... 600 mbar (2.409 ... 240.9 inH
2
O) } E
16 ... 1600 mbar (6.424 ... 642.4 inH
2
O) } F
50 ... 5000 mbar (20.08 ... 2008 inH
2
O) } G
0.3 ... 30 bar (4.35 ... 435 psi) } H
(stainless steel process flanges)
Seal diaphragm Parts of measuring cell
Stainless steel Stainless steel } A
Hastelloy Stainless steel B
Hastelloy Hastelloy C
Tantalum
3)
Tantalum E
Monel
3)
Monel H
Gold
3)
Gold L
Version for diaphragm seal
4)

5)
Y
Process connection
Female thread -18 NPT with flange connection
Sealing screw opposite process connection
- Mounting thread M10 to DIN 19213 } 0
- Mounting thread
7
/
16
-20 UNF to EN 61518 2
Vent on side of process flange
2)
- Mounting thread M10 to DIN 19213 4
- Mounting thread
7
/
16
-20 UNF to EN 61518 6
Process flange screws Electronics housing
Stainless steel Die-cast aluminium } 2
Stainless steel Stainless steel precision
casting
6)
3
Version
Standard version 1
International version, English label inscriptions,
documentation in 5 languages on CD
} 2
Without A
With ATEX, Type of protection:
- "Intrinsic safety (EEx ia)" B
- "Explosion-proof (EEx d)"
7)
D
- "Intrinsic safety and explosion-proof enclosure
(EEx ia + EEx d)"
8)
P
- "n (Zone 2)" E
- "Intrinsic safety, explosion-proof enclosure
and dust explosion protection
(EEx ia + EEx d + Zone 1D/2D)"
8)
} R
With FM + CSA, Type of protection:
- "Intrinsic safety and explosion-proof
(is + xp)"
7)
NC
Electrical connection / cable entry
Screwed gland Pg 13.5
9)
A
Screwed gland M20x1.5 } B
Screwed gland -14 NPT C
Han 7D plug (plastic housing) incl. mating
connector
9)
D
Display
without (digital indicator hidden, setting: mA) } 1
With visible digital indication 6
With customer-specific digital indication (setting
as specified, Order code "Y21" or required)
7
} Available ex stock
Power supply units see "SITRANS I power supply units and isolation
amplifiers".
Included in delivery of the device:
Brief instructions (Leporello)
CD-ROM with detailed documentation
Sealing plug(s) or sealing screw(s) for the process flanges(s)
1)
For oxygen application, add Order code E10.
2)
Not suitable for connection of remote seal
3)
Only together with max. spans 250, 1600, 5000 and 30000 mbar
(100.4, 240.9, 2008 inH
2
O and 435 psi)
4)
5)
6)
Not together with Electrical connection Screwed gland Pg 13.5 and
Han7D plug.
7)
Without cable gland, with blanking plug
8)
With enclosed cable gland EEx ia and blanking plug
9)
Not together with type of protection "Explosion-proof"
SITRANS P pressure transmitters for differen-
tial pressure and flow, Series DS III HART
PN 32/160 (MWP 464/2320 psi)
7 MF 4 4 3 3 -
77777 - 7777
TID
1340
TID
1120
ITEM: 1120,1340, 1355

TID 1120
TID 1340
TID 1120
TID 1340
DS III series
2/103
Siemens FI 01 2007
2
Further designs
Add "-Z" to Order No. and
specify Order code.
HART PA FF
Pressure transmitter with mounting
bracket made of:
Steel A01 9 9 9
Stainless steel A02 9 9 9
O-rings for process flanges
(instead of FPM (Viton))
PTFE (Teflon) A20 9 9 9
FEP (with silicone core, approved for food) A21 9 9 9
FFPM (Kalrez, compound 4079) A22 9 9 9
NBR (Buna N) A23 9 9 9
Plug
Han 7D (metal, gray) A30 9
Han 8U (instead of Han 7D) A31 9
Sealing screws
-18 NPT, with valve in mat. of process flanges
A40
9 9 9
Cable sockets for M12 connectors (metal) A50 9 9 9
Rating plate inscription (instead of German)
English B11 9 9 9
French B12 9 9 9
Spanish B13 9 9 9
Italian B14 9 9 9
English rating plate (calibration certificate) B21 9 9 9
Pressure units in inH
2
O or psi
Manufacturer's test certificate M
1)
C11 9 9 9
To DIN 55350, Part 18 and to ISO 8402
Acceptance test certificate
2)
To EN 10 204-3.1
C12 9 9 9
Factory certificate
To EN 10 204-2.2
C14 9 9 9
"Functional Safety (SIL)" certificate C20 9
Setting of upper limit of output signal to
22.0 mA
D05 9
Manufacturer's declaration acc. to NACE D07 9 9 9
(only together with seal diaphragm made of
Hastelloy and stainless steel)
Type of protection IP68
(not together with 7D/
Han 8U plug, cable gland Pg 13.5)
D12 9 9 9
Digital indicator alongside the input keys D27 9 9 9
(only together with the devices 7MF4433-
. .. .2-. A.6 or -.A.7-Z, Y21 or Y22 + Y01)
Process flange screws made of Monel
(max. nominal pressure PN20)
D34 9 9 9
Supplied with oval flange set D37 9 9 9
(2 items), PTFE packings and screws in
thread of process flanges
Use in or on zone 1D/2D E01 9 9 9
Use on zone 0 E02 9 9 9
TV approval to AD/TRD E06 9
Overfilling safety device for flammable
and non-flammable liquids
(max. PN 32 (MVWP 464 psi), basic device
with type of protection "Intrinsic safety
(EEx ia)", to WHG and VbF, not together with
measuring cell filling "inert liquid")
E08 9 9 9
Oxygen application E10 9 9 9
(max. 160 bar (2320 psi) with oxygen
measurement and inert liquid)
INMETRO (Brazil)
E25 9 9 9
Explosion-proof "Intrinsic safety" to NEPSI
(China)
E55 9 9 9
Explosion protection "Explosion-proof" to
NEPSI (China)
(only for transmitter 7MF4...-.....-.D..)
E56 9 9 9
Explosion-proof "Zone 2" to NEPSI (China) E57 9 9 9
(only for transmitter 7MF4...-.....-.E..)
Interchanging of process connection side H01 9 9 9
Vent on side for gas measurements H02 9 9 9
Stainless steel process flanges for vertical
differential pressure lines
(not together with K01, K02 and K04)
3)
H03 9 9 9
Process flange
Hastelloy K01 9 9 9
Monel K02 9 9 9
Stainless steel with PVDF insert
max. PN 10 (MWP 145 psi),
max. temperature of medium 90 C (194 F)
K04 9 9 9
For -14 NPT inner process connection on
the side in the middle of the process flange,
vent valve not possible
9 = available
1)
2)
3)
Not suitable for connection of remote seal
Further designs
Add "-Z" to Order No. and
specify Order code.
HART PA FF
ITEM: 1120,1340, 1355

DS III series
2/104
Siemens FI 01 2007
2
Additional data
code.
HART PA FF
Measuring range to be set
With linear characteristic (max. 5 digits):
Y01 9
With square-rooted characteristic (max. 5
digits):
Y02 9
Measuring point number (TAG No.) Y15 9 9 9
Max. 16 char., specify in plain text: Y15: .......
Measuring point text Y16 9 9 9
Entry of HART address (TAG) Y17 9
Setting of pressure indicator in pressure
units
Specify in plain text (standard setting: mA):
Y21: mbar, bar, kPa, MPa, psi, ...
Y21 9 9 9
Note:
The following pressure units can be selected:
bar, mbar, mm H
2
O
*)
, inH
2
O
*)
, ftH
2
O
*)
,
mmHG, inHG, psi, Pa, kPa, MPa, g/cm
2
,
kg/cm
2
, Torr, ATM oder %
*) ref. temperature 20 C
Setting of pressure indicator in
non-pressure units
Y22
1)
+
Y01 or
Y02
1)
Not together with over-filling safety device for flammable and
non-flammable liquids (Order code "E08")
9
Y22: ..... up to ..... l/min, m
3
/h, m, USgpm, ...
(specification of measuring range in pressure
units "Y01" or "Y02" is essential, unit with
max. 5 characters)
Preset bus address
Specify in plain text: Y25: .....................
Y25 9
Only "Y01", "Y21", "Y22", "Y25" and "D05" can be factory preset
9 = available
ITEM: 1120,1340, 1355

ITEM 1120, 1340, 1355
A5E00047092D-06 GN: 30060_DuoDrDif
Automation and Drives (A&D)
Sensors and Communication
Process Sensors
76181 KARLSRUHE
GERMANY
SITRANS P, DS III series
with HART communication

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A5E00047092-06
@1PA5E00047092@
A5E00047092
ITEM 1120, 1340, 1355
UNIT IS beING INSTalled where heavy coNdeNSaTIoN IS expecTed,
verTIcal moUNTING (preSSUre coNNecTIoN dowN) IS reqUIred. do
NoT moUNT IN ambIeNT TemperaTUreS exceedING pUblIShed lImITS.
c o n t r o l s may b e mo u n t e d a n d o p e r a t e d i n a ny
position. They may be surface mounted via the two mounting ears on
either side of the enclosure, or directly to a rigid pipe by using the pres-
sure connection. low pressure and differential pressure units, models
520-535, 540-543, 544-548, are also available with an optional
surface mounting bracket. Should the control be installed where con-
densation is expected, vertical mounting is recommended as a means of
keeping water away from switch terminals.
Never use the enclosure for leverage to hand tighten the pressure con-
nection. always use a wrench to tighten the pressure connection to the
pipe.To prevent damaging the pressure sensor, use a back-up wrench
to hold the hex nut in place when surface mounting.
on models supplied with an external manual reset button, be sure to
leave sufficient finger space over the reset button for the operator to
reset the control.
WIRIng
dIScoNNecT all SUpply cIrcUITS before wIrING.

elecTrIcal raTINGS STaTed IN lITeraTUre aNd oN
NameplaTeS ShoUld Never be exceeded. overload
oN a SwITch caN caUSe faIlUre oN The fIrST cycle.

wIre UNITS accordING To NaTIoNal aNd local elecTrIcal
codeS. maxImUm recommeNded wIre SIze IS 14 awG.
remove the two screws retaining the cover and cover gasket. a 1/2 NpT
conduit connection is provided on the left hand side of the enclosure.
Two cast-in knockouts for the 1/2 conduit are located on the side and
back of the enclosure. These can easily be knocked out by placing
the blade of a screwdriver in the groove and tapping sharply with a
hammer. The t hr ee swi t ch t er mi nal s ar e cl ear l y l abel ed
common, nor mal l y open and nor mal l y cl osed. for
optional switches supplied with leadwires, the following color
coding applies:
gEnERAL
before INSTallING, checK The SeNSor model SelecTed
for compaTIbIlITy To The proceSS medIa IN coNTacT wITh
The SeNSor aNd weTTed parTS.
The h100 and h100K differential pressure switches are activated when
a bellows, diaphragm or piston sensor responds to a pressure change.
This response, at a pre-determined set point, actuates a single snap-
acting switch, converting the pressure signal into an electrical signal.
control set point may be varied by turning the internal adjustment hex.
(See adjustment -parT II).
proof preSSUre* lImITS STaTed IN The lITeraTUre aNd oN
NameplaTeS mUST Never be exceeded, eveN by SUrGeS IN
The SySTem. occaSIoNal operaTIoN of UNIT Up To proof
preSSUre IS accepTable (e.G., STarT-Up, TeSTING). coNTINUoUS op-
eraTIoN ShoUld NoT exceed The deSIGNaTed over raNGe preS-
SUre.
*Proof Pressure
The maximum pressure to which a pressure sensor may be occasionally
subjected, which causes no permanent damage (e.g., start-up, testing).
The unit may require re-gapping.
These ProducTs do noT have any field rePlaceable
ParTs.
please refer to product bulletin for product specifications. product bul-
letin may be found at www.ueonline.com.

Tools needed
adjustable wrench
Screwdriver
hammer (for alternate wire knockouts)
MounTIng
INSTall UNIT where ShocK, vIbraTIoN aNd TemperaTUre
flUcTUaTIoNS are mINImal. orIeNT UNIT So ThaT moIS-
TUre IS preveNTed from eNTerING The eNcloSUre. If
100 Series
Type H100
(Pressure Switch)

Type H100K
(Differential Pressure)
IMP100-08
Please read all instructional literature carefully and thoroughly before starting. Refer to the final page for the listing of Recommended
Practices, Liabilities and Warranties.
Part I - Installation
UNI TED ELECTRI C
CONTROLS
Installation and Maintenance
Instructions
iMP100-08
ITEM 1350
iMP100-08
Models Flats Approx. gap
171-174 2-2 1/2 .0085 to .0105
183-194 1-1 1/2 .004 to .006
483-494 1-1 1/2 .004 to .006
358-376 5-6 .020 to .025
700-706 3 1/2 - 4 .014 to .017
521-525 2-2 1/2 .0085 to .0105
15737 5-6 .020 to .025
531-535 2-2 1/2 .0085 to .0105
540-548 2-2 1/2 .0085 to .0105
560-567 1-1 1/2 .004 to .006
15623 5-6 .020 to .025
15731-15736 5-6 .020 to .025
Manual DPDT
Reset
(option 1530) (option 1010)
SPDT SWT1 SWT2
common violet violet yellow
Normally open blue blue orange
Normally closed black black red
a grounding screw and clamp (cast in symbol) is provided which meets
a 35 lb. pull test. Keep the wire as short as possible to prevent inter-
face with the plunger and the optional adjustable differential switch
wheel, if applicable.
Tools needed
5/8 open end wrench
1/4 wrench
3/16 wrench
Some modelS have a Two- pI ece, adj USTable
plUNGer. ThIS feaTUre IS characTerIzed by a 3/16 hex
head Screw INSTalled IN The 1/4 hex plUNGer. The
leNGTh of ThIS aSSembly IS adjUSTed aT oUr facTory
aNd IS crITIcal To The fUNcTIoN of The coNTrol.
H100 and H100K
remove pressure switch cover. loosen phillips screw adjustment lock.
adjust set point by turning 5/8 hex adjustment screw clockwise (left) to
raise set point, or counter clockwise (right) to lower set point. Tension
on adjustment screw can be increased by tightening adjustment lock
onto it. (See diagram 1). controls include uncalibrated reference scales
for high, low or mid range settings.
Adjustable Deadband Models
model 15623, 15731-15737, and control types with option code 1519
incorporate a snap switch with internal adjustment wheel. Turning this
wheel raises or lowers the pressure rise set point. The fall set point
remains constant. consult factory for additional information.
Manual Reset Button
control types with option code 1530 incorporate a snap switch which
when actuated, remains actuated until the pressure drops sufficiently
to allow the reset button (located on top of the control) to be manually
depressed to reset the switch.
gapping
1) loosen adjustment lock.
2) Turn 5/8 hex adjustment screw clockwise (left), to approximately
mid range. This puts a load on the sensor and exposes the plunger
flats. Using a 1/4 wrench on the plunger and a 3/16 wrench on the
plunger hex screw, turn hex screw counter-clockwise (right) from plung-
er until switch actuates. If switch is already actuated, turn plunger hex
screw clockwise (left), until switch deactuates. Turn hex screw clock-
wise (left) from this point. (See chart 1 for flats and approximate Gap.)
3) check set point per above.
4) connect wires and replace cover securely.
Part II - Adjustments
Diagram 1
Chart 1
- DO NOT
ADJUST
Set-point
ITEM 1350
iMP100-08
Models 171-174,
471-474
Models 183-186,
483-486
Models 188-194.
488-494
Dimensions
Dimensional drawings for all models may be found at www.ueonline.com.
Models 218-376,
610-706, 15623, 15731-15736
Models 520-525 Models 530-535, 15737
A
2.34
(59.4mm)
1/2 NPT
CONDUIT
4.22
(107.2mm)
1.63
(41.4mm)
4" WITH COVER
(101.6mm)
CLEARANCE FOR
1/4 (6.35mm) SCREW
2 MT'G HOLES
.895 (22.7mm) DIA.
KNOCK-OUT 2 PLACES
2.75
(69.9mm)
KNOCK
OUT
Dimension A
Models Inches mm NPT
Pressure
171-174 7.63 193.8 1/2
183-186, 484-486 7.56 192.0 1/2
188-189, 488-489 6.63 168.4 1/2
190-194, 490-494 6.63 168.4 1/2
218 6.56 166.6 1/4
270-274 7.00 177.8 1/4
358-376 7.00 177.8 1/4
520-525, 15737 8.44 214.4 1/2
530-535 8.00 203.2 1/2
560-564 6.63 168.4 2 Sanitary Fitting
565-567 6.63 168.4 1-1/2 Sanitary Fitting
610-616, 680 7.00 177.8 1/4
701-706, 15623,
15731-15736
6.63 168.4 1/4
Differential Pressure
540-543 8.47 215.1 1/8
544-548 8.53 216.7 1/8
Pressure Connections
ITEM 1350
iMP100-08
cp120810000
Model 540-543
Models 544-548
Models 560-564
Models 565-567
U NI T E D E L E C T R I C
C ONT R OL S
180 dexter ave. p.o. box 9143, watertown, ma 02472-9143 USa
617 926-1000 fax 617 926-2568
www.ueonline.com
RECOMMENDED PRACTICES AND WARNINGS
United Electric Controls Company recommends careful consideration of the fol-
lowing factors when specifying and installing UE pressure and temperature units.
Before installing a unit, the Installation and Maintenance instructions provided
with unit must be read and understood.
Toavoiddamagingunit,proofpressureandmaximumtemperaturelimitsstat-
edinliteratureandonnameplatesmustneverbeexceeded,evenbysurgesin
thesystem.Operationoftheunituptomaximumpressureortemperatureis
acceptable on a limited basis (e.g., start-up, testing) but continuous operation
must be restricted to the designated adjustable range. Excessive cycling at
maximumpressureortemperaturelimitscouldreducesensorlife.
Aback-upunitisnecessaryforapplicationswheredamagetoaprimaryunit
couldendangerlife,limborproperty.Ahighorlowlimitswitchisnecessary
for applications where a dangerous runaway condition could result.
The adjustable range must be selected so that incorrect, inadvertent or
malicious setting at any range point cannot result in an unsafe system con-
dition.
Installunitwhereshock,vibrationandambienttemperaturefluctuationswill
not damage unit or affect operation. When applicable, orient unit so that
moisture does not enter the enclosure via the electrical connection. When
appropriate, this entry point should be sealed to prevent moisture entry.
Unitmustnotbealteredormodifiedaftershipment.ConsultUEifmodifica-
tion is necessary.
Monitor operation to observe warning signs of possible damage to unit,
suchasdriftinsetpointorfaultydisplay.Checkunitimmediately.
Preventativemaintenanceandperiodictestingisnecessaryforcriticalappli-
cations where damage could endanger property or personnel.
Electricalratingsstatedinliteratureandonnameplatemustnotbeexceed-
ed. Overload on a switch can cause damage, even on the first cycle. Wire
unit according to local and national electrical codes, using wire size recom-
mended in installation sheet.
Donotmountunitinambienttemp.exceedingpublishedlimits.
LIMITED WARRANTY
Seller warrants that the product hereby purchased is, upon delivery, free from
defectsinmaterialandworkmanshipandthatanysuchproductwhichisfoundto
bedefectiveinsuchworkmanshipormaterialwillberepairedorreplacedbySeller
(Ex-works, Factory, Watertown, Massachusetts. INCOTERMS); provided, however,
that this warranty applies only to equipment found to be so defective within a
period of 36 months from the date of manufacture by the Seller. Seller shall not be
obligatedunderthiswarrantyforallegeddefectswhichexaminationdisclosesare
due to tampering, misuse, neglect, improper storage, and in any case where prod-
ucts are disassembled by anyone other than authorized Sellers representatives.
EXCEPT FOR THE LIMITED WARRANTY OF REPAIR AND REPLACEMENT STATED
ABOVE, SELLER DISCLAIMS ALL WARRANTIES WHATSOEVER WITH RESPECT TO
THE PRODUCT, INCLUDING ALL IMPLIED WARRANTIES OF MERCHANTABILITY
ORFITNESSFORANYPARTICULARPURPOSE.
LIMITATION OF SELLERS LIAbILITY
SELLERSLIABILITYTOBUYERFORANYLOSSORCLAIM,INCLUDINGLIABILITY
INCURRED IN CONNECTION WITH (I) BREACH OF ANY WARRANTY WHATSO-
EVER,EXPRESSEDORIMPLIED,(II)ABREACHOFCONTRACT,(III)ANEGLIGENT
ACTORACTS(ORNEGLIGENTFAILURETOACT)COMMITTEDBYSELLER,OR(IV)
AN ACT FOR WHICH STRICT LIABILITY WILL BE INPUTTED TO SELLER, IS LIM-
ITEDTOTHELIMITEDWARRANTYOFREPAIRAND/ORREPLACEMENTASSO
STATEDINOURWARRANTYOFPRODUCT.INNOEVENTSHALLTHESELLERBE
LIABLEFORANYSPECIAL,INDIRECT,CONSEqUENTIALOROTHERDAMAGESOF
ALIkEGENERALNATURE,INCLUDING,WITHOUTLIMITATION,LOSSOFPROFITS
OR PRODUCTION, OR LOSS OR EXPENSES OF ANY NATURE INCURRED BY THE
BUYERORANYTHIRDPARTY.
UE specifications subject to change without notice.
ITEM 1350
100 Seri es
1
0
0

S
e
r
i
e
s
6 w w w . u e o n l i n e . c o m 1 0 0 - B - 0 6
model adjustable set Point range Deadband Over range Proof
Low end of range on fall; Pressure* Pressure**
High end of range on rise
psi bar (unless noted) psi bar (unless noted) psi bar psi bar
type h100
1.5 sanitary welded 316L stainless steel diaphragm and pressure connection. Mates with Tri-Clamp ftting systems (not UE supplied)
565 5 to 30 0,3 to 2,1 1 to 5 68,9 mbar to 0,3 bar 1000 68,9 1500 103,4
567 15 to 300 1,0 to 20,7 3 to 22 0,2 to 1,5 1000 68,9 1500 103,4
Buna-N diaphragm and O-ring with nickel-plated brass 1/4 NPT (female) pressure connection; Option M540 Viton diaphragm and O-ring
available for models 701-705
701 1.5 to 30 103,4 mbar to 2,1 bar 1 to 2 68,9 mbar to 0,1 bar 500 34,5 600 41,4
704 15 to 500 1,0 to 34,5 2 to 8 0,1 to 0,6 1500 103,4 2500 172,4
705 30 to 1000 2,1 to 68,9 3 to 20 0,2 to 1,4 1500 103,4 2500 172,4
706 100 to 1700 6,9 to 117,2 10 to 30 0,7 to 2,1 2000 103,4 2500 172,4
psi bar psi bar psi bar psi bar
Viton diaphragm and O-Ring with 316 stainless steel 1/4 NPT (female) pressure connection (includes adjustable deadband switch)
15623 20 to 200 1,4 to 13,8 12 to 26 0,8 to 1,8 500 34,5 1000 68,9
model adjustable set adjustable Deadband Over range Proof
Point range Pressure* Pressure**
Low End Mid Range High End
psi bar psi bar psi bar psi bar psi bar psi bar
Buna N diaphragm and O-Ring nickel-plated brass 1/4 NPT (female) pressure connection; includes adjustable deadband microswitch
15731 3 to 30 0,2 to 2,1 1.5 to 4 0,1 to 0,3 2 to 4.5 0,1 to 0,3 2.5 to 5 0,2 to 0,3 500 34,5 1000 68,9
15732 5 to 100 0,3 to 6,9 3 to 6 0,2 to 0,4 4 to 7.5 0,3 to 0,5 5 to 9 0,3 to 0,6 500 34,5 1000 68,9
15733 9 to 300 0,6 to 27,0 4 to 11 0,3 to 0,8 5 to 13 0,3 to 0,9 5 to 16 0,3 to 1,1 500 34,5 1000 68,9
model adjustable set Point range Deadband Over range Proof
Lower 75% Top 25% Pressure* Pressure**
range span range span
psi bar psi bar psi bar psi bar psi bar

Welded 316 stainless steel diaphragm and 1/2 NPT (female) pressure connection, large 0.72 orifce for clean-out purposes (NACE MR-0175 compliant)
190 5 to 30 0,3 to 2,1 1 to 3 0,1 to 0,2 6 max 0,4 1500 103,4 2500 172,4
191 10 to 100 0,7 to 6,9 1 to 8 0,1 to 0,6 15 max 1,0 1500 103,4 2500 172,4
192 15 to 300 1,0 to 20,7 3 to 18 0,2 to 1,2 25 max 1,7 1500 103,4 2500 172,4
193 20 to 500 1,4 to 34,5 4 to 30 0,3 to 2,1 45 max 3,1 1500 103,4 2500 172,4
194 80 to 1700 5,5 to 117,2 5 to 120 0,3 to 8,3 150 max 10,3 2000 137,9 2500 172,4
Tri-Clamp is a registered trademark of Tri-Clover Inc.
application note: The use of metallic diaphragms where higher pressure shock or heavy cycling is expected should be avoided. Models 171-174 should not be used where system or start-up vacuum
pressure might exceed 26 Hg Vac (-0.9 bar).
pressure model chart
ITEM 1350
100 Seri es
1
0
0

S
e
r
i
e
s
10 w w w . u e o n l i n e . c o m 1 0 0 - B - 0 6
how to order
building a part number
type deScription
preSSure Type H100 - One SPDT output; epoxy coated enclosure; internal adjustment with High-Low reference scale
differential preSSure Type H100K- One SPDT output; epoxy coated enclosure; internal adjustment with High-Low reference scale
temperature Type B100 - Immersion stem; one SPDT output; internal adjustment with reference dial
Type C100 - Immersion stem; one SPDT output; internal adjustment with no reference
Type E100 - Bulb and capillary; one SPDT output; internal adjustment with reference dial
Type F100 - Bulb and capillary; one SPDT output; internal adjustment with no reference
Switch optionS*
0140 Gold contacts, 1A 125 VAC resistive. NOT AVAILABLE MODELS 13545, 13546, 15623, 15731-15737
0500 Close deadband, 5A 125/250 VAC resistive.
NOT AVAILABLE MODELS 520-535, 13545, 13546, 15623, 15731-15737
1010 DPDT switch, 10A 125/250 VAC resistive; deadband and minimum set point will increase.
NOT AVAILABLE TEMPERATURE VERSIONS, TyPE H100K OR MODELS 171-194, 483-567, 680, 15623, AND 15731-15737
1070 10 A 125 VDC resistive; deadband and minimum set point will increase.
NOT AVAILABLE MODELS 171-194, 483-535, 560-567, 13545, 13546, 15623, 15731-15737
1519 Adjustable deadband, 15 A 125/250/480 VAC resistive; adjustment wheel changes rise setting only. If adjustment on
fall setting is required, use primary adjustment. NOT AVAILABLE TyPES B100, E100 OR MODELS 171-194, 483-494,
560-567, 610-616, 51623, 15731-15737
1530 External manual reset, 15 A 125/250/480 VAC resistive; latches on rise, only.
NOT AVAILABLE MODELS 13545, 13546, 15623, 15731-15737
1535 High ambient, 15 A 125/250 VAC resistive; temperatures up to 250F (121.1C).
NOT AVAILABLE MODELS 520-535, 13545, 13546, 15623, 15731-15737
1537 Vapor sealed switch, 15 A 125/250 VAC resistive.
NOT AVAILABLE MODELS 523, 533, 13545, 13546, 15623, 15731-15737
2000 20 A 125/250/480 VAC resistive.
NOT AVAILABLE TyPE H100K OR MODELS 520-535, 13545, 13546, 15623, 15731-15737
3000 30 A 125/250/277 VAC resistive.
NOT AVAILABLE TyPE H100K OR MODELS 171-194, 483-567, 680, 13545, 13546, 15623, 15731-15737
* All switches have limited DC capabilities. Consult factory for details.
Select a type
Refer to the Type section below.
Determine type number based on switch
output, enclosure, adjustment and
reference.
Fill in the type portion of your part
number with the corresponding number.
Select a model
Refer to the Model Charts.
Determine model based on adjustable
range, deadband and proof pressure.
Fill in the model portion of your part
Select an option
Refer to the Options section.
Determine option number based on
switch output, optional materials or
other product enhancements.
Fill in the option portion of your part
Leave option portion blank if no
options are needed.
FOR MULTIPLE OPTIONS: Call United
Electric Controls.
ITEM 1350
100 S e r i e s
1 0 0 - B - 0 6 w w w . u e o n l i n e . c o m 11
other optionS
M020 Red status light, 115 VAC only. NOT AVAILABLE MODELS 13545, 13546, 15623, 15731-15737
M201 Factory set one switch; specify increasing or decreasing pressure or temperature and setpoint
M277 Range indicated on nameplate in kPa or MPa, factory selected. NOT AVAILABLE ON TEMPERATURE VERSIONS
M278 Range indicated on nameplate in Kg/cm
2
. NOT AVAILABLE ON TEMPERATURE VERSIONS
M405 Intrinsic safety compliance for European Union per ATEX standards
M406 Intrinsic Safety compliance for Russia per Gosgortechnadzor standards.
M444 Paper ID tag
M446 Stainless steel ID tag & wire attachment
M449 Mounting bracket kit. Required for models 520-535, 15737 when surface mounting. Use kit part number
6361-704 for other models
M504 316L stainless steel immersion stem. AVAILABLE TEMPERATURE MODELS 120, 121 ONLy
M540 Viton construction (deadband and low end range may increase slightly); wetted parts include Viton
diaphragm and O-ring plus stainless steel pressure connection. AVAILABLE ON MODELS 610-616 (O-ring only),
701-705 (Viton diaphragm & O-ring, stainless steel pressure connection), AND 540-548 (sealing diaphragms
only, main diaphragm remains Kapton, pressure connections remain aluminum)
M550 Oxygen service cleaning; internal construction may change. NOT AVAILABLE ON PRESSURE MODEL 706
M914 1/2 NPT (female) stainless steel pressure connection. AVAILABLE MODELS 358-376, 610-616
M921 Brass pressure connection. AVAILABLE MODELS 610-616
6361-704 Surface and Pipe Mounting Hardware (required for model 520-535, 15737, 540-548 when surface mounting)
SD6286-51 Watertight conduit ftting; connects 7/8 hole to 1/2 NPT (female) ftting
optional SenSor material for wc rangeS. AVAILABLE MODELS 520-525
XC001 Aluminum pressure connection, Viton diaphragm, Viton O-ring
XC002 Aluminum pressure connection, Kapton diaphragm, Buna N O-ring
XC003 Aluminum pressure connection, Kapton diaphragm, Viton O-ring
XC004 316L Stainless steel pressure connection, 316L stainless steel diaphragm, Viton O-ring.
(Over range pressure is limited to 100 psi)
XC005 316L Stainless steel pressure connection, Viton diaphragm, Viton O-ring
XC006 316L Stainless steel pressure connection, Kapton diaphragm, Viton O-ring
XC007 316L Stainless steel pressure connection, Tefon diaphragm, Viton O-ring
optional SenSor materialS for corroSiVe media. AVAILABLE MODELS 183-189, 483-489
XD002 Hastelloy C diaphragm
XD003 Monel diaphragm
XP112 Hastelloy C pressure connection
XP113 Monel pressure connection
XR211 Kalrez O-ring
XR212 Silicone O-ring. NOT AVAILABLE MODELS 188-189, 488-489
XR213 Ethylene propylene O-ring
XR214 Afas O-ring
optional fluSh mount flangeS. AVAILABLE MODELS 560-567
Other fanges (150# and 300#) available, please consult UE. Flanges conform to ANSI B16.5. Maximum pressure is limited by fange rating.
F196 Flush mounted fange, 150#, 1 lap joint, raised face AVAILABLE MODELS 565-567 ONLy
note: No options are available on Heat Trace and Freeze Protection models 13546 and 13545 or pump switch model 15623 except M201, M444 and M446.
ITEM 1350
ITEM 1370
ITEM 1375 Document Name: 4607T-1375 Rev 0
ITEM 1375
ITEM 1375
Sensors and Cabling Accessories

XS Tubular Inductive Sensors

18mm Diameter, AC/DC; Universal Standard Length

1997 Schneider Electric All Rights Reserved

190

4/00

Minimum mounting clearances

(mm/inches)
XS1/XS3 Shielded

e: 10/.39 e: 60/2.36 e: 15/.59 D: 18/.71, H: 0/0

XS2/XS4 Non-shielded

e: 16/.63 e: 96/3.78 e: 24/.94 D: 54/2.13, H: 16/.63
Side by side
e
Face to face
e
Facing a metal object
e
Mounting in a metal support
D
H

Features

360LED indicators
Extended temperature range
Extended supply voltage range
IP68 AC/DC power supply
Patented plastic mounting bracket
Connector options
Extensive protective circuitry
Metal locknuts for metal or plastic mounting nuts for plastic housings included
Normally closed (N.C.) output available on versions marked

a

UL Listed, CSA Certied and CE Mark

a

To order a normally closed (N.C.) version change the

A

to

B

, example: XS1M12P

A

260 to XS1M12P

B

260.

See next page under specications for LED function.

Nominal
Sensing
Distance
AC or
AC/DC
Output
Mode
Voltage Range
Max
Operating Frequencies
SCP
Indicator
LED

Mating
Connector
Style (see p. 297)
Catalog
Number AC DC

Nickel brass case

Shielded, 2m (6.6') cable

5 mm AC/DC N.O.

a

20-264 Vac/dc 25 Hz 3000 Hz no A

XS1M18MA230

5 mm AC/DC N.O.

a

20-264 Vac/dc 25 Hz 3000 Hz yes C

XS1M18MA250
Shielded, connector - micro style AC

5 mm AC/DC N.O.

a

20-264 Vac/dc 25 Hz 3000 Hz no B 13,14

XS1M18MA230K

5 mm AC/DC N.O.

a

20-264 Vac/dc 25 Hz 3000 Hz yes B 13,14

XS1M18MA250K
Shielded, connector - mini style

5 mm AC/DC N.O.

a 20-264 Vac/dc 25 Hz 3000 Hz no B 18, 20 XS1M18MA230A
5 mm AC/DC N.O.a 20-264 Vac/dc 25 Hz 3000 Hz yes C 18, 20 XS1M18MA250A
Shielded, screw terminal connection
5 mm AC/DC N.O.a 20-264 Vac/dc 25 Hz 3000 Hz no B XS1M18MA230B
Non-shielded, 2m (6.6') cable
8 mm AC/DC N.O.a 20-264 Vac/dc 25 Hz 2000 Hz no A XS2M18MA230
8 mm AC/DC N.O.a 20-264 Vac/dc 25 Hz 2000 Hz yes C XS2M18MA250
Non-shielded, connector - micro style AC
8 mm AC/DC N.O.a 20-264 Vac/dc 25 Hz 2000 Hz no B 13,14 XS2M18MA230K
8 mm AC/DC N.O.a 20-264 Vac/dc 25 Hz 2000 Hz yes B 13,14 XS2M18MA250K
Non-shielded, connector - mini style
8 mm AC/DC N.O.a 20-264 Vac/dc 25 Hz 2000 Hz no B 18 XS2M18MA230A
8 mm AC/DC N.O.a 20-264 Vac/dc 25 Hz 2000 Hz yes C 18 XS2M18MA250A
Plastic case
Shielded, 2m (6.6') cable
5 mm AC/DC N.O.a 20-264 Vac/dc 25 Hz 3000 Hz no A XS3P18MA230
Shielded, connector - micro style
5 mm AC/DC N.O.a 20-264 Vac/dc 25 Hz 3000 Hz no B 13,14 XS3P18MA230K
Shielded, connector - mini style
5 mm AC/DC N.O.a 20-264 Vac/dc 25 Hz 3000 Hz no B 17,18,19,20 XS3P18MA230A
Non-shielded, 2m (6.6') cable
8 mm AC/DC N.O.a 20-264 Vac/dc 25 Hz 2000 Hz no A XS4P18MA230
Non-shielded, connector - micro style
8 mm AC/DC N.O.a 20-264 Vac/dc 25 Hz 2000 Hz no A 13,14 XS4P18MA230K
Non-shielded, connector - mini style
8 mm AC/DC N.O.a 20-264 Vac/dc 25 Hz 2000 Hz no A 18,20 XS4P18MA230A
Shielded, screw terminal connection
8 mm AC/DC N.O.a 20-264 Vac/dc 25 Hz 2000 Hz no B XS4P18MA230B
2
.
3
6
6
0
2
.
0
2
5
1
.
5
LED
2
.
9
5
7
5
2
.
1
6
5
5
LED
2
.
0
4
5
2
.
3
1
8
1
.
7
1
4
3
.
5
LED
2
.
4
4
6
2
.
3
1
8
1
.
7
1
4
3
.
5
LED
2
.
6
3
6
7
.
3
1
8
1
.
8
5
4
7
LED
2
.
8
9
7
3
.
5 2
.
0
4
5
2
LED
2
.
7
5
7
0
2
.
0
2
5
1
.
5
LED
2
.
3
6
6
0
2
.
0
2
5
1
.
5
LED
XS1M18
XS1M18K
XS1M18A
XS2M18
XS2M18K
XS2M18A
XS3/XS4P18230
XS3/XS4P18230K
XS3/XS4P18230A
2
.
7
5
7
0
2
.
0
2
5
1
.
5
LED

thread
M18x1
ITEM 1395
INSTALLATION
Assemble the adapter nut into the well and tighten
securely. (See Figure 3.)
Before installing the Bimetal Dial Thermometer into
the adapter and well, coat the lower 3 section of the
thermometer with a layer of heat conducting medium.
This will improve the temperature response of the
thermometer.
The metal liner is then slipped over the end of the
thermometer stem and a coating of heat conducting
medium is applied to the outside wall of the liner.
The thermometer and the liner are then inserted into
the well and tightened in position. Do not tighten more
than is necessary to prevent the thermometer from
turning.
Where service temperatures exceed 350F the heat
conducting medium may smoke when first subjected
to a high temperature. This is caused by the vehicle, in
the heat conducting medium, vaporizing and leaving
the dry solids behind. This should not be cause for
alarm. The dry solids will act equally well as a heat
conducting medium for temperatures up to 1000F.
The Type 91 Series Adapter Sets were designed to
provide a simple means of installing a bimetal dial
thermometer into an existing industrial glass ther-
mometer well.
The adapter set consists of:
1. A metal liner and spring assembly.
2. An adapter nut.
3. A small supply of heat conducting medium.
METHOD OF SELECTING THE SET
The Adapter Sets are available in four different sizes,
to cover various depths of wells. The Selection Chart
shows the Adapter Set number and the Bimetal Dial
Thermometer stem length to use for any well depth
from 3
5
8 up to 25
1
8.
To select the proper Adapter Set and Bimetal Dial
Thermometer stem length, measure first the well
depth by inserting a pencil, or any small diameter rod
or stiff wire until it reaches the bottom. (See Figure 1.)
Be sure the rod does not hang up on any shoulder
inside the well. Using your thumb as an index, with-
draw the rod and measure the distance from the end
of the rod to the index point. (See Figure 2.)
Then use the chart to select the Adapter Set and the
Bimetal Dial Thermometer stem length to fit the well.
Note that one stem length of thermometer covers several
different well depths by using the correct Adapter Set.
For example, a thermometer with a 9 long stem can
be used for well depths between 7
1
8 and 10
1
8, by
choosing the correct Adapter Set.
The liner is tapped with a
5
16 - 18 machine thread so it
can be removed from the well if desired.
Figure 1
Figure 2
WELL
STEM
DEPTH ADAPTER
LENGTH
IN SET NO.
S
INCHES
3
4
91B
4
91A
5
91C
6
91B 6
91A
7
91D
8
91C
9
9
91B
91A
10
WELL
STEM
DEPTH ADAPTER
LENGTH
IN SET NO.
S
INCHES
10
91D
11
91C
12
12
91B
91A
13
91D
14
91C
15
15
91B
91A
16
91D
17
18
91C
18
WELL
STEM
DEPTH ADAPTER
LENGTH
IN SET NO.
S
INCHES
18
91B
18
91A
19
20
21
22
91D
23
91C
24
24
91B
91A
25
Figure 3
SELECTION CHART
Note: If the measured well
depth falls on the dividing line
between two stem lengths
and/or two Adapter Sets choose
the stem and/or Adapter Set
above the line.
INSTALLATION AND MAINTENANCE
INSTRUCTIONS FOR ASHCROFT
TYPE 91 SERIES ADAPTER KIT

2007 Ashcroft Inc., 250 East. Main Street, Stratford, CT 06614-5145, USA Tel: 203-378-8281, Fax: 203-385-0499, www.ashcroft.com
All sales subject to standard terms and conditions of sale. I&M008-10004K-11/05 AMR
ITEM: 1410, 1420, 1430, 1435
CAUTION:
Bimetal Thermometers operating below freezing must
have a perfectly tight case to prevent entrance of moisture
which eventually will condense and freeze inside the stem.
This condition shows up as a failure of the thermometer to
read accurately below 32F or 0C. For this reason it is
important to avoid damage to the glass front while the
stem temperature is at freezing or below. All thermometers
are hermetically sealed in a dry atmosphere at the factory
and require no further maintenance.
CAUTION: Thermowells should be used on all pres-
surized applications, to protect the thermometer
from corrosion or physical damage, and to facilitate
removal of the thermometer without disturbing the
process.
TESTING
Ashcroft Bimetal Dial Thermometers are carefully cali-
brated at the factory and under most operating condi-
tions will retain their accuracy indefinitely. However, as
in the case of all instruments, it is well to make period-
ic checks for accuracy against known standards.
ADJUSTMENT
If it is necessary to make an adjustment to the ther-
mometer proceed as follows:
On thermometers fitted with an External Adjustment
Use a small wrench, small screwdriver or a coin to
turn the slotted hexagon head in the back of the case
until the pointer indicates the proper temperature on
the dial.
MAINTENANCE OF
DIAL THERMOMETERS
Aside from occasional testing, little or no maintenance
is required.
Be sure that the gasketed glass cover is on the case at
all times, as moisture and dirt inside the case will even-
tually cause the thermometer to lose its accuracy. (See
caution note below.)
If the thermometer is used for measuring the tempera-
ture of a material that may harden and build up an
insulating layer on the stem, the thermometer should
be removed from the apparatus occasionally, and the
stem cleaned. Observe this precaution to ensure the
sensitivity of the instrument.
GENERAL
In removing the thermometer out of the packing box,
handle it by the case or case outlet. Avoid handling it by
the stem.
INSTALLATION OF THERMOMETERS
The thermometer should be mounted at any convenient
location where it will be subjected to the average tem-
perature variations to be indicated.
Avoid bending the stem as this will cause misalignment
of the internal parts, resulting in undue frictional errors.
To tighten the thermometer to the apparatus, use a
wrench applied to the hexagon head of the threaded
connection located just outside of the case.
INSTALLATION
Locate the stem so that at least two inches will be sub-
jected to the average temperature to be measured.
Exposing the stem to a temperature in excess of the
highest dial reading should be avoided.
The thermometer is normally provided with a threaded
connection. To tighten the thermometer to the appara-
tus or into the well, use an open-end wrench applied to
the hexagon head of the threaded connection.Turn until
reasonably tight, then tighten still further in the same
manner as a pipe elbow or similar pipe fitting until the
scale is in the desired position for reading. DO NOT
TIGHTEN BY TURNING THE THERMOMETER CASE.
Install the dry type thermometer so that the maximum
case temperature is kept below 200F at all times.
Install the liquid filled type thermometer so that the
maximum case temperature is kept below 150F at all
times.
When a thermometer is equipped with a well, the well
should be installed onto the apparatus first. The stem of
the thermometer should then be coated with a heat
conducting medium (a mixture of glycerin and graphite
or vaseline or any other heavy lubricant may be used),
after which the thermometer stem is inserted, and tight-
ened into the well.
XC2 INSTALLATION
The XC2 variation meets the NSF/ANSI standard 2
(2002E) guidelines for non-exposed applications.
Please refer to the NSF guidelines for certified installa-
tion instructions and approved materials.
INSTALLATION AND MAINTENANCE
INSTRUCTIONS FOR ASHCROFT
BIMETAL DIAL THERMOMETERS

2007 Ashcroft Inc., 250 East. Main Street, Stratford, CT 06614-5145, USA Tel: 203-378-8281, Fax: 203-385-0499, www.ashcroft.com
All sales subject to standard terms and conditions of sale. I&M008-10004K-11/05 AMR
ITEM: 1410, 1420, 1430, 1435
114
a Halliburton company
Overtemperature Limits
Top of Range F
up to 250 100% of span
250/ 550 50% of span
550/ 1000 800F * *

Case Size Stem
Stem Lengths
Temperature Range
Available
S
Dial Code
Style
Connection Code Location Code Length Code
F*
/Div.
Fig. C
/Div.
Fig.
Code
(inches)
Fahrenheit Inter. Celsius Inter.
Plain 40 Rear R 80/120
2 20
50/50 1 10
2 20 Pointed Plain 50 Rear R 2
1
2 025 20/120 20/120 2 20
1
4 NPT 60 Rear R 4 040 30/130 1 10 0/50 1 5
1
2 NPT Union 42
Everyangle E
6 060 0/200 20 0/100 1 10
3 30 EI
1
2 NPT 60 9 090 0/250 2 10/150
2 20
1
2 NPT 60
Rear R 12 120 50/300 0/200
Lower L 15 150 50/400 50 0/300
1
2 NPT Union 42
Everyangle E
18 180 50/550 5 50/450** 5 50
5 50
1
2 NPT 60 24 240 200/700 100/500**
1
2 NPT 60
Rear R 100/800 10 100
Lower L 200/1000**
Select: 30 EI 60 R 040 0/250F XNH
1. Case Size: 3 Code 30
2. Style: Code EI
3. Stem Conn:
1
2 NPT Code 60
4. Stem Location: Rear Code R
5. Stem Length: 4 Code 040
6. Range: Code 0/250F
7. Options: Stainless Steel Tag (see page 33)
Hermetically sealed
External adjustment
Maxivision
dial
1% full-span accuracy
(ASME B40.3 Grade A)
All-welded stainless steel
construction
Silicone on the coil provides
vibration dampening and superior
time response
Heavy-duty glass standard; plastic
or shatterproof glass optional
Limited five-year warranty
SELECTION TABLE
TO ORDER THIS EI SERIES BIMETAL THERMOMETER:
Maximum
Overtemperature
* Dual scale ranges available for all standard F ranges (3
and 5 case only)
** Satisfactory for continuous service up to 800F or 425C.
Can be used for intermittent service from 800 to 1000F,
or 425 to 500C.
Use Ashcroft Duratemp thermometers for ranges above and
below those listed above.
Minimum stem length for these ranges is 4.
Minimum stem length lower connection and Everyangle 4.
Thermowells must be used on all pressure or velocity
applications, to protect the stem of thermometer from
corrosion and physical damage, and to facilitate removal
of the thermometer without disturbing the process.
Maximum ambient temperature 200F (95C).
This series has a hermetic seal
and an external adjustment in the
rear of the case. As with other
Ashcroft
industrial bimetal ther-

mometers, it has a Maxivision
dial
which eliminates parallax by placing
the pointer on the same plane as
the graduations. The connection
locations are rear, lower, and
Everyangle.
The hermetic seal prevents entry

of moisture into the casing, thus
minimizing the possibility of icing or
fogging inside the case. The window
stays clear, and with the Maxivision
dial, precise readings are certain.
Reference Bulletin BM-1
MADE IN U.S.A.
Bimetal Thermometers
Series EI, Grade A (1%)
Consult factory for guidance in product selection
Phone (203) 378-8281, FAX (203) 385-0499 or
visit our web site at www.ashcroft.com
ITEM 1410
114
a Halliburton company
Overtemperature Limits
Top of Range F
up to 250 100% of span
250/ 550 50% of span
550/ 1000 800F * *

Case Size Stem
Stem Lengths
Temperature Range
Available
S
Dial Code
Style
Connection Code Location Code Length Code
F*
/Div.
Fig. C
/Div.
Fig.
Code
(inches)
Fahrenheit Inter. Celsius Inter.
Plain 40 Rear R 80/120
2 20
50/50 1 10
2 20 Pointed Plain 50 Rear R 2
1
2 025 20/120 20/120 2 20
1
4 NPT 60 Rear R 4 040 30/130 1 10 0/50 1 5
1
2 NPT Union 42
Everyangle E
6 060 0/200 20 0/100 1 10
3 30 EI
1
2 NPT 60 9 090 0/250 2 10/150
2 20
1
2 NPT 60
Rear R 12 120 50/300 0/200
Lower L 15 150 50/400 50 0/300
1
2 NPT Union 42
Everyangle E
18 180 50/550 5 50/450** 5 50
5 50
1
2 NPT 60 24 240 200/700 100/500**
1
2 NPT 60
Rear R 100/800 10 100
Lower L 200/1000**
Select: 30 EI 60 R 040 0/250F XNH
1. Case Size: 3 Code 30
2. Style: Code EI
3. Stem Conn:
1
2 NPT Code 60
4. Stem Location: Rear Code R
5. Stem Length: 4 Code 040
6. Range: Code 0/250F
7. Options: Stainless Steel Tag (see page 33)
Hermetically sealed
External adjustment
Maxivision
dial
1% full-span accuracy
(ASME B40.3 Grade A)
All-welded stainless steel
construction
Silicone on the coil provides
vibration dampening and superior
time response
Heavy-duty glass standard; plastic
or shatterproof glass optional
Limited five-year warranty
SELECTION TABLE
TO ORDER THIS EI SERIES BIMETAL THERMOMETER:
Maximum
Overtemperature
* Dual scale ranges available for all standard F ranges (3
and 5 case only)
** Satisfactory for continuous service up to 800F or 425C.
Can be used for intermittent service from 800 to 1000F,
or 425 to 500C.
Use Ashcroft Duratemp thermometers for ranges above and
below those listed above.
Minimum stem length for these ranges is 4.
Minimum stem length lower connection and Everyangle 4.
Thermowells must be used on all pressure or velocity
applications, to protect the stem of thermometer from
corrosion and physical damage, and to facilitate removal
of the thermometer without disturbing the process.
Maximum ambient temperature 200F (95C).
This series has a hermetic seal
and an external adjustment in the
rear of the case. As with other
Ashcroft
industrial bimetal ther-

mometers, it has a Maxivision
dial
which eliminates parallax by placing
the pointer on the same plane as
the graduations. The connection
locations are rear, lower, and
Everyangle.
The hermetic seal prevents entry

of moisture into the casing, thus
minimizing the possibility of icing or
fogging inside the case. The window
stays clear, and with the Maxivision
dial, precise readings are certain.
Reference Bulletin BM-1
MADE IN U.S.A.
Bimetal Thermometers
Series EI, Grade A (1%)
Phone (203) 378-8281, FAX (203) 385-0499 or
ITEM 1420
ITEM 1430
ITEM 1435
PRESSURE GAUGE
INSTALLATION,
OPERATION AND
MAINTENANCE
I&M008-10098-5/02 (250-1353H) 1M AMR 5P1/08
ITEM: 1520, 1540
3
Page
CONTENTS
1.0 Selection and Application
1.1 Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.3 Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.4 Oxidizing media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.5 Pulsation/Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.6 Gauge fills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.7 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.0 Temperature
2.1 Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.2 Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.3 Steam service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.4 Hot or very cold media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.5 Diaphragm seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.6 Autoclaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.0 Installation
3.1 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.2 Gauge reuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.3 Tightening of gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.4 Process isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.5 Surface mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.6 Flush mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4.0 Operation
4.1 Frequency of inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4.2 In-service inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4.3 When to check accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4.4 When to recalibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4.5 Other considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4.6 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
5.0 Gauge Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
6.0 Accuracy: Procedures/Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10
6.1 Calibration - Rotary movement gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
6.2 Calibration - 1009 Duralife
Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

6.3 Positive Pressure Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-15
ITEM: 1520, 1540
4
CONTENTS
7.0 Diaphragm Seals
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
7.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
7.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
7.4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
7.5 Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
8.0 Dampening Devices
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
8.2 Throttle Screws & Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
8.3 Ashcroft Gauge Saver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
8.4 Ashcroft Pulsation Dampener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
8.5 Ashcroft Pressure Snubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
8.6 Campbell Micro-Bean
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
8.7 Ashcroft Needle Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
8.8 Chemiquip
Pressure Limiting Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

9.0 Resources
9.1 Training Videos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
9.2 Pressure Instrument Testing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
9.3 Tools & Tool Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Page
Cover photo courtesy of Johnson/Yokogawa Co.
Campbell Micro-Bean
is a registered trademark of J.A. Campbell Co.

Chemiquip
is a registered trademark of Chemiquip Products Co. Inc.

ITEM: 1520, 1540
1.0 SELECTION & APPLICATION
Users should become familiar with ASME
B40.1 (Gauges Pressure Indicating Dial
Type Elastic Element) before specifying
pressure measuring instruments. That docu-
ment containing valuable information
regarding gauge construction, accuracy, safety,
selection and testing may be ordered from:
ASME International
Three Park Avenue
New York, N.Y. 10016-5990
800-843-2763 (US/Canada)
95-800-843-2763 (Mexico)
973-882-1167 outside North America
Email: infocentral@asme.org
WARNING: To prevent misapplication, pres-
sure gauges should be selected considering
media and ambient operating conditions.
Improper application can be detrimental to the
gauge, causing failure and possible personal
injury, property damage or death. The infor-
mation contained in this manual is offered as
a guide in making the proper selection of a
pressure gauge. Additional information is
available from Ashcroft Inc.
The following is a highlight of some of the more
important considerations:
1.1 Range The range of the instrument
should be approximately twice the maximum
operating pressure. Too low a range may
result in (a) low fatigue life of the elastic ele-
ment due to high operating stress and (b) sus-
ceptibility to overpressure set due to pressure
transients that exceed the normal operating
pressure. Too high a range may yield insuffi-
cient resolution for the application.
1.2 Temperature Refer to page 6 of this
manual for important information concerning
temperature related limitations of pressure
gauges, both dry and liquid filled.
1.3 Media The material of the process sensing
element must be compatible with the process
media. Use of a dia-phragmseal with the gauge
is recommended for process media that (a) are
corrosive to the process sensing element; (b)
contain heavy particulates (slurries) or (c) are
very viscous including those that harden at
room temperature.
1.4 Oxidizing media Gauges for direct use
on oxidizing media should be specially
cleaned. Gauges for oxygen service should be
ordered to variation X6B and will carry the
ASME required dial marking USE NO OIL
in red letters. Gauges for direct use on other
oxidizing media may be ordered to variation
X6W. They will be cleaned but carry no dial
marking. Plus!
gauges or Halocarbon filled

gauge or diaphragm fill is required for use
with oxidizing media; order variation XCF.
1.5 Pulsation/Vibration Pressure pulsation
can be dampened by several mechanisms; the
patented PLUS! Performance gauge will han-
dle the vast majority of applications. One
exception to this is high frequency pulsation
which is difficult to detect. The only indication
may be an upscale zero shift due to movement
wear. These applications should be addressed
with a liquid filled gauge, or in extreme cases,
a remotely mounted liquid filled gauge con-
nected with a length of capillary line. The
small diameter of the capillary provides excel-
lent dampening, but can be plugged. The
Ashcroft 1106 pulsation dampener and 112
snubber are auxiliary devices which dampen
pulsation with less tendency to plug.
1.6 Gauge fills. Once it has been determined
that a liquid filled gauge is in order, the next
step is selecting the type of fill. Glycerin sat-
isfies most applications. While being the least
expensive fill, its usable temperature range is
20/250F. Silicone filled gauges have a
broader service range: 40/250F. Oxidizing
media require the use of Halocarbon, with a
service range of 50/250F. Pointer motion
will be slowed at the low end of the low end of
these temperature ranges.
1.7 Mounting Users should predetermine
how the gauge will be mounted in service:
stem (pipe), wall (surface) or panel (flush).
Ashcroft wall or panel mounting kits should be
ordered with the gauge. See paragraph 3
Installation.
5
ITEM: 1520, 1540
6
2.0 TEMPERATURE
2.1 Ambient Temperature To ensure long
life and accuracy, pressure gauges should
preferably be used at an ambient tempera-
ture between 20 and +150F (30 to +65C). At
very low temperatures, standard gauges may
exhibit slow pointer response. Above 150F, the
accuracy will be affected by approximately
1.5% per 100F. Other than discoloration of the
dial and hardening of the gasketing, non-liq-
uid filled type 1279 (phenolic case) and 1379
(aluminum case) Duragauge
, with standard
glass windows, and Duralife
gauges types
1008 and 1009, can withstand continuous
operating temperatures up to 250F. Liquid
filled gauges can withstand 200F but glycerin
fill and the acrylic window of Duragauge
gauges will tend to yellow. Silicone fill will

have much less tendency to yellow. Low pres-
sure, liquid filled types 1008 and 1009 gauges
may have some downscale errors caused by
liquid fill expansion. This can be alleviated by
burping the gauge by gently pushing the top
fill plug to one side to admit air to the case.
Although the gauge may be destroyed and cal-
ibration lost, gauges can withstand short
times at the following temperatures: gauges
with all welded pressure boundary joints,
750F (400C); gauges with silver brazed joints,
450F (232C) and gauges with soft soldered
joints, 250F (121C). For expected long term
service below 20F (30C) Duragauge
and
4
1
2 1009 gauges should be hermetically
sealed and specially lubricated; add H to the
product code for hermetic sealing. Add varia-
tion XVY for special lubricant. Standard
Duralife gauges may be used to 50F (45C)
without modification.
2.2 Accuracy Heat and cold affect accuracy
of indication. A general rule of thumb for dry
gauges is 0.5% of full scale change for every
40F change from75F. Double that allowance
for gauges with hermetically sealed or liquid
filled cases, except for Duragauge
gauges
where no extra allowance is required due to
the elastomeric, compensating back. Above
250F there may exist very significant errors
in indication.
2.3 Steam service In order to prevent live
steam from entering the Bourdon tube, a
siphon filled with water should be installed
between the gauge and the process line.
Siphons can be supplied with ratings up to
4,000 psi. If freezing of the condensate in the
loop of the siphon is a possibility, a diaphragm
seal should be used to isolate the gauge from
the process steam. Siphons should also be
used whenever condensing, hot vapors (not
just steam) are present. Super heated steam
should have enough piping or capillary line
ahead of the siphon to maintain liquid water
in the siphon loop.
2.4 Hot or very cold media A five foot capil-
lary line assembly will bring most hot or cold
process media within the recommended gauge
ambient temperature range. For media above
750F (400C) the customer should use his own
small diameter piping to avoid possible corro-
sion of the stainless steel. The five foot capillary
will protect the gauges used on the common
cryogenic (less than 300F (200C) gases, liquid
argon, nitrogen, and oxygen. The capillary and
gauge must be cleaned for oxygen service. The
media must not be corrosive to stainless steel,
and must not plug the small bore of the capillary.
2.5 Diaphragm seals As mentioned above, a
diaphragm seal should be used to protect
gauges from corrosive media, or media that
will plug the instrument. Diaphragm seals
are offered in a wide variety of designs and
corrosion resistant materials to accommodate
almost any application and most connections.
Request bulletin OH-1 for details.
2.6 Autoclaving Sanitary gauges with
clamp type connections are frequently steam
sterilized in an autoclave. Gauges equipped
with polysulfone windows will withstand
more autoclave cycles than those equipped
with polycarbonate windows. Gauges
equipped with plain glass or laminated safety
glass should not be autoclaved. Gauge
cases should be vented to atmosphere (remov-
ing the rubber fill/safety plug if necessary)
before autoclaving to prevent the plastic
window from cracking or excessively distort-
ing. If the gauge is liquid filled, the fill should
ITEM: 1520, 1540
7
also be drained fromthe case and the front ring
loosened before autoclaving.
3.0 INSTALLATION
3.1 Location Whenever possible, gauges
should be located to minimize the effects of
vibration, extreme ambient temperatures and
moisture. Dry locations away from very high
thermal sources (ovens, boilers etc.) are pre-
ferred. If the mechanical vibration level is
extreme, the gauge should be remotely locat-
ed (usually on a wall) and connected to the
pressure source via flexible tubing.
3.2 Gauge reuse ASME B40.1 recommends
that gauges not be moved indiscriminately
from one application to another. The cumula-
tive number of pressure cycles on an in-service
or previously used gauge is generally
unknown, so it is generally safer to install a
new gauge whenever and wherever possible.
This will also minimize the possibility of a
reaction with previous media.
3.3 Tightening of gauge Torque should
never be applied to the gauge case. Instead,
an open end or adjustable wrench should
always be used on the wrench flats of the
gauge socket to tighten the gauge into the fit-
ting or pipe. NPT threads require the use of a
suitable thread sealant, such as pipe dope or
teflon tape, and must be tightened very
securely to ensure a leak tight seal.
CAUTION: Torque applied to a diaphragm
seal or its attached gauge, that tends to loosen
one relative to the other, can cause loss of fill
and subsequent inaccurate readings. Always
apply torque only to the wrench flats on the
lower seal housing when installing filled,
diaphragm seal assemblies or removing same
from process lines.
3.4 Process isolation A shut-off valve
should be installed between the gauge and
the process in order to be able to isolate the
gauge for inspection or replacement without
shutting down the process.
3.5 Surface mounting Also known as wall
mounting. Gauges should be kept free of piping
strains. The gauge case mounting feet, if applic-
able, will ensure clearance between the pres-
sure relieving back and the mounting surface.
3.6 Flush mounting Also known as panel
mounting. The applicable panel mounting
cutout dimensions can be found at
www.ashcroft.com
4.0 OPERATION
4.1 Frequency of inspection This is quite
subjective and depends upon the severity of
the service and how critical the accuracy of
the indicated pressure is. For example, a
monthly inspection frequency may be in order
for critical, severe service applications.
Annual inspections, or even less frequent
schedules, are often employed in non-critical
applications.
4.2 In-service inspection If the accuracy of
the gauge cannot be checked in place, the user
can at least look for (a) erratic or random
pointer motion; (b) readings that are suspect
especially indications of pressure when the
user believes the true pressure is 0 psig. Any
gauge which is obviously not working or indi-
cating erroneously, should be immediately
valved-off or removed from service to avoid a
possible pressure boundary failure.
4.3 When to check accuracy Obviously any
suspicious behavior of the gauge pointer war-
rants a full accuracy check be performed.
Even if the gauge is not showing any symp-
toms of abnormal performance, the user may
want to establish a frequency of bench type
inspection.
4.4When to recalibrate This depends on the
criticality of the application. If the accuracy of
a 3-2-3% commercial type gauge is only 0.5%
beyond specification, the user must decide
whether its worth the time and expense to
bring the gauge back into specification.
Conversely if the accuracy of a 0.25% test
gauge is found to be 0.1% out of specification
then obviously the gauge should be recalibrat-
ed.
ITEM: 1520, 1540
4.5 Other considerations These include (a)
bent or unattached pointers due to extreme
pressure pulsation; (b) broken windows which
should be replaced to keep dirt out of the
internals; (c) leakage of gauge fill; (d) case
damage dents and/or cracks; (e) any signs of
service media leakage through the gauge
including its connection; (f) discoloration of
gauge fill that impedes readability.
4.6 Spare parts As a general rule it is rec-
ommended that the user maintain in his
parts inventory one complete Ashcroft
instrument for every ten (or fraction thereof)

of that instrument type in service.
5.0 GAUGE REPLACEMENT
It is recommended that the user stock one
complete Ashcroft
instrument for every ten

(or fraction thereof) of that instrument type in
service. With regard to gauges having a ser-
vice history, consideration should be given to
discarding rather than repairing them.
Gauges in this category include the following:
a. Gauges that exhibit a span shift greater
than 10%. It is possible the Bourdon tube
has suffered thinning of its walls by corro-
sion.
b. Gauges that exhibit a zero shift greater
than 25%. It is likely the Bourdon tube
has seen significant overpressure leaving
residual stresses that may be detrimental
to the application.
c. Gauges which have accumulated over
1,000,000 pressure cycles with significant
pointer excursion.
d. Gauges showing any signs of corrosion
and/or leakage of the pressure system.
e. Gauges which have been exposed to high
temperature or simply exhibit signs of
having been exposed to high temperature
specifically 250F or greater for soft sol-
dered systems; 450F or greater for brazed
systems; and 750F or greater for welded
systems.
f. Gauges showing significant friction error
and/or wear of the movement and linkage.
g. Gauges having damaged sockets, especially
damaged threads.
h. Liquid filled gauges showing loss of case
fill.
NOTE: ASME B40.1 does not recommend
moving gauges from one application to anoth-
er. This policy is prudent in that it encourages
the user to procure a new gauge, properly tai-
lored by specification, to each application that
arises.
6.0 ACCURACY:
PROCEDURES/DEFINITIONS
Accuracy inspection Readings at approxi-
mately five points equally spaced over the
dial should be taken, both upscale and down-
scale, before and after lightly rapping the
gauge to remove friction. A pressure standard
with accuracy at least 4 times greater than
the accuracy of the gauge being tested is rec-
ommended.
Equipment A finely regulated pressure sup-
ply will be required. It is critical that the pip-
ing system associated with the test setup be
leaktight. The gauge under test should be
positioned as it will be in service to eliminate
positional errors due to gravity.
Method ASME B40.1 recommends that
known pressure (based on the reading from
the pressure standard used) be applied to the
gauge under test. Readings including any
error from the nominal input pressure, are
then taken from the gauge under test. The
practice of aligning the pointer of the gauge
under test with a dial graduation and then
reading the error from the master gauge
(reverse reading) can result in inconsistent
and misleading data and should NOT be used.
8
ITEM: 1520, 1540
9
Calibration chart After recording all of the
readings it is necessary to calculate the errors
associated with each test point using the fol-
lowing formula: ERROR in percent = 100
times (TRUE VALUE minus READING)
RANGE. Plotting the individual errors
(Figure 1 on page 10) makes it possible to
visualize the total gauge characteristic. The
plot should contain all four curves: upscale
before rap; upscale after rap; downscale
before rap; downscale after rap. Rap means
lightly tapping the gauge before reading to
remove friction as described in ASME B40.1.
Referring to Figure 1 on page 10, several
classes of error may be seen:
Zero An error which is approximately equal
over the entire scale. This error can be mani-
fested when either the gauge is dropped or
overpressured and the bourdon tube takes a
permanent set. This error may often be cor-
rected by simply repositioning the pointer.
Except for test gauges, it is recommended
that the pointer be set at midscale pressure to
split the errors.
Span A span error exists when the error at
full scale pressure is different from the error
at zero pressure. This error is often propor-
tional to the applied pressure. Most Ashcroft
gauges are equipped with an internal, adjust-
ing mechanism with which the user can cor-
rect any span errors which have developed in
service.
Linearity A gauge that has been properly
spanned can still be out of specification at
intermediate points if the response of the
gauge as seen in Figure 1 on page 10 is not
linear. The Ashcroft Duragauge
pressure
gauge is equipped with a rotary movement
feature which permits the user to minimize
this class of error. Other Ashcroft gauge
designs (e.g., 1009 Duralife
) require that the

dial be moved left or right prior to tightening
the dial screws.
Hysteresis Some Bourdon tubes have a
material property known as hysteresis. This
material characteristic results in differences
between the upscale and downscale curves.
This class of error can not be eliminated
by adjusting the gauge movement or dial
position.
Friction This error is defined as the differ-
ence in readings before and after lightly tap-
ping the gauge case at a check point. Possible
causes of friction are burrs or foreign materi-
al in the movement gearing, bound linkages
between the movement and the bourdon tube,
or an improperly tensioned hairspring. If cor-
recting these potential causes of friction does
not eliminate excessive friction error, the
movement should be replaced.
(Continued on page 10)
ITEM: 1520, 1540
10
TYPICAL CALIBRATION CHART
INDICATEDVALUE (PSI)
True Value Increasing Increasing Decreasing Decreasing
PSI Without RAP With RAP Without RAP With RAP
0 .4 0 .4 0
40 +.8 +1.0 +1.4 +1.1
80 +.4 +.5 +1.2 +1.0
120 .4 1.0 +.8 +.6
160 .8 .5 +.6 +.4
200 +.4 +.8 +.4 +.4
ERROR (% OF FULL SCALE)
True Value Increasing Increasing Decreasing Decreasing
% of Range Without RAP With RAP Without RAP With RAP
0 .20 0 .20 0
20 +.40 +.50 +.70 +.55
40 +.20 +.25 +.60 +.50
60 .20 .05 +.40 +.30
80 .40 .25 +.30 +.20
100 +.20 +.40 +.20 +.20
1.0
0.5
0.0
0.5
1.0
0 20 40 60 80 100
% of Range
N
N
N
N
I
I
I
I
G
G
G
G
G
G
L
L
L
L
L
L
L L upscale without rap
G G upscale with rap
N N downscale without rap
I I downscale with rap
E
r
r
o
r
(
%
o
f
F
u
l
l
S
c
a
l
e
)
Fig. 1
ITEM: 1520, 1540
11
6.1 Calibration Rotary Movement Gauges
Inspect gauge for accuracy. Many times
gauges are simply off zero and a simple
pointer adjustment using the micrometer
pointer is adequate. If inspection shows the
gauge warrants recalibration to correct span
and/or linearity errors, proceed as follows:
a. Remove ring, window and, if solid front
case, the rear closure assembly.
b. Pressurize the gauge once to full scale and
back to zero.
c. Refer to Figure 2 on page 8 for a view of a
typical Ashcroft system assembly with
component parts identified.
d. For solid front gauges, adjust the microme-
ter pointer so that it rests at the true zero
position. For open front gauges the pointer
and dial must also be disassembled and
the pointer should then be lightly pressed
onto the pinion at the 9:00 oclock position.
e. Apply full scale pressure and note the
magnitude of the span error. With open
front gauges, ideal span (270 degrees) will
exist when at full scale pressure the point-
er rests exactly at the 6:00 oclock position.
f. If the span has shifted significantly (span
error greater than 10%), the gauge should
be replaced because there may be some
partial corrosion inside the bourdon tube
which could lead to ultimate failure. If the
span error exceeds 0.25%, loosen the lower
link screw and move the lower end of the
link toward the movement to increase
span or away to decrease span. An adjust-
ment of 0.004 inch will change the span by
approximately 1%. This is a repetitive pro-
cedure which often requires more than one
adjustment of the link position and the
subsequent rechecking of the errors at zero
and full scale pressure.
g. Apply midscale pressure and note error in
reading. Even though the gauge is accu-
rate at zero and full scale, it may be inac-
curate at the midpoint. This is called lin-
earity error and is minimized by rotating
the movement. If the error is positive, the
movement should be rotated counter clock-
wise. Rotating the movement one degree
will change this error by approximately
0.25%. Rotating the movement often
affects span and it should be subsequently
rechecked and readjusted if necessary
according to step 6.1e and 6.1f.
h. While recalibrating the gauge, the friction
error difference in readings taken with
and without rap should be noted. This
error should not exceed the basic accuracy
of the gauge. If the friction error is exces-
sive, the movement should be replaced.
One possible cause of excessive friction is
improper adjustment of the hairspring.
The hairspring torque,or tension, must be
adequate without being excessive. The
hairspring should also be level, unwind
evenly (no turns rubbing) and it should
never tangle.
NOTES:
1 For operation of test gauge external zero
reset, refer to Figure 3 on page 12.
2 For test gauge calibration procedure,
refer to Figure 4 on page 13.
6.2 Calibration 1009 Duralife
Gauge
Inspect gauge for accuracy. Many times
gauges are simply off zero and a simple
pointer adjustment using the adjustable
pointer is adequate. If the inspection shows
that the gauge warrants recalibration to cor-
rect span and/or linearity errors, proceed as
follows:
Remove ring, window, gasket and pointer
using Ashcroft tool kits 1205T and 1206T.
6.3 Positive Pressure Ranges
a. Remove dial and lightly press pointer onto
pinion at 9:00 oclock position.
b. Apply full scale pressure and rotate span
block as shown in Figure 5a on page 15
until pointer rests at 6:00 oclock position.
c. Fully exhaust pressure and check that
pointer still is at 9:00 oclock position. If
not repeat steps 1 and 2 until span is
correct.
(Continued on page 10)
ITEM: 1520, 1540
12
BOURDON TUBE
SEGMENT
TIP
LINK
BACKPLATE
SOCKET
ROTARY MOVEMENT
PINION
HAIRSPRING
Fig. 2
TYPE 1082 EXTERNAL ZERO ADJUST FEATURE*
A
RING
INSTRUCTIONS FOR USE:
LOOSEN RING LOCKING SCREW A
OBTAIN REQUIRED ADJUSTMENT BY ROTATING
KNOB B CLOCKWISE OR COUNTER-CLOCKWISE.
TIGHTEN SCREW A DOWN ON KNOB B.
*
Applicable only for test gauge with hinged ring design.
B
ASHCROFT SYSTEM ASSEMBLY
Fig. 3
ITEM: 1520, 1540
13
TYPE 1082 TEST GAUGE CALIBRATION PROCEDURE
Fig. 4
ITEM: 1520, 1540
14
d. Remove pointer and reassemble dial and
dial screws (finger tight).
e. Lightly press pointer onto pinion.
f. Check accuracy at full scale. If error exceeds
1% return to step 1, otherwise proceed.
g. Check accuracy at midscale. If error exceeds
1% slide dial left or right to compensate.
h. Continue at * below.
Vacuum range
a. Using a pencil, refer to dial and mark the
0 and 25 inch of Hg positions on the case
flange.
b. Remove the dial.
c. Apply 25 inches of Hg vacuum.
d. Lightly press pointer onto pinion carefully
aligning it with the 25 inch of Hg vacuum
mark on case flange.
e. Release vacuum fully.
f. Note agreement of pointer to zero mark on
case flange.
g. If span is high or low, turn span block as
shown in Figure 5b on page 15.
h. Repeat steps 4 through 8 until span is
correct.
i. Remove the pointer.
j. With 25 inches of Hg vacuum applied,
reassemble dial, dial screws (finger tight)
and pointer.
k. Apply 15 inches of Hg vacuum and note
accuracy of indication. If required, slide dial
left or right to reduce error to 1%maximum.
l. Continue at * below.
*Now complete calibration of the gauge as
follows:
a. Firmly tighten dial screws.
b. Firmly tap pointer onto pinion, using brass
back-up tool from Ashcroft kit 1205T if
gauge has rear blow-out plug. If gauge has
top fill hole no back-up is required.
c. Recheck accuracy at zero, midscale and full
scale points (Figures 5a & 5b on page 15).
d. Reassemble window, gasket and ring.
ITEM: 1520, 1540
15
25
V
s
1009 DURALIFE
PRESSURE GAUGE CALIBRATION

ITEM: 1520, 1540
16
7.0 DIAPHRAGM SEALS
7.1 General A diaphragm seal (isolator) is a
device which is attached to the inlet connec-
tion of a pressure instrument to isolate its
measuring element from the process media.
The space between the diaphragm and the
instruments pressure sensing element is
solidly filled with a suitable liquid.
Displacement of the liquid fill in the pressure
element, through movement of the
diaphragm, transmits process pressure
changes directly to a gauge, switch or any
other pressure instrument. When diaphragm
seals are used with pressure gauges, an addi-
tional 0.5% tolerance must be added to the
gauge accuracy because of the diaphragm
spring rate.
Used in a variety of process applications
where corrosives, slurries or viscous fluids
may be encountered, the diaphragm seal
affords protection to the instrument where:
The process fluid being measured would
normally clog the pressure element.
Pressure element materials capable of
withstanding corrosive effects of certain
fluids are not available.
The process fluid might freeze due to
changes in ambient temperature and dam-
age the element.
7.2 Installation Refer to sales bulletin OH-1
for information regarding (a) seal configura-
tions; (b) filling fluids; (c) temperature range
of filling fluids; (d) diaphragm material pres-
sure and temperature limits; (e) bottom hous-
ing material pressure and temperature lim-
its; (f) pressure rating of seal assembly; (g)
accuracy/temperature errors of seal assembly;
(h) diaphragm seal displacement. The volu-
metric displacement of the diaphragm must
at least equal the volumetric displacement of
the measuring element in the pressure
instrument to which the seal is to be attached.
It is imperative that the pressure instru-
ment/diaphragm seal assembly be properly
filled prior to being placed in service. Ashcroft
diaphragm seal assemblies should only be
filled by a seal assembler certified by Ashcroft
Inc. Refer to section 3.3 for a cautionary note
about not applying torque on either the
instrument or seal relative to the other.
7.3 Operation All Ashcroft
diaphragm
seals, with the exception of Type 310 mini-
seals, are continuous duty. Should the pres-
sure instrument fail, or be removed acciden-
tally or deliberately, the diaphragm will seat
against a matching surface preventing dam-
age to the diaphragm or leakage of the
process fluid.
7.4 Maintenance Clamp type diaphragm
seals Types 100, 200 and 300 allow for
replacement of the diaphragm or diaphragm
capsule, if that ever becomes necessary. The
Type 200 top housing must also be replaced
with the diaphragm. With all three types the
clamping arrangement allows field disassem-
bly to permit cleaning of the seal interior.
7.5 Failures Diaphragm failures are gener-
ally caused by either corrosion, high tempera-
tures or fill leakage. Process media build-up
on the process side of the diaphragm can also
require seal cleaning or replacement. Consult
Customer Service, Stratford CT for advice on
seal failures and/or replacement.
WARNING: All seal components should be
selected considering process and ambient
operating conditions to prevent misapplica-
tion. Improper application could result in fail-
ure, possible personal injury, property
damage or death.
8.0 DAMPENING DEVICES
8.1 General Some type of dampening device
should be used whenever the pressure gauge
may be exposed to repetitive pressure fluctu-
ations that are fairly rapid, high in magni-
tude and especially when transitory pressure
spikes exceeding the gauge range are present
(as with starting and stopping action of valves
and pumps). A restricted orifice of some kind
is employed through which pressure fluctua-
ITEM: 1520, 1540
17
tions must pass before they reach the bourdon
tube. The dampener reduces the magnitude of
the pressure pulse thus extending the life of
the Bourdon tube and movement. This reduc-
tion of the pressure pulsation as seen by the
pressure gauge is generally evidenced by a
reduction in the pointer travel. If the orifice is
very small the pointer may indicate the aver-
age service pressure, with little or no indica-
tion of the time varying component of the
process pressure.
Commonly encountered media (e.g. water
and hydraulic oil) often carry impurities
which can plug the orifice over time thus ren-
dering the gauge inoperative until the damp-
ener is cleaned or replaced.
Highly viscous media and media that tend to
periodically harden (e.g., asphalt) require a
diaphragm seal be fitted to the gauge. The
seal contains an internal orifice which damp-
ens the pressure fluctuation within the fill
fluid.
8.2 Throttle Screws & Plugs These acces-
sories provide dampening for the least cost.
They have the advantage of fitting completely
within the gauge socket and come in three
types: (a) a screwed-in type which permits
easy removal for cleaning or replacement; (b)
a pressed in, non-threaded design and (c) a
pressed in, threaded design which provides a
highly restrictive, helical flow path. Not all
styles are available on all gauge types.
8.3 Ashcroft Gauge Saver Type 1073
Ashcroft gauge saver features an elastomeric
bulb that fully isolates the process media
from the bourdon tube. In addition to provid-
ing dampening of pressure pulses, the bour-
don tube is protected from plugging and cor-
rosion. The space between the bulb and bour-
don tube is completely filled with glycerin.
Felt plugs located between the bulb and bour-
don tube are first compressed some amount to
restrict the flow of glycerin through an orifice
and thus provide a degree of dampening. The
greater the compression of the felts the
greater the degree of dampening.
8.4 Ashcroft Pulsation Dampener Type
1106 Ashcroft pulsation dampener is a mov-
ing pin type in which the restricted orifice is
the clearance between the pin and any one of
five preselected hole diameters. Unlike a sim-
ple throttle screw/plug, this device has a self-
cleaning action in that the pin moves up and
down under the influence of pressure fluc-
tuations.
8.5 Ashcroft Pressure Snubber The heart
of the Type 1112 pressure snubber is a thick
porous metal filter disc. The disc is available
in four standard porosity grades.
8.6 Campbell Micro-Bean
Type 1110
Micro-Bean is a precision, stainless steel, nee-
dle valve instantly adjustable to changing
conditions of flow and viscosity. A very slight
taper on the valve stem fits into tapered hole
in the body. The degree of dampening is easi-
ly adjusted by turning the valve handle. A fil-
ter is built into the Micro-Bean to help pre-
vent plugging.
8.7 Ashcroft Needle Valves Type 7001 thru
7004 steel needle valves provide varying
degrees of dampening similar to the Campbell
Micro-Bean but with a less precise and less
costly adjustability. Like the Micro-Bean
these devices, in the event of plugging, can
easily be opened to allow the pressure fluid to
clear away the obstruction.
8.8 Chemiquip
Pressure Limiting Valves

Model PLV-255, PLV-2550, PLV-5460, PLV-
5500 and PLV-6430, available with and with-
out built-in snubbers, automatically shut off
at adjustable preset values of pressure to pro-
tect the gauge from damage to overpressure.
They are especially useful on hydraulic sys-
tems wherein hydraulic transients (spikes)
are common.
ITEM: 1520, 1540
18
9.0 RESOURCES
9.1 Training Videos
9.1.1 Test gauge calibration
9.1.2 1009 Duralife
gauge calibration
9.1.3 Duragauge
gauge calibration
9.1.4 Diaphragm seal filling
9.2 Pressure Instrument Testing Equipment
9.2.1 Type 1305D Deadweight Tester
9.2.2 Type 1327D Pressure Gauge Comparator
9.2.3 Type 1327CM Precision Gauge Comparator
9.3 Tools &Tool Kits
9.3.1 Type 2505 universal carrying case for 1082 test gauge
9.3.2 Type 266A132-01 span wrench for 1082 test gauge
9.3.3 Type 1280 conversion kit for 4
1
2 lower connect 1279/1379
9.3.4 Type 1283 conversion kit for 4
1
2 back connect 1279/1379
9.3.5 Type 1284 conversion kit for 6 lower & back connect
9.3.6 Type 1281 socket O-Ring kit for 1279/1379 lower connect
9.3.7 Type 1285 4
1
2 ring wrench for 1279/1379 lower & back connect
9.3.8 Type 1286 6 ring wrench for 1379 lower & back connect
9.3.9 Type 1287 cone tool for installing diaphragm & spring on 1279/1379 back connect
9.3.10 Type 1105T calibration tool kit (all gauges except 1009 Duralife
)
9.3.11 Type 3220 pointer puller (all gauges except 1009 Duralife
)
9.3.12 Type. 3530 pinion back-up tool for 1009 Duralife
9.3.13 Type 1230 throttle plug insertion (

1
4 NPT) for 1009 Duralife
9.3.14 Type 1231 throttle plug insertion (

1
2 NPT) for 1009 Duralife
(body only)
9.3.15 Type 1205T calibration hand tools for 1009 Duralife
9.3.16 Type 1206T ring removal & assembly tools for 1009 Duralife
ITEM: 1520, 1540
14
Type 1279 Duragauge
pressure
gauge is offered in 4
1
/2 phenolic
case for superior chemical and heat
resistance. Solid-front case design
with blow-out back for safety. Dry,
liquid-lled, hermetically sealed or
PLUS! options available. Field con-
vertible to liquid-ll with conversion
kit (detailed on page 170). All case
styles provide full temperature com-
pensation.
Exclusive Teon coated 400 series
stainless steel rotary movement
for longer life
Patented Duratube with Welded-
Tube construction controls stress
for longer life
Exclusive Round Cap Tip con-
struction lowers stresses for
longer life
Easily adjustable, self-locking
micrometer pointer
New PLUS! Performance Option:
- Liquid-lled performance in a dry
gauge
- Fights vibration and pulsations
without liquid-lled headaches
- See page 174 for details
- Order as option XLL
Reference Bulletin DU-1
MADE IN U.S.A.
Duragauge
Pressure Gauge
Type 1279, Grade 2A (0.5%)

Phone (203) 378-8281, FAX (203) 385-0499 or
BOURDON SYSTEM SELECTION
Ordering Bourdon Tube & Tip Material
(1)
Socket Tube Range Selection NPT
Code (all joints TIG welded except A)

Material Type Limits (psi) Conn.
(2)

A
Grade A Phosphor Bronze
Brass C-Tube 12/1000
1
/4,
1
2
Tube-Brass Tip, Silver Brazed
B 4130 alloy steel 1019 steel
C-Tube 15/1500
1
4,
1
2
,
Helical 2000/5000
1
4,
1
2
R 316L stainless steel 1019 steel
C-Tube 12/1500
1
4,
1
2
Helical 2000/20,000
1
4,
1
2
S 316L stainless steel 316 stainless steel
C-Tube 12/1500
1
4,
1
2
Helical 2000/20,000
1
4,
1
2

P
(3)
K Monel Monel 400
C-Tube 15/1500
1
4,
1
2
Helical 2000/30,000

1
4,
1
2
(4)
(1) For selection of the correct bourdon system material, see the
media application table on page 178.
(2) Other connections available on application.
(3) Use for applications where NACE standard MR-01-75 is
specied.
(4) 30,000 psi range supplied with
1
4 high pressure
connection,
1
2 NPT optional.
STANDARD RANGES
Pressure Compound

psi

psi

0/15 30 Hg/15 psi
0/30 30 Hg/30 psi
0/60 30 Hg/60 psi
0/100 30 Hg/100 psi
0/160 30 Hg/150 psi
0/200 30 Hg/300 psi
0/300
0/400 Vacuum
0/600 30/0 in.Hg
0/800 34/0 ftH2O
0/1000
0/1500
0/2000
0/3000
0/5000
0/10,000
0/20,000
0/30,000
NOTE:
Equivalent standard
kg/cm
2
, and kPa metric
ranges are available.
(
*
) S denotes solid front case design
TO ORDER THIS 1279 DURAGAUGE:
Select: 45 1279 RS* 04L XXX 0/2000 psi
1. Dial size4
1
2
2. Case type1279
Ringthreaded reinforced polypropylene
3. Bourdon system selection ordering code
4. Connection
1
4 NPT (02),
1
2 NPT (04), Lower (L), Back (B)
5. Optional featuressee page 108
6. Standard pressure range
7. Accessoriessee pages 165-171
ITEM 1520
14
Type 1279 Duragauge
pressure
gauge is offered in 4
1
/2 phenolic
case for superior chemical and heat
resistance. Solid-front case design
with blow-out back for safety. Dry,
liquid-lled, hermetically sealed or
PLUS! options available. Field con-
vertible to liquid-ll with conversion
kit (detailed on page 170). All case
styles provide full temperature com-
pensation.
Exclusive Teon coated 400 series
stainless steel rotary movement
for longer life
Patented Duratube with Welded-
Tube construction controls stress
for longer life
Exclusive Round Cap Tip con-
struction lowers stresses for
longer life
Easily adjustable, self-locking
micrometer pointer
New PLUS! Performance Option:
- Liquid-lled performance in a dry
gauge
- Fights vibration and pulsations
without liquid-lled headaches
- See page 174 for details
- Order as option XLL
Reference Bulletin DU-1
MADE IN U.S.A.
Duragauge
Pressure Gauge
Type 1279, Grade 2A (0.5%)

Phone (203) 378-8281, FAX (203) 385-0499 or
BOURDON SYSTEM SELECTION
Ordering Bourdon Tube & Tip Material
(1)
Socket Tube Range Selection NPT
Code (all joints TIG welded except A)

Material Type Limits (psi) Conn.
(2)

A
Grade A Phosphor Bronze
Brass C-Tube 12/1000
1
/4,
1
2
Tube-Brass Tip, Silver Brazed
B 4130 alloy steel 1019 steel
C-Tube 15/1500
1
4,
1
2
,
Helical 2000/5000
1
4,
1
2
R 316L stainless steel 1019 steel
C-Tube 12/1500
1
4,
1
2
Helical 2000/20,000
1
4,
1
2
S 316L stainless steel 316 stainless steel
C-Tube 12/1500
1
4,
1
2
Helical 2000/20,000
1
4,
1
2

P
(3)
K Monel Monel 400
C-Tube 15/1500
1
4,
1
2
Helical 2000/30,000

1
4,
1
2
(4)
(1) For selection of the correct bourdon system material, see the
media application table on page 178.
(2) Other connections available on application.
(3) Use for applications where NACE standard MR-01-75 is
specied.
(4) 30,000 psi range supplied with
1
4 high pressure
connection,
1
2 NPT optional.
STANDARD RANGES
Pressure Compound

psi

psi

0/15 30 Hg/15 psi
0/30 30 Hg/30 psi
0/60 30 Hg/60 psi
0/100 30 Hg/100 psi
0/160 30 Hg/150 psi
0/200 30 Hg/300 psi
0/300
0/400 Vacuum
0/600 30/0 in.Hg
0/800 34/0 ftH2O
0/1000
0/1500
0/2000
0/3000
0/5000
0/10,000
0/20,000
0/30,000
NOTE:
Equivalent standard
kg/cm
2
, and kPa metric
ranges are available.
(
*
) S denotes solid front case design
TO ORDER THIS 1279 DURAGAUGE:
Select: 45 1279 RS* 04L XXX 0/2000 psi
1. Dial size4
1
2
2. Case type1279
Ringthreaded reinforced polypropylene
3. Bourdon system selection ordering code
4. Connection
1
4 NPT (02),
1
2 NPT (04), Lower (L), Back (B)
5. Optional featuressee page 108
6. Standard pressure range
7. Accessoriessee pages 165-171
ITEM 1540
VISIT OUR WEBSITES: www.dwyer-inst.com www.dwyer-inst.co.uk www.dwyer-inst.com.au
212
F
l
o
w
SPECIFICATIONS
Service: Compatible gases and liquids.
Wetted Materials:
Window: Glass.
Body: Plated steel.
Temperature Limit: 200F (93C).
Pressure Limit: 125 psig (8.6 bar).
Connections: 1/4 to 2 male NPT.
Si ght Wi ndow
Shows Level or Contents of Tanks, Pi pel i nes; Fused Gl ass and Steel Constr ucti on
Fused glass style sight windows feature glass to metal bond for utmost re-
liability. Plated steel bodies have convenient hex wrench surfaces. Connections
are standard NPT in sizes from 1/4" to 2". Windows are clear, ripple free, and
flush with the front face, having no recess on which dirt might collect.
APPLICATIONS
Hydraulic Tanks
Pressure Vessels
Coolant Tanks
Hydraulic Lines
Oil Reservoirs
APPLICATIONS
Hydraulic Tanks
Pressure Vessels
Coolant Tanks
Hydraulic Lines
Oil Reservoirs
SPECIFICATIONS
Service: Compatible gases and liquids.
Wetted Materials:
Window: Tempered glass.
Body: Brass, carbon steel, or 316 SS.
Gasket: Buna-N on brass and carbon steel body, PTFE on 316 SS
body.
Temperature Limit: 200F (93C).
Pressure Limit: 125 psig (8.6 bar).
Connections: 3/4 to 2 male NPT.
Series
550
Tough, tempered glass window resists chemical attack and abrasion.
Seamless gasket assures perfect seal and is easily field replaceable. In addi-
tion to the standard brass body, Model 500 Sight Windows are also available
in carbon steel or 316 SS to suit a wide range of chemical compatibility.
Si ght Wi ndow
Shows Level or Contents of Tanks, Pi pel i nes; Temper ed, Repl aceabl e Gl ass Wi ndow
Series
500
Model
SFI-500-3/4
SFI-500-1
SFI-500-1-1/4
SFI-500-1-1/2
SFI-500-2
A
3/4
1
1-1/4
1-1/2
2
B
3/4(19)
15/16 (24)
1-1/4 (32)
1-27/64(37)
1-1/4 (32)
C
1-3/8(35)
1-3/8(35)
2-1/8 (54)
2-1/8 (54)
2-1/2 (64)
E
1-3/8(35)
1-3/8 (35)
1-9/16 (40)
1-9/16 (40)
1-21/32(42)
D
45/64(18)
45/64(18)
27/32(22)
27/32(22)
15/32(12)
Dimensions Inches (mm)
Model
SFI-550-1/4
SFI-550-3/8
SFI-550-1/2
SFI-550-3/4
SFI-550-1
SFI-550-1-1/4
SFI-550-1-1/2
SFI-550-2
A
1/4
3/8
1/2
3/4
1
1-1/4
1-1/2
2
B
11/32(9)
7/16 (11)
9/16 (14)
3/4(19)
15/16 (24)
1-3/16 (30)
1-7/16 (37)
1-7/8 (48)
C
5/8(16)
3/4(19)
15/16 (24)
1-1/16 (27)
1-3/8 (35)
1-3/4 (45)
2 (51)
2-1/2 (64)
E
5/8(16)
23/32 (18)
25/32 (19)
15/16 (24)
1-1/16 (27)
1-7/32 (31)
1-7/32 (31)
1-9/32 (33)
D
3/16(5)
7/32(6)
7/32(6)
5/16(8)
5/16(8)
13/32(10)
13/32(10)
13/32(10)
Dimensions Inches (mm)
Model
Carbon Steel
SFI-500CS-3/4
SFI-500CS-1
SFI-500CS-1-1/4
SFI-500CS-1-1/2
SFI-500CS-2
Model
SFI-550-1
SFI-550-1-1/4
SFI-550-1-1/2
SFI-550-2
Model
316 SS
SFI-500SS-3/4
SFI-500SS-1
SFI-500SS-1-1/4
SFI-500SS-1-1/2
SFI-500SS-2
Model
Brass
SFI-500B-3/4
SFI-500B-1
SFI-500B-1-1/4
SFI-500B-1-1/2
SFI-500B-2
Model
SFI-550-1/4
SFI-550-3/8
SFI-550-1/2
SFI-550-3/4
p212:Layout 6 7/9/09 8:28 AM Page 1
ITEM 1820
SAGE THERMAL GAS MASS FLOW METER
Operations and
Instruction Manual
For General Purpose Blind Models SIL and SRL
Make the Wise Choice.
Choose Sage Flow Meters.
SAGE METERING, INC.
8 Harris Court, D1
Monterey, CA 93940
1-866-677-SAGE (7243)
Tel 831-242-2030
Fax 831-655-4965
www.sagemetering.com
ITEM 1910
ITEM 1910
3 S A G E ME T E R I N G , I N C .
REV. 02-SIL/SRL
O p e r a t i o n s a n d I n s t r u c t i o n Ma n u a l
Table of Contents
Introduction Welcome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SECTION A Unpacking Your Sage Meter . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Getting Started
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
In-line Flow Meter Application . . . . . . . . . . . . . . . . . . . . . . . . . 10
Locating Proper Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . 11
Self-Powered 4-20 ma or User-Powered 4-20 ma . . . . . . . . . . . . . . . . 11
Sage Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Compression Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Probe Insertion Guideline Drawing. . . . . . . . . . . . . . . . . . . . . . . 13
Installation Depth Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Conguration for Utilizing Four Flow Meters for Large Round Pipes . . . . . 15
Terminal Hook-Up Series SIL, SRL (SIL NT Version) . . . . . . . . . . . . . . 16
Circuit Board Wiring for General Purpose NT Style Meter . . . . . . . . . . . 17
Junction Box Wiring Terminals for Remote Style Meters . . . . . . . . . . . 18
Cable Connector Diagram for AC Powered General Purpose
Sage Lite (SIL or SRL) Meters. . . . . . . . . . . . . . . . . . . . . . . . . 19
SECTION B Sage Thermal Mass Flow Meters . . . . . . . . . . . . . . . . . . . . . . . . 23
Theory / Styles / Specications
Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Basic General Purpose (Blind) Sage Flow Meter Styles . . . . . . . . . . . . . 24
SECTION C SIL Series Integral Style Lite (Blind) General Purpose Mass Flow Meters . . . 27
Drawing
SRL Series Remote Style Lite (Blind) General Purpose Mass Flow Meters . . . 28
SIL Series Integrated Style Lite (Blind) Optional Explosion Proof
Mass Flow Meters (XP2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SRL Series Integrated Style Lite (Blind) Optional Explosion Proof
Mass Flow Meters (XP2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Mounting Hardware:
SVA Series Isolation Valve Assembly for Insertion Meters . . . . . . . . . 31
Wall Mounting Procedure for Remote General Purpose Enclosure . . . . . . 32
Flanged Ends for In-Line Meter (Optional) . . . . . . . . . . . . . . . . . . . 33
Flow Conditioning Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
General Purpose Probe and Transmitter Head Assembly Procedure . . . . . . 34
continued on next page
ITEM 1910
S A G E ME T E R I N G , I N C . O p e r a t i o n s a n d I n s t r u c t i o n Ma n u a l
4
REV. 02-SIL/SRL
SECTION D Sensor Functionality and Zero Calibration Self Check. . . . . . . . . . . . . 37
User Interface
Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Pulsed Outputs on SIL NT . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
SILCOM Interface Cable Instructions. . . . . . . . . . . . . . . . . . . . . . 40
SECTION E Common Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Diagnostics
SECTION F Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Warranties and Service Work
Cancellation/Return Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Returning Your Sage Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . 51
Return Material Authorization Form . . . . . . . . . . . . . . . . . . . . . . 52
SECTION G Junction Box and Upstream Orientation. . . . . . . . . . . . . . . . . . . . 55
Appendix
Captive Flow Conditioners . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
What Is a Thermal Mass Flow Meter? . . . . . . . . . . . . . . . . . . . . . 57
ITEM 1910
5
Welcome
We are pleased that you have purchased a Sage Metering Mass Flow Meter for your
requirement. We hope that you are satised with the performance, operation and
design of our highly precise, NIST traceable Thermal Gas Mass Flow Meter.
The innovative Sage design (whether congured as an In-Line or Insertion Flow Meter)
provides high accuracy and repeatability for optimum measurement and control of
your process and provides a 4-20 ma output (isolated [user powered], or ground based)
of ow rate as well as a 0-5 VDC output of temperature. Alternately, the meter can be
offered with pulsed outputs of totalized ow (in lieu of ow rate and temperature out-
puts). For even greater exibility, specify SILCOM, and you will be provided with an
interconnect cable and software for user congurability via a laptop (change Full Scale,
Filtering, Output Conguration, etc.). If a display of ow rate and total is required,
please contact Sage for assistance in selecting other Sage products and styles.
Sage Meters measure mass ow directly there is no need for ancillary instrumentation
such as temperature or pressure transmitters. Furthermore, our instruments have excep-
tional signal sensitivity, have no moving parts, require little if any maintenance, have
negligible pressure drop and have a rangeability as high as 1000 to 1. Sage Flow Meters
can measure and control the mass ow rate and consumption of air, oxygen, natural
gas, nitrogen, digester gas, biogas, are gas, hydrogen, argon, carbon dioxide and other
gases and gas mixes. We anticipate that our Flow Meter will provide you with the means
to increase productivity, reduce energy costs, and/or improve product yields.
Please let us know if we can assist you in any way with your Sage Meter, or if you
have any questions about its installation, operation, or features. Simply phone us at
866-677-SAGE (7243), or visit our website at www.sagemetering.com to contact a
factory representative in your area. (To access this manual on the website, enter in
passcode 7243737 when prompted.)
Sincerely,
Robert Steinberg
President
S A G E ME T E R I N G , I N C .
REV. 02-SIL/SRL
ITEM 1910
ITEM 1910
Section
GETTING STARTED
A
ITEM 1910
ITEM 1910
UNPACKING YOUR SAGE METER
Your Sage ow meter is a sensitive, yet rugged,
precision built electronic instrument. Upon delivery,
care should be taken when opening the shipping
container and removing your meter. The meter
should be inspected for any damage that may have
occurred during transit. If damage is found, please
contact the carrier immediately to place a claim for
damaged goods. The contents of the container
should be checked against the packing list for any
discrepancies. If there are any questions as to the
contents or conguration of the equipment includ-
ing calibration ranges, or mounting hardware,
contact Sage Metering as soon as possible. Please
save shipping container and packaging materials
(including PVC tube probe protector on Sage
Insertion Flow Meters) in case the unit needs to
be returned for any reason.
MAINTENANCE
Sage thermal mass ow meters essentially require
little or no maintenance. While the sensing element
is somewhat resistant to dirt and particulate build
up, it may become necessary to clean it from time to
time if mounted in extremely dirty environments.
NOTE: ALWAYS DISABLE THE TRANSMITTER
POWER SUPPLY PRIOR TO ANY CLEANING OR
MAINTENANCE. A simple blast of compressed air
may be sufficient; or a detergent or appropriate
non-corrosive solvent for removing the buildup
may be required. A soft brush can be used to gently
clean the sensing elements surface, using caution
to avoid damaging the RTDs. If any disassembly is
necessary, contact Sage Metering, Inc. for instruc-
tions. In general, it is recommended that your
Sage Thermal Mass Flow Meter be returned to
the factory if cleaning, repair, or recalibration is
needed. This is usually the most cost-effective
and reliable alternative.
CALIBRATION
Sage thermal mass ow meters have built-in diag-
nostics. The menuing system (accessible if you
purchased the SILCOM Cable/Assembly) has provi-
sions to check the sensors operation by accessing the
sensors output and comparing it to the original
reported zero ow value noted on the next to last
line of your meters Certicate of Conformance. This
method helps validate the meters performance, and
depending on your companys quality control pro-
cedures, may eliminate, or at least postpone the
need for annual factory calibrations. See Sensor
Functionality and Zero Calibration Self Check
on page 37.
Getting Started
REV. 02-SIL/SRL
a
CAUTION cable glands shipped with unit are for shipping purposes only.
Remove shipping cable glands before installing.
ITEM 1910
10
INSTALLATION AND MOUNTING
Check the Certicate of Conformance included
with your Sage Thermal Mass Flow Meter for
system pressure, temperature, gas composition,
power input, and signal output.
Check the installation. Choose the longest
straight-run section of pipe available to allow a
uniform, well-developed ow prole. Allow for
a minimum ten (10) diameters (15 preferred)
straight-run upstream of the sensors and ve (5)
diameters straight-run downstream of the sensors.
Avoid, if possible, installations immediately down-
stream of bends, fans, nozzles, heaters, or anything
else installed in the line that may cause non-
uniform ow proles and swirls which can result
in signal output errors (refer to Probe Insertion
Guideline Drawing on page 13). If insufficient
straight run, consider Sage Captive Flow
Conditioners (see Appendix).
Check the orientation: Standard calibration ow
direction is left to right when facing the ow
meter. Gas ow direction is marked with an arrow
on In-line ow meters; UPSTREAM is marked on
insertion probes.
Hook up the system per the wiring diagram pro-
vided with your Sage ow meter. Double check
that wiring for the proper power and signal con-
nections are correct.
Check that all plumbing and electrical hook-ups
are in accordance with OSHA, NFPA, and all other
safety requirements.
For Remote Style Meter (SRL), be sure that
the Remote Electronics is matched with the
Transmitter (Probe or Flow Body). There will be
Metal Serial Number Tags on both ends. Do not
mismatch the serial numbers of the Remote
Electronics and the Transmitter, or calibration
errors will occur.
IN-LINE FLOW METER APPLICATION
In-line mounting styles are available through Sage
Metering, Inc. in sizes from 1/4" pipe through 4"
pipe. Threaded male NPT ends are standard up to
2-1/2"; ANSI 150lb anged ends are standard for 3"
and 4" models. Contact the factory if optional end
mounting styles are required. Pipe sizes in excess
of 4" require the insertion style mass ow meter.
The In-line style ow meter assembly ow section is
typically specied to match the users ow conduit
and is plumbed directly in the ow line by thread-
ing, anging, welding, etc. DO NOT USE REDUCERS.
It includes the sensing element (a self-heated ow
sensor and a temperature/reference sensor) mounted
directly in the specied ow section for exposure to
the process gas; a sensor drive circuit; microprocessor
meter board, and transmitter enclosure.
B
2.55
L
5.00
5.00
REV. 02-SIL/SRL
ITEM 1910
REV. 02-SIL/SRL
LOCATING PROPER WIRING DIAGRAM
1) Look at the sticker on your meter. The rst three
digits describe the basic model that you have.
Refer to the appropriate page numbers below for
your wiring diagram
2) SIL: See page 16
3) SRL: See page 16 for input/output terminals;
see page 18 (Junction Box Wiring Terminals for
Remote Style Meters)
SELF-POWERED 4-20 ma or
USER POWERED 4-20 ma
Please note, Sage Meters are not loop powered.
The 4-20 ma outputs can be Self-Powered or User-
Powered. All Sage Meters ship set up for Self-Power.
A jumper is pre-installed to bring 24 VDC to the
4-20 ma outputs. If you require isolated 4-20 ma
outputs, the Terminal Hook-Up Drawings will
instruct you to remove the jumper and connect to
different terminals. In addition, in the User-Powered
Mode, you will need to supply separate power for
the 4-20 ma circuit (between 9 and 27 volts DC).
SAGE VALVE ASSEMBLY OPERATION
Valve assemblies (SVA05) are an optional mounting
hardware available through Sage Metering Inc. They
allow the removal of insertion style meters for serv-
ice, cleaning, re-calibration, relocation, etc. without
the need to "shut-down" your process. The probe
insertion depth is adjustable to permit sensor to be
located at center to optimize measurement accuracy.
(Refer to PROBE INSERTION GUIDELINE DRAWING
and CHART.) The ball valve will seal off leaks of the
process gas at the point of insertion after the probe
assembly has been removed. The assembly includes
a valve, threadolet, compression tting with Teon
ferrule, a cable restraint, and a collar clamp.
A threaded half coupling (3/4" FNPT) properly sized
to accommodate the isolation valve retractor assem-
bly must be tted to the pipe/duct to which the
insertion probe will be inserted. Direct threading
together (or with necessary bushings) of the retractor
assembly may be required. In other cases, the thread-
olet must be welded in place and a clearance hole
must be drilled through the pipe/ duct to accept the
probe assembly. If the pipe/duct is under pressure
during installation, a hot tap drill (not available
through Sage Metering) may be required.
N OT E :
Detailed
Drawing
is shown
on page 31.
ITEM 1910
12
REV. 02-SIL/SRL
COMPRESSION FITTING
A bored through tube tting, properly sized to
accommodate an insertion probes particular OD,
can be provided by the user or purchased as an
option from Sage Metering. Prior to installation,
a clearance hole to accommodate the insertion probe
assembly must be drilled in the pipe/duct. A tting
(1/2" FNPT) is then welded in place or threaded into
the half-threadolet which has been welded to the
pipe/duct. The probe insertion depth is adjustable
to permit sensor to be located at center, to optimize
measurement accuracy. (Refer to PROBE INSERTION
GUIDELINE DRAWING and CHART, pages 13 &14.)
INSTALLATION INSTRUCTIONS
1. Insert tubing into the tube tting.
2. Make sure that the tubing is positioned properly
per the PROBE INSERTION GUIDELINE DRAW-
ING AND CHART, pages 13 &14.
3. Due to the variations of tubing diameters, a
common starting point is desirable. Therefore,
tighten the nut until the tubing will not turn
by hand or move axially in the tting.
4. Scribe the nut at the 6 oclock position.
5. While holding tting body steady, tighten the nut
1
1
4 turns to the 9 oclock position.
Insert the probe shaft tubing into the
compression tting to the position indicted
in the Probe Insertion guidelines.
Mark the nut at the 6 oclock
position.
While holding the tting body steady,
tighten the nut one and one-quarter
turns to the 9 oclock position.
ITEM 1910
REV. 02-SIL/SRL
INSERTION FLOW METER APPLICATION
Straight Run Requirements. Choose the longest
straight run section of pipe available to allow a
uniform, well developed ow prole. Allow for a
minimum of 10 diameters straight run (15 preferred)
upstream of the sensors, and 5 down stream to
minimize ow prole inaccuracies. Alternately, refer
to Appendix for Optional Captive Flow Conditioners.
Insertion styles are available through Sage Metering,
Inc. with a standard 1/2" OD probe support assem-
bly; 3/4" is also available. Standard probe lengths
are 6", 12", 15", 18", 24", 30", 36" and 48". A com-
mon method of mounting the probe assembly
through a pipe wall or duct is with a compression
tting. A Sage valve assembly is useful and highly
recommended. Flange mounting is optionally
available.
Sage insertion style ow meters can be assembled
and calibrated for use in virtually any size pipe
Probe Insertion Guideline Drawing
1
or duct (as small as 1). Sage insertion ow meters
include a probe assembly that supports the sensing
element (a self-heated ow sensor and a temperature/
reference sensor); a sensor drive circuit; micropro-
cessor meter board, and transmitter enclosure. The
probe assembly must be inserted into the correct
position in the process gas ow conduit to allow the
gas to ow through the sensor window across the
sensor element. The sensing point or active part
of the sensor (0.5" from the end of the probe) should
be positioned as described below:
INSTALLATION DEPTH
The center of the pipe (assuming a well developed
turbulent ow prole) is fairly at, and easy to
locate. See Installation Depth Chart on next
page to determine proper insertion depth.
Z
Y
X
4" PIPE SHOWN
LESS THAN IDEAL LOCATION
(User needs to traverse the pipe to establish the
point of average velocity location, and will then
need to add a K-Factor of 1.22 in Menu Item 304.
Also see "Menu Item Descriptions on page 43.)
GOOD LOCATION
2,3,4

(See Installation Depth Chart for X and Y Dimension)
Center
of Pipe
1. SIL General Purpose Meter shown in drawing.
2. Probe should be inserted per Installation Depth Chart (see following page),
so sensors are in the center of the pipe.
3. The portion of the probe that remains outside of the pipe, is simply the factory
ordered probe length (i.e. -15 = 15 inches) minus the Y dimension.
4. If gas stream is prone to condensation, the pipe walls tend to form droplets which
may roll down probe support and hit sensors (this can be avoided by keeping pipe
wall above 32F). The output would read maximum flow until the droplet evaporates
(usually about 5 minutes). To prevent the droplets from hitting the sensors, install the
probe with a 30-45 tilt (moving probe forward or backward).
ITEM 1910
14
REV. 02-SIL/SRL
METHODS FOR PROBE INSERTION TO PIPE CENTER
METHOD 1
Using charts below, select pipe size (column 1),
determine X. Insert probe until the end touches the
bottom of the pipe (ID), mark probe as it exits top
of tting. Lift probe distance X and tighten com-
pression tting.
Installation Depth Chart
METHOD 2
Using charts below, select pipe size (column 1),
determine Y. Subtract Y from the factory supplied
probe length. That difference, Z, should be outside
of the pipe, and is measured from the bottom of the
probe weld to pipe OD.
PIPE SIZE OD ID X Y PIPE AREA
1"
1.5" 1.900 1.500 .15" 1.56" 0.0123
2" 2.375 1.939 .35" 1.82" 0.0205
2.5" 2.875 2.323 .55" 2.07" 0.0294
3" 3.500 2.900 .80" 2.38" 0.0459
4" 4.500 3.826 1.30" 2.86" 0.0798
6" 6.625 5.761 2.25" 3.95" 0.1810
8" 8.625 7.625 3.25" 4.90" 0.3171
10" 10.750 9.750 4.25" 6.00" 0.5185
12" 12.750 11.374 5.13" 7.00" 0.7056
14" 14.000 12.500 5.70" 7.50" 0.8522
16" 16.000 14.312 6.60" 8.60" 1.1172
18" 18.000 16.124 7.50" 9.60" 1.4180
24" 24.000 21.562 10.25" 12.60" 2.5357
S C H E D U L E 4 0 P I P E S C H E D U L E 8 0 P I P E
PIPE SIZE OD ID X Y PIPE AREA
1"
1.5" 1.900 1.610 .20" 1.56" 0.0141
2" 2.375 2.067 .40" 1.82" 0.0233
2.5" 2.875 2.469 .60" 2.07" 0.0332
3" 3.500 3.068 .90" 2.38" 0.0513
4" 4.500 4.026 1.40" 2.86" 0.0884
6" 6.625 6.065 2.40" 3.95" 0.2006
8" 8.625 7.981 3.40" 4.90" 0.3474
10" 10.750 10.020 4.40" 6.00" 0.5476
12" 12.750 11.938 5.50" 7.00" 0.7773
14" 14.000 13.124 6.00" 7.50" 0.9394
16" 16.000 15.000 7.00" 8.60" 1.2272
18" 18.000 16.876 8.00" 9.60" 1.5533
24" 24.000 22.625 10.75" 12.60" 2.7919
C O N S U L T F A C T O R Y C O N S U L T F A C T O R Y
ITEM 1910
REV. 02-SIL/SRL
Conguration for Utilizing Four (4) Sage Insertion
Mass Flow Meters for Large Round Pipes or Ducts Larger
than 36" to Minimize Effects of Varying Flow Proles
Insert Probes 15% into
round pipe or duct
NOTE: Each Probe is mounted in the centroid
(geometric center) of each quadrant. By aver-
aging the outputs of all four probes, better
accuracy is achieved.
The outputs of the four meters will be averaged
by customers PLC or other method to improve
overall accuracy in measuring the ow rate.
(For medium sized round pipes [18" to 36"],
two meters, on the opposite side of the same
diameter, may be sufficient [insert parallel to an
upstream 90 degree bend for optimal benet.])
Note, in this conguration, each sensor needs
to be averaged. A K-factor (Menu 304) of 1.22
is required in each meter to correct for this
averaging method of insertion or alternately,
put a 1.22 factor in your PLC, if Factory meter was
supplied for Center, versus Average, installation.
ITEM 1910
16
REV. 02-SIL/SRL
Power and Signal
Terminal Block
Probe/Flowbody Sensor
Terminal Block
Probe Support
6 5 4 3 2 1
1 2 3 4 5 6
6 5 4 3 2 1
1 2 3 4 5 6
1 4-20mA outputs could also be congured for Temperature
2 0-5 VDC outputs could also be congured for Flow
3 Pulsed Outputs of Totalized Flow (50msec Pulse)
4 Remove Jumpers for User-Powered 4-20 ma Outputs and connect between 3
and 4 instead of 4 and 6. In User-Powered mode, user must supply power to the
4-20 mA (9-27 volts) to power the loop.
1 2 3 4 5 6
R
E
D
G
R
E
E
N
B
L
U
E
W
H
I
T
E
B
L
A
C
K
O
R
A
N
G
E
1 2 3 4 5 6
R
E
D
R
E
D
W
H
I
T
E
W
H
I
T
E
Terminal Hook-Up Series SIL, SRL (SIL NT Version)
INTEGRAL HOOK-UP (SIL) REMOTE HOOK-UP (SRL)
JUMPERS
4
F L OW
1
6 5 4 3 2 1
G
R
O
U
N
D
0
-
5

V
D
C
4
-
2
0

F
L
O
W
D
C

I
N
P
U
T

(
2
4

V
D
C
)
G
R
O
U
N
D
See page 19 which shows
removable Power Cable Plug
for AC Powered Meters
JUMPERS
4
F L O W
1
6 5 4 3 2 1
G
R
O
U
N
D
0
-
5

V
D
C
4
-
2
0

F
L
O
W
D
C

I
N
P
U
T

(
2
4

V
D
C
)
G
R
O
U
N
D
NOTE: When cong-
ured for Pulsed Out-
puts, the 420mA
outputs are disabled.
(You cannot have both
pulse and 420mA
ow outputs.)
Temp
2
or pulsed
outputs
3
Temp
2
or pulsed
outputs
3
ITEM 1910
REV. 02-SIL/SRL
FACTORY PRE-WIRED
SENSOR DRIVER BOARD NT STYLE
REMOTE HOOKUP
SENSOR DRIVER BOARD NT STYLE
INTEGRAL HOOKUP
6 White (Temp)
5 N/C
4 White (Temp)
3 Red (Flow)
2 N/C
1 Red (Flow)
6 Orange (Temperature & Sense Return)
5 Black (Temperature Sense)
4 White (Temperature Send)
3 Blue (Flow & Sense Return)
2 Green (Flow Sense)
1 Red (Flow Send)
SENSOR SIDE
PIN 1
SENSOR SIDE
PIN 1
Circuit Board Wiring for General Purpose NT Style Meters
(DO NOT MISMATCH SERIAL NUMBER OF ELECTRONICS WITH SERIAL NUMBER ON JUNCTION BOX SENSOR)
1
1 A Sage Thermal Mass Flow Meter with remote electronics is a custom
calibrated meter. All components (sensors, electronics, boards, etc.) are
matched-sets that share the same serial number and MUST BE INSTALLED
TOGETHER AS A SYSTEM. Mixing components from different meters
can result in signicant errors/malfunctions.
ITEM 1910
18
REV. 02-SIL/SRL
Junction Box Wiring Terminals for Remote Style Meters
(THERE ARE NO ELECTRONICS INSIDE JUNCTION BOX)
CUSTOMER SIDE
(Wired at Installation Site)
FACTORY SIDE
(Wired at Factory)
Red
Black
Red
White
Black
White
NOT USED
Blue
Green
Red
Orange
Black
White
NOT USED
CAUTION: Strip wires 3/8" and
do not crimp insulation.
4.37
3/4 FNPT
Conduit Receptacle
Grounding Screw
GROUNDING SCREW NOT USED
1

(The shield [drain wire] is only connected
on the other end [the electronics end]).
Metal Conduit
is recommended
with appropriate
grounding to
minimize effects
from external
noise sources.
Sage supplies 25 feet of cable for the interconnect wires
between the junction box and the Remote Enclosures:
Carroll (manufacturer), Part #C0783, 20 gauge, 6 conductor,
foil shielded, grey PVC jacket.
SEE THE PREVIOUS PAGE FOR THE OTHER END OF THE REMOTE WIRING HOOKUP (the electronics side).
1 CSA standards require grounding this end as well. Refer to proper electrical code: CEC Part 1
Appendix J18-100
aCAUTION: Cable and cable glands are not for use in hazardous area environ-
ments. Power, ground, outputs, shielded cable, seal ttings and conduits are
to be supplied by customer. CSA approved installations must comply with
CEC Part 1 Appendix J18-100
NOTE: The Sensor Junction Box
will have a serial number tag.
It is important to match this serial
number with the serial number of
the electronics. Mixing compo-
nents from different meters can
result in signicant errors.
ITEM 1910
REV. 02-SIL/SRL
Cable Connector Diagram for AC Powered
General Purpose Sage Lite (SIL or SRL) Meters
XP AC115 Power Board
Power Cable Plug Receptacle
Power Cable Plug with
Screw Clamp Wire Terminals
Black (AC1)
White (AC2)
Green (Earth)
Read Terminal Block Left to Right
NOTE: Screw for terminals on
bottom of terminal block.
ITEM 1910
ITEM 1910
Section
THEORY / STYLES / SPECIFICATIONS
B
ITEM 1910
ITEM 1910
Theory / Styles / Specications
SAGE THERMAL MASS FLOW METERS
Sage Thermal Mass Flow Meters are designed for
high performance mass ow measurement of ow
rate and consumption of gases such as air, oxygen,
natural gas, nitrogen, digester gas, bio gas, are gas,
hydrogen, argon, carbon dioxide and other gases
and gas mixes. They are eld rangeable and have
a convenient user interface.
Our state-of-the-art, microprocessor technology
features fault tolerant multiprocessors that transfer
bi-directional system information via digital proto-
col. This ensures a clean, error-free ow signal is
transferred as high resolution digital data within
the Sage meter subsystems which makes the unit
virtually impervious to external analog noise.
Features and Benets
The Sage SIL/SRL high performance gas mass ow
meter product line (Sage Lite) has many features of
the standard product line, but does not have a dis-
play, does not have a menuing keypad, does not sup-
port multiple channels, and does not support relay
outputs. However it has linear outputs of ow rate
and temperature. It is offered in a 5x5x4 NEMA 4X
enclosure, or optional Explosion Proof Enclosure
(XP2), or as a single circuit board for customized
end-user packaging.
Sage also offers Sage Prime Industrial Thermal
Mass Flow Meters (Series SIP or SRP) or the Heavy
Industrial Series (Series SIE or SRE). Sage also offers
the General Purpose (SIG or SRG) Series. The SIE/SRE
and SIG/SRG Models provide an easy-to-use menuing
system via a 4-button Keypad as well as RS232 com-
munication to an extensive menuing system for user
congurability. Also, these Models are available with
multiple calibrations (up to four channels, A-D).
Contact Sage for details. If there are any features that
you require, or if you need application assistance,
feel free to contact our local factory trained represen-
tative in your area. Refer to www.sagemetering.com,
or phone the Sage Sales or Service Staff to assist you
(866-677-7243).
PRINCIPLE OF OPERATION OF THE
THERMAL MASS FLOW METER
Sage Thermal Mass Flow Meters have two sensors
constructed of reference grade platinum windings
(RTDs). The two RTDs are clad in a protective 316SS
sheath and are driven by a proprietary sensor drive
circuit. One of the sensors is self-heated (ow sen-
sor), and the other sensor (temperature/reference
sensor) measures the gas temperature. The pair is
referred to as the sensing element, and is either in-
stalled in a probe as an Insertion style, or inserted
into a pipe section as an In-Line style ow meter.
As gas ows by the ow sensor, the gas molecules
carry heat away from the surface, and the sensor
cools down as it loses energy. The sensor drive
circuit replenishes the lost energy by heating the
ow sensor until it is a constant temperature dif-
ferential above the reference sensor. The electrical
power required to maintain a constant temperature
differential is directly proportional to the gas mass
ow rate and is linearized to be the output signal
of the meter.
It is essential that this constant temperature dif-
ferential be maintained, even if there are wide uc-
tuations in gas temperature. It is the job of the
Sage proprietary sensor drive circuit to maintain the
differential, whether or not the gas temperature
changes, or however quickly molecules cool off the
ow sensor. It is also necessary to properly calibrate
the device with the actual gas (or close equivalent
with certain gases), in the Sage National Institute of
Standards certied (NIST) calibration facility. By ac-
complishing these two critical objectives, the Sage
meters provide an extremely repeatable (0.2% of full
scale) and accurate output directly proportional to
the mass ow rate of the gas being measured.
REV. 02-SIL/SRL
ITEM 1910
REV. 02-SIL/SRL
INTEGRAL GENERAL PURPOSE
IN-LINE INSERTION
REMOTE GENERAL PURPOSE
IN-LINE INSERTION
SIL-XXX SIL-XX-XX SRL-XXX SRL-XX-XX
BASIC GENERAL PURPOSE BLIND SAGE FLOW METER STYLES
ITEM 1910
Section
DRAWINGS
C
ITEM 1910
ITEM 1910
REV. 02-SIL/SRL
SIL Series Integral Style Lite
1
(Blind) General Purpose
Mass Flow Meters
1 Lite refers to Sage Lite Product Line for OEM customers (consisting of blind enclosures) or
optionally offered as a single round circuit board only. Also available upon request with explosion
proof enclosures.
2 NPT Fittings standard
3 Flow Conditioning built in to Flow Meter Pipe Sizes 3/4" and up. Contact Sage for optional
1/4" tube ow body.
4 Flanged Mounting available for high pressure operation
5 Cord Grips shown have 1/2" NPT access holes.
INSERTION STYLE
4,5
NEMA 4X Enclosure. 150#, 300#, or 600# anged mounting
is optionally available. Available probe lengths (C) are 6",
12", 15", 18", 24", 30", 36" or 48".
5.00
5.00 4.00
C
IN-LINE STYLE
2,3,5
NEMA 4X Enclosure. 150#, 300#, or 600# anged ends are
optionally available. (1" Flow Body Shown)
B
2.55
L
5.00
5.00
4.00
IN-LINE METER DIMENSIONS
Gen. Purpose (A)
8.03"
8.09"
8.15"
8.28"
8.40"
8.53"
8.65"
8.90"
9.15"
9.40
9.90"
Pipe Size x
Flow Body Length (L)
3
3/8" x 6"
1/2" x 7"
3/4" x 7"
4" x 12"

1" x 8"
1-1/2" x 12"
3" x 12"
1-1/4" x 10"
2-1/2" x 12"
2" x 12"

1/4" x 6"
ITEM 1910
28
REV. 02-SIL/SRL
SRL Series Remote Style Lite
1
(Blind) General Purpose
Mass Flow Meters
5.00
5.00
1.5
C
HUB FITTING
INSERTION STYLE
4
is optionally available. Available probe lengths (C) are 6",
12", 15", 18", 24", 30", 36" or 48".
3.00 dia.
L
5.00
5.00
IN-LINE STYLE
2,3
is optionally available. (1" Flow Body shown)
HUB FITTING 25' CABLE SUPPLIED
Can be shortened or even
lengthened in the eld
by up to 1000 feet with-
out affecting calibration.
4.00 DEPTH
4.00 DEPTH
25' CABLE SUPPLIED
by up to 1000 feet with-
out affecting calibration.
optionally offered as a single round circuit board only. Also available upon request with explosion
proof enclosures.
1/4" tube ow body.
5 Cord Grips shown have 1/2" NPT access holes.
JUNCTION BOX
(No Electronics)
JUNCTION BOX
(No Electronics)
JUNCTION BOX
Class I, Group B, C, D
Class II, Group E, F, G
NEMA 7 & NEMA 9
CONDUIT FITTING
(Customer Supplied)
CONDUIT FITTING
(Customer Supplied)
ITEM 1910
REV. 02-SIL/SRL
SIL Series Integral Style Lite
1
(Blind) Optional
Explosion Proof Mass Flow Meters (XP2)
optionally offered as a single round circuit board only.
1/4" tube ow body.
INSERTION STYLE
4
Class I, Division I, Group B, C, D. 150#, 300#, or 600#
anged mounting is optionally available. Available probe
lengths (C) are 6", 12", 15", 18", 24", 30", 36" or 48".
C C
4.81
4.50
4.81
3.44
IN-LINE STYLE
2,3
anged ends are optionally available. (1" Flow Body shown)
B
3.44
4.69
4.50
L
IN-LINE METER DIMENSIONS
Expl. Proof (B)
7.33"
7.39"
7.45"
7.58"
7.70"
7.83"
7.95"
8.20"
8.45"
8.70
9.20"
Pipe Size x
Flow Body Length (L)
3
1/4" x 6"
3/8" x 6"
1/2" x 7"
3/4" x 7"
1" x 8"
1-1/4" x 10"
1-1/2" x 12"
2" x 12"
2-1/2" x 12"
3" x 12"
4" x 12"
Class III
CENELEC: EExd IIC, 1P66
NEMA 4X, 7BCD, 9EFG
TRANSDUCER ENCLOSURE
ITEM 1910
30
REV. 02-SIL/SRL
4.69
4.50
3.00 dia.
L
3.44
SRL Series Remote Style Lite
1
(Blind) Optional
Explosion Proof Mass Flow Meters (XP2)
4.69
4.50
3.00
3.44
1.5
C
INSERTION STYLE
4
anged mounting is optionally available. Available probe
lengths (C) are 6", 12", 15", 18", 24", 30", 36" or 48".
IN-LINE STYLE
2,3
anged ends are optionally available. (1" Flow Body shown)
25' CABLE SUPPLIED
Can be shortened
or even lengthened
in the eld by up to
1000 feet without
affecting calibration.
25' CABLE SUPPLIED
by up to 1000 feet without
affecting calibration.
JUNCTION BOX
(No Electronics)
optionally offered as a single round circuit board only.
1/4" tube ow body.
JUNCTION BOX
(No Electronics)
Class III
CENELEC: EExd IIC, 1P66
NEMA 4X, 7BCD, 9EFG
TRANSDUCER ENCLOSURE JUNCTION BOX
NEMA 7 & NEMA 9
CONDUIT FITTING
(Customer Supplied)
HUB FITTING
HUB FITTING
CONDUIT FITTING
(Customer Supplied)
ITEM 1910
4"
4"
REV. 02-SIL/SRL
SVA SERIES ISOLATION VALVE ASSEMBLY
FOR INSERTION METERS
Used for pressures to 650 psig
1
(shown for use
with 1/2" diameter insertion meters). 150# or 300#
anged mounting is optionally available. Available
sizes are 1/2" x 3/4" NPT (shown) and 3/4" x 1" NPT.
11.00
Mounting Hardware
3
STCF SERIES TEFLON FERRULE
COMPRESSION FITTING
1/2" tube x 1/2" pipe tting (shown, not to scale), is
used for low pressure insertion applications to 125
psig (Stainless Steel Ferrule optional for higher pres-
sure applications up to 225 psig). Also available in
3/4" tube x 3/4" pipe size.
1.92
1 At 650 psig, force exerted on 1/2" diameter probe is approx. 125 psig
2 Safety chain is designed to prevent probe from accidentally escaping from assembly during removal from pressurized pipe
3 Insertion meters can have optional anged mounting (generally used for high pressure or very hot gases). This adaptation is not
shown. Consult factory for details.
SENSOR ASSEMBLY
EXTENDS 2.25" L
BELOW THE LOWER
EDGE OF THE
WELDED COLLAR
CLAMP WITH
CHAIN TAUT
1/2" BORE
SINGLE PIECE
COLLAR CLAMPS
3/4"x1.5"
PIPE NIPPLES
3/4"x3"
BALL VALVE
SVA SERIES ISOLATION VALVE ASSEMBLY DETAIL
Cut away view of probe inserted through isolation
ball valve assembly.
1/2"3/4" BALL VALVE
WELDMENT WITH
1/2" TUBE TO PIPE
COMPRESSION FITTING
3/4"x1" HALF COUPLING
(WELDLET)
MOUNTING PLATE FOR THIN WALLED DUCTS
(INCLUDES STCF05 COMPRESSION FITTING)
NOTE: User needs to weld a 3/4" female
weldlet (of appropriate radius) to mate
with existing pipe after a 3/4" hole has
been drilled in pipe. The 3/4" Male Coupling
of the Sage Isolation Valve Assembly will
thread into the users 3/4" weldlet.
SAFETY CHAIN
PROBE LENGTH SAFETY
(with sensor)
2
CHAIN LENGTH
2
12" 8.25"
15" 11.25"
18" 14.25"
24" 20.25"
ITEM 1910
32
REV. 02-SIL/SRL
Wall Mounting Procedure for Remote General Purpose Enclosure
A 6-32 Pan Head Phillips machine screw is recom-
mended for each corner of the SRL remote enclosure.
The screw will have to pass through .296 inches
(roughly 19/64") of overall thickness at the bottom
of the enclosure mounting hole before the screw
threads emerge. The thickness of the enclosure mate-
rial is 1/8". The over-all length of the screw depends
on the customers mounting conguration and how
much depth they have to penetrate on their mount-
ing plate that the enclosure is being fastened to.
4.21
4.21
DIMENSIONS ABOVE ARE FROM
HOLE CENTER TO HOLE CENTER
ITEM 1910
REV. 02-SIL/SRL
Flanged Ends for In-Line Meter (OPTIONAL)
LENGTH L SAME AS NON-FLANGED METER
(See table on page 29. For example, 1"x8" ow
body has an 8" length.The length will be the same
whether an NPT ow body, or whether anged.
If a anged ow body, the 8" dimension will be
a Face-to-Face dimension.)
Flanges for 3
1
2" pipe sizes and up,
have 8 bolt holes
Flanges for 3" pipe sizes and
smaller have 4 bolt holes
Flow Conditioning Screens FOR FLOW BODIES 3/4" AND UP
Screens shown
with NPT tting.
ITEM 1910
34
REV. 02-SIL/SRL
General Purpose Probe and Transmitter Head Assembly Procedure
ASSEMBLY STEPS
A Slip Buna Gasket over 3/4" MNPT threads on probe
so it ts ush against the face of the at stainless
gasket sealing ring.
B Place 3/4" MNPT threaded end of probe through
the receiving hole in the center of the bottom bulk-
head of the electronic enclosure.
C Thread the 3/4" external tooth lock washer on the
3/4" MNPT threaded probe end.
D Secure probe with 1/4-1/2 turn past hand tight to
seal probe support in place. Make sure that sensor
window aperture is properly positioned in
upstream/downstream orientation.
3/4" EXTERNAL TOOTH LOCK
WASHER THREADS OVER
3/4 MNPT THREADS ON PROBE
C
D
A
BUNA GASKET
B
ENLARGED TO SHOW DETAIL
ITEM 1910
Section
USER INTERFACE
D
ITEM 1910
ITEM 1910
REV. 02-SIL/SRL
Sensor Functionality and Zero Calibration Self Check
USING A LAPTOP WITH OPTIONAL
SILCOM CABLE ASSEMBLY (see page 40)
Sage Meters have provisions to check the meters
Zero Flow calibration against the original factory
calibration using Sage VIP. This procedure conrms
that the sensor is functioning properly, that the
sensor is clean, and is also a strong indication that
the entire meter is still in calibration. Refer to the
last line of the Certicate of Conformance that was
supplied with the meter, and note the gases Flow
Zero value in mw. Also note the calibration pressure
of the gas on the certicate. In order to access the
Flow Zero value with Sage VIP, you will rst need
to create a Zero Flow condition (usually done by
closing valves in your system) with the same gas
and at the same pressure as the calibration pressure
(that is, the pressure must be maintained to simulate
the factorys original zero calibration point).
The procedure is as follows: Open up Sage VIP.
1) Load Sage VIP onto Desktop
2) CAUTION: POWER MUST BE OFF BEFORE
YOU PROCEED TO THE FOLLOWING THREE
STEPS (3, 4, and 5), OR SERIOUS DAMAGE
WILL OCCUR.
3) Connect the optionally supplied cable/connector
assembly to the mating connector on the round
board
4) Connect other end (DB9) to mating connector to
computer
5) Power up the Sage Meter, and the menus below
will appear (see footnote 1, if problems)
1
6) At the prompt enter 39 to bring up ow output
data in mw
7) Look at the air=cal values. The system is report-
ing real time ow output (of whatever gas it was
calibrated with, not necessarily air).
8) Wait approximately 2 minutes for the data to
stabilize (i.e., value will remain relatively con-
stant [within a few mw]), then type g to freeze
and record the last reading
9) You can take, and freeze, additional points by
repeatedly typing g
10) Optionally, you can press the Print Screen key
on your computer, and later print and store the
calibration information
11) The value should closely match Flow Zero
value (within a few mw, depending on full
scale range) on the next to last line of your
Certicate of Conformance. (Note: Meters are
checked with sensor in vertical position. The
mw will be slightly lower in horizontal position)
12) To exit, hit the Tab key
13) Alternately, remove probe from process, cap
sensor with a plastic bag or other means of pre-
venting ow, and compare to the Air Flow Zero
Value in mw on the last line of Certicate,
instead of the actual process gas (both values
are shown on the certicate.)
1 If data is not transmitting, select ViewSettings to select the active COM port (1-4), then shut down
and restart VIP. If necessary, verify that your computers Serial Port has the correct Serial Cable Port
Settings. Open Control Panel (Start, Control Panel). Then select System, Hardware, Device Manager,
Ports (COM & LPT), Communications, Port Settings.
Bits per Second: 19200 Data Bits: 8 Flow Control: None
Parity: None Stop Bits: 1
ITEM 1910
38
REV. 02-SIL/SRL
SIL NT Version Menuing InterfaceRev. 3.029 USED WITH REV. 2.066 METERS
(SILCOM NT RS232 INTERCONNECT CABLE/ASSEMBLY REQUIRED [See Page 40])
STEPS
1. Load Sage VIP onto Desktop
2. CAUTION: POWER MUST BE OFF BEFORE
YOU PROCEED TO THE FOLLOWING
THREE STEPS (3, 4, and 5), OR SERIOUS
DAMAGE WILL OCCUR.
3. Connect the optionally supplied cable/con-
nector assembly to the mating connector on
the round board
SIL MENUING INTERFACE
2
Upon power-up, the SIL will transmit the
following menu to a host PC through its
factory interface plug (SILCOM). The data is
4. Connect other end (DB9) to mating con-
nector to computer
5. Power up the Sage Meter, and the menus
below will appear (footnote 1, if problems)
1
formatted as ASCII text for a VT-100 at
19200,8,None,1,None settings. VIP Terminal
will default to these settings.
10) Calib mw Val FACTORY ONLY (not for customer use)
11) TempExciteRes FACTORY ONLY (not for customer use)
12) Temp VREFVal FACTORY ONLY (not for customer use)
13) Flow Load Res FACTORY ONLY (not for customer use)
14) Temp Calib [A] FACTORY ONLY (not for customer use)
15) Temp Calib [B] FACTORY ONLY (not for customer use)
16) Temp Calib [C] FACTORY ONLY (not for customer use)
17) Temp Calib [D] FACTORY ONLY (not for customer use)
18) Temp Displ [A] FACTORY ONLY (not for customer use)
19) Temp Displ [B] FACTORY ONLY (not for customer use)
20) Temp Displ [C] FACTORY ONLY (not for customer use)
21) Temp Displ [D] FACTORY ONLY (not for customer use)
22) Flow Coeff [A] NORMALLY NOT USED BY CUSTOMER UNLESS FACTORY AUTHORIZED
23) Flow Coeff [B] NORMALLY NOT USED BY CUSTOMER UNLESS FACTORY AUTHORIZED
24) Flow Coeff [C] NORMALLY NOT USED BY CUSTOMER UNLESS FACTORY AUTHORIZED
25) Flow Coeff [D] NORMALLY NOT USED BY CUSTOMER UNLESS FACTORY AUTHORIZED
26) Flow Coeff [E] NORMALLY NOT USED BY CUSTOMER UNLESS FACTORY AUTHORIZED
27) Flow Coeff [F] NORMALLY NOT USED BY CUSTOMER UNLESS FACTORY AUTHORIZED
28) IIR Coeff CAN BE USED BY CUSTOMER (Filtering)
3
29) Min SCFM CAN BE USED BY CUSTOMER
30) Max SCFM CAN BE USED BY CUSTOMER
31) Min Temp F CAN BE USED BY CUSTOMER (however, if item 37=8, contact Factory)
32) Max Temp F CAN BE USED BY CUSTOMER (however, if item 37=8, then Value Entered
corresponds to how many SCF per pulse (50 msec pulse width is xed)
33) DAC1 Min FACTORY ONLY (not for customer use)
34) DAC1 Max FACTORY ONLY (not for customer use)
35) DAC2 Min FACTORY ONLY (not for customer use)
36) DAC2 Max FACTORY ONLY (not for customer use)
37) Output Cong CAN BE USED BY CUSTOMER (see Table)
38) Serial Number FACTORY ONLY (not for customer use)
39) RealTime Disp CAN BE USED BY CUSTOMER
40) Save2EEPROM CAN BE USED BY CUSTOMER
1 If data is not transmitting, select ViewSettings to select the active COM port (1-4), then shut down
and restart VIP. If necessary, verify that your computers Serial Port has the correct Serial Cable Port
Settings. Open Control Panel (Start, Control Panel). Then select System, Hardware, Device Manager,
Ports (COM & LPT), Communications, Port Settings.
2 Period (.) escapes out without changing setting; if in item 39. Type g to freeze and record the last
reading. You can take, and freeze, additional points by repeatedly typing g
3 (Low Value=Fast, High Value=Slow, Factory Default=10)
VALUE
0-3
4
5
6
7
8
FUNCTION
DAC1 DAC2
NOP
1
NOP
Flow Flow
Flow Temp
Temp Flow
Temp Temp
NOP Pulse
1 NOP=No Operation
Bits per Second: 19200 Data Bits: 8 Flow Control: None
Parity: None Stop Bits: 1
ITEM 1910
REV. 02-SIL/SRL
Pulsed Outputs on SIL NT DETAILS OF OPTIONAL CONFIGURATION
(OPTIONAL SILCOM RS232 INTERCONNECT CABLE/ASSEMBLY REQUIRED [See page 40])
DAC2 controls the 0-5 VDC output driver amplier.
This amplier will drive the output pin to the limits
set in menu items #35 & #36. The output will gen-
erate a 0-5 volt pulse at 50 msec in width. Contact
Factory if it is required to have a pulse output
amplitude other than 0-5 volts.
The pulse width is not adjustable; however the
repetition of pulses is proportional to the ow rate
over time.
The pulse amplitude is adjusted by the menu item
limits.
Since the output is controlled by the menu item
limits, any pulse amplitude and steady state voltage
level can be generated. Typically, the output will idle
at logic low or zero volts and pulse high at 5 volts.
However, the menu item limits may be swapped to
create a high logic level idle with a 50 msec pulse
driving low level.
The pulse output can drive loads not to exceed
20mA. This allows it to directly interface with TTL
logic, optoisolators, and low power relays. The out-
put pulse is logic level compatible with no mechani-
cal contacts to wear out. Do not apply any voltage to
the output pin as it will damage the drive amplier.
SIL NT MENU DESCRIPTIONS
THAT APPLY TO PULSED OUTPUTS
The following menu items have been changed to
provide for additional functionality including PULSE
output of the SIL2 product line. These functions are
only active during standalone operation.
While Output Conguration register setting is 0-7
31) Min Temp F
32) Max Temp F Lower and upper limits of reported tem-
perature output value.
While Output Conguration register setting is 8
31) Min Temp F Enter the timebase value for pulse
updates. (See table)
TIMEBASE VALUE
Seconds .02
Minutes .000333333
32) Max Temp F Enter totalizer trip reset value. Example,
enter 100 to send a pulse out every 100 SCF.
The IDAC and VDAC names have been changed to
DAC1 and DAC2 respectively. The following menu
items reect this change. The operation is the same
as in previous revisions.
33) DAC1 MINFactory Only (unless authorized)
34) DAC1 MAXFactory Only (unless authorized)
35) DAC2 MINFactory Only (unless authorized)
36) DAC2 MAXLower and upper limits of both DAC
channels. The units are in DAC values and range from
0 to 4095. Contact Factory if pulse output is other than
a 0-5 volt pulse (All pulse settings are 50 msec pulse
width).
Pulse output has been added to DAC2 and is selected
by entering an 8 in the output conguration register.
DAC1 will be inoperative during pulse output selection.
37) Output CongSelects DAC
output routing.
(See table at right)
VAL FUNCTION
DAC1 DAC2
0-3 nop nop
4 ow ow
5 ow temp
6 temp ow
7 temp temp
8 nop Pulse
ITEM 1910
40
REV. 02-SIL/SRL
SILCOM Interface Cable Instructions
The SILCOM computer interface cable must be
attached to the SILNT board assembly as shown in
the drawing below. The cable itself is 6 feet in length
and has a dual row ten pin header socket on one end
which attaches to the SILNT board assembly and a
DB9 pin socket on the other end which attaches to
your computer.
ITEM 1910
Section
DIAGNOSTICS
E
ITEM 1910
ITEM 1910
REV. 02-SIL/SRL
Common Diagnostics
SYMPTOM: Meter output reading zero continuously,
or full scale continuously, or temperature reading is
abnormally low (hundreds of degees below zero).
POSSIBLE CAUSES/SUGGESTED CORRECTIVE ACTION:
a) It is likely that a wire is loose. But in rare cases,
a sensor could fail (i.e., if a standard sensor, HT01
or HT02 sensor exceeds a process temperature of
450F, or if a very high temperature sensor, HT03,
exceeds 800F).
b) Check for continuity to be sure the wiring is mak-
ing good contact at the terminals of the Junction
Box. (See the note on the Junction Box drawing
on page 18 requiring that the wires be stripped
3/8" and that the insulation is not interfering with
the contact.) (An Ohm Meter can be placed
between the Electronics end of the wire and the
Sensor side [the left side] of the Junction Box to
assure of continuity and good contact.)
c) Also, to verify that the electronics is not mixed
up with the sensors, the serial number will come
up upon power up, right after Initializing on the
Display. Alternately, depress the Back/Down but-
ton and it reports the serial number. If the serial
number doesn't agree with the Junction Box labels,
that would effect calibration (in other words,
sensors and electronics are a matched pairmix-
ing them up will cause false readings). Also metal
Serial Number Tags are fastened to both the elec-
tronics as well as the Junction Box. They must
have identical Serial numbers.
d) To check if a sensor has failed on a remote style
meter, it is easy to use the Junction Box to do so.
You must Power Down (shut off power), but you
do not need to remove the probe from the pipe.
Refer to page 18.
e) An Ohm Meter is required to check across the sen-
sor leads of the Flow Sensor. Look at the drawing
of the Junction Box. Disconnect the red wires on
the Factory Side to isolate and measure the resist-
ance. If the reading is innity or a short, it means
that sensor is burned out.
f) Now check the Temperature Sensor. Disconnect
the white wires on the Factory Side to isolate
and measure the resistance. If you have innity
or a short, it means that sensor is burned out.
Note: Normally the sensors will read approximately
110 ohms at 70 F. At higher temperatures they should
read a higher resistance, but both sensors should have
a similar value.
g) On integral style meters (SIL), there is no Junction
Box. In that case, refer to the Circuit Board Wiring
drawing on page 17 and check the sensor on the
SDB Terminal. Remove the appropriate wires rst
(red pair for ow, then white pair for temperature).
Measure their resistance. If reading innity or
short, it means that sensor is burned out.
h) In some instances, a user may have inadvertently
changed menu settings inappropriately. If so, the
meter can report erroneous readings, or possibly
exhibit the symptoms described above. In that
case, item 708 can be used. On the System Set Up
Menu, 708 (Factory All), restores meter to original
factory settings (remember to rst put in passcode
99999 for item 708 to successfully restore settings).
SYMPTOM: Meter output Railing (Pegging) or
Reading High
POSSIBLE CAUSES/SUGGESTED CORRECTIVE ACTION:
a) Possibly caused by water droplets hitting the sen-
sor (which generally causes output to spike; but if
droplets are near continuous, output may rail).
b) Poor Wiring.
c) A downstream valve too close to the meter (ow
may be reecting back).
ITEM 1910
44
REV. 02-SIL/SRL
d) Possible jet effect if upstream pipe is smaller than
meter ow body or if valve is too close upstream)
to meter.
e) Not following Probe Insertion Guideline.
f) Sensor may be contaminated. Remove probe,
wipe off or clean with a solvent. Reinsert.
g) Insufficient straight run (i.e. ow prole is dis-
turbed, causing errors).
h) Using a different gas or gas mix than the meter
was specied and calibrated for.
i) If a Remote Style Meter (SRL), be sure Serial
Numbers of Probe and Remote Electronics are
identical (if not, errors in calibration are inevi-
table). To conrm, verify that Junction Box Serial
Number Tag has identical Serial Numbers to Tag
on Remote Enclosure.
j) If sensor is not aligned properly, with Upstream
mark facing upstream, rotation greater than 5
degrees may cause change in reading (greater
than 5 degrees and less than 20 degrees
causes meter to over-report; a greater rotation
actually blocks the sensor, and causes meter to
under-report).
k) Meter may appear to be reading high if user is
comparing Sage ow meter readings (SCFM) to
an uncorrected volumetric device (ACFM). For
example, at constant volume, a decrease in gas
temperature will increase the mass ow (SCFM).
That is completely normal.
SYMPTOM: Reading Low
POSSIBLE CAUSES:
a) Poor ow prole Upstream (insufficient upstream
straight run).
b) Insufficient power supplyrequire minimum
250 mA (see Specications).
c) Excessive load on the 4-20 mA if using Self-
Powered terminal hook up (Ground based).
d) Ground loop problem. Solution: hook up meters
in opto-isolated mode (user-powered 4-20 mA
mode).
e) To check if problem is due to 4-20 mA output
device, temporarily remove device, and observe if
display reads as expected (if so, see c or d).
f) Not following Probe Insertion Guideline.
g) Sensor may be contaminated. Remove probe,
wipe off or clean with a solvent. Reinsert.
h) Using a different gas or gas mix than the meter
was specied and calibrated for.
i) If a Remote Style Meter (SRL), be sure Serial
Numbers of Probe and Remote Electronics are
identical (if not, errors in calibration are inevita-
ble). To conrm, verify that Junction Box Serial
Number Tag has identical Serial Numbers to Tag
on Remote Enclosure.
j) If sensor is not aligned properly, with Upstream
mark facing upstream, rotation greater than 5
degrees may cause change in reading (greater
than 5 degrees and less than 20 degrees
causes meter to over-report; a greater rotation
actually blocks the sensor, and causes meter to
under-report).
ITEM 1910
REV. 02-SIL/SRL
k) Meter may appear to be reading low if user is
comparing Sage ow meter readings (SCFM) to
an uncorrected volumetric device (ACFM). For
example, at constant volume, an increase in gas
temperature will lower the mass ow (SCFM).
That is completely normal.
l) If gas temperature falls signicantly below freez-
ing, ow meter may slightly over-report or
under-report.
SYMPTOM: Display does not have power
POSSIBLE CAUSE: Mis-wiring may have caused one or
both of the Fuses to blow.
CORRECTIVE ACTION: Contact Sage to send replace-
ment fuse(s). ALL FUSES ARE PLUG IN, NOT
SOLDER IN.
ITEM 1910
ITEM 1910
Section
WARRANTIES AND
SERVICE WORK
F
ITEM 1910
ITEM 1910
REV. 02-SIL/SRL
Warranties and Service Work
LIMITED WARRANTY
Sage Meterings products are warranted against faulty
materials or workmanship for one year from the date
of shipment from the factory. Sages obligation is
limited to repair, or at its sole option, replacement of
products and components which, upon verication
by Sage at our factory in Monterey, California, prove
to be defective. Sage shall not be liable for installa-
tion charges, for expenses of Buyer for repairs or
replacement, for damages from delay or loss of use,
or other indirect or consequential damages of any
kind. This warranty is extended only to Sage prod-
ucts properly used and properly installed for the par-
ticular application for which intended and quoted;
and does not cover water damage due to improper
use of cord grips or removal of protective caps; and
does not cover Sage products which have been
altered without Sage authorization or which have
been subjected to unusual physical or electrical
stress. Sage makes no other warranty, express or
implied, and assumes no liability that goods sold to
any purchaser are t for any particular purpose.
Transportation charges for materials shipped to the
factory for warranty repair are to be paid by the ship-
per although, in the case of International returns, the
inbound shipping charges can be initially billed to
Sage, and then recovered in the nal invoice upon
returning the repaired or warranteed product. Sage
will return items repaired or replaced under warranty
prepaid. NOTE: No items will be returned for warran-
ty repair without prior written authorization from
Sage Metering, Inc.
Sage does not warranty damage due to corrosion.
CANCELLATION / RETURN POLICY
Cancellation or Return: After issuance of a purchase
order (by phone, mail, e-mail or fax) or a credit card
order (by phone, mail, e-mail or fax), there will be a
cancellation fee for any cancelled order. Cancella-
tions must be in writing (by mail, e-mail or fax):
1) If credit card order or non-credit card order is
cancelled within 7 days of issuance of purchase
order or date order was placed (which ever is
earlier), there will be a 10% cancellation fee.
2) If credit card order or non-credit card order is
cancelled after 7 days, but prior to shipment,
there will be a 20% cancellation fee. (If order is
cancelled due to late delivery, the cancellation
fee will be waived. Late delivery is dened as
shipping a meter 7 days or later than the delivery
date acknowledged by Sage Metering at time of
placing order).
3) If a credit card customer decides to return the
equipment after shipment for credit, credit will
not be issued if equipment is damaged or if equip-
ment is returned after four (4) months of ship-
ment. If equipment is not damaged, then equip-
ment can be returned after issuance of a Return
Meter Authorization (RMA) by Sage. Returned
package must be insured by customer and must
reference proper RMA# on outside of package,
or package may be rejected (i.e., package will be
returned unopened). Credit Card customers will
be charged a 30% re-stocking fee (70% balance
will be credited back). Customer is responsible for
return shipping charges and any damage if
improperly packaged.
continued on next page
ITEM 1910
50
4) If a non-credit card customer decides to return
the equipment after shipment for credit, credit
will not be issued if equipment is damaged or if
equipment is returned after 1 month of ship-
ment, unless authorized by a representative at
Sage Metering, Inc. The Sage representative will
issue a Return Material Authorization (RMA) at
that time and will advise of the restocking fee.
Returned package must be insured by cus-
tomer and must reference proper RMA# on
outside of package, or package may be rejected
(i.e., package will be returned unopened).
Customer is responsible for return shipping
charges and any damage if improperly packaged.
REV. 02-SIL/SRL
ITEM 1910
51
RETURNING YOUR SAGE METER
A Return Material Authorization Number (RMA#)
must be obtained prior to returning any equipment
to Sage Metering for any reason. RMA#s may be
obtained by calling Sage Metering at 866-677-7243 or
831-242-2030 between 8:00 am and 5:00 pm
Monday through Friday.
A Sage RMA Form (see page 52) must be lled out
and included with the meter being returned to Sage
Metering.
A purchase order is required prior to an RMA being
issued. Most repairs or recalibrations can be quoted
over the phone. For equipment that must be evaluat-
ed, an Evaluation purchase order in the amount of
$150 is required. Once an evaluation is completed
and a quote has been issued, you can choose to pro-
ceed with the work or have the unit returned with
only the evaluation and freight fee billed.
In accordance with the Right to Know Act and
applicable US Department of Transportation (DOT)
regulations, Sage Metering will not accept delivery of
equipment that has been contaminated without writ-
ten evidence of decontamination, and has instituted
the following Return/Repair conditions. Strict adher-
ence to these conditions is required. Returned equip-
ment that does not conform to the requirements list-
ed below will not be processed. If Sage Metering nds
evidence of contamination, we may, at our option,
have the unit returned at your expense. For your ref-
erence, the requirements for packaging and labeling
hazardous substances are listed in DOT regulations
49 CFR 172, 178, and 179.
1. The equipment must be completely cleaned and
decontaminated prior to shipment to Sage
Metering. This decontamination includes the sen-
sor, probe, electronics and enclosures internally
and externally. All packaging must be clean and
free from contamination.
2. A Material Safety Data Sheet (MSDS) is required
for all process uids and gases that have been in
contact with the equipment. This includes uids
or gases used in cleaning the equipment. A
Decontamination Statement is also required for
each meter returned using a different gas or uid.
Both the MSDS and the Decontamination
Statement are to be attached to the OUTSIDE of
the shipping container. If both documents are not
attached, you will be called, and the equipment
sent back to you at your expense.
3. The decontamination Statement must include
the following required information
A. A list of all chemicals and process uids used
in the equipment, including decontamination
uids or gases.
B. The model and serial number of the equip-
ment being returned.
C. A company officer or other authorized persons
signature on the statement.
Return Shipping Address:
Sage Metering, Inc.
8 Harris Court, Building D1
Monterey, CA 93940
S A G E ME T E R I N G , I N C .
REV. 02-SIL/SRL
ITEM 1910
52
REV. 02-SIL/SRL
RETURN MATERIAL AUTHORIZATION RMA #
RETURN CUSTOMER INFORMATION
Customers Name Fax #
Customers Contact Name Phone #
Email Address
CUSTOMERS RETURN ADDRESS
Bill to: Ship to:
RETURN PRODUCT INFORMATION
Model No. Serial No(s).
TEMP: MIN NORMAL MAX
PRESSURE: MIN NORMAL MAX
GAS
REASON FOR RETURN / DESCRIPTION OF SYMPTOMS
(All non-warranty repairs could be subject to a minimum evaluation charge)
Recommended steps to be used to duplicate problem/symptoms
Sage Metering Technical Contact
SAGE METERING, INC.
8 Harris Court, Building D-1 / Monterey, California 93940
PHONE: 831-242-2030 / FAX: 831-655-4965
ITEM 1910
G
Section
APPENDIX
G
ITEM 1910
ITEM 1910
REV. 02-SIL/SRL
Junction Box and Upstream Orientation
5.0
4.40
5.0
2.72 2.72
FLOW DIRECTION
FLOW DIRECTION
FRONT VIEW LOOKING DOWNSTREAM LOOKING UPSTREAM
FLOW DIRECTION
ITEM 1910
56
REV. 02-SIL/SRL
CAPTIVE FLOW CONDITIONERS
NOTE: The larger of the two perforated plates of the Sage
conditioning basket is positioned between two anges and two
gaskets as shown. The smaller of the two perforated plates of
the conditioner will freely slide into the application pipe, facing
downstream. The compression will be placed one diameter
downstream of the downstream plate.
ITEM 1910
REV. 02-SIL/SRL
What is a Thermal Mass Flow Meter?
FLOW SENSOR
(Self Heated)
TEMPERATURE SENSOR
(Reference Sensor)
What is a Thermal Mass Flow Meter? It is a meter
that directly measures the gas mass ow based
on the principle of conductive and convective
heat transfer.
All Meters have probes (Insertion Style) or Flow
Bodies (In-Line Style) that support a pair of
sensors, which are in contact with the gas.
The sensors are RTDs, which are resistance tem-
perature detectors. They consist of highly stable
reference-grade platinum windings. In fact, we
use the same material that is used as Platinum
Resistance Standards at the NIST.
The RTDs are clad in a protective 316 SS sheath
for industrial environments.
One of the RTDs [See Diagram below] is self-heated
by the circuitry and serves as the ow sensor. The
other RTD acts as a reference sensor, and measures
the gas temperature. Essentially it is used for tem-
perature compensation.
The Sage proprietary sensor drive circuitry main-
tains a constant overheat between the ow sensor
and the reference sensor. As gas ows by the
heated sensor (ow sensor), the molecules of ow-
ing gas carry heat away from this sensor, and the
sensor cools down as it loses energy. The circuit
equilibrium is disturbed, and momentarily the
temperature difference between the heated sensor
and the reference sensor has changed. The circuit
will automatically (within 1 second) replace this
lost energy by heating up the ow sensor so the
overheat temperature is restored.
The current required to maintain this overheat
represents the mass ow signal. There is no need
for external temperature or pressure devices.
ITEM 1910
Part No. 123655-01
Revision D, November 1999
990 TRANSMITTER SYSTEM
MANUAL
ITEM 2000
Vibration
Current (mA) & 4 mA
16 mA
Full Scale Mils (or m) pp
Thrust Position
Current (mA) & 12 mA
8 mA
Full Scale
990 Transmitter System Manual
1
System Description
The System
The 990 series of transmitters consists of two systems, the 990 Vibration Transmitter
System and the 991 Thrust Transmitter System. Both systems contain three parts - a
3300 NSv or 3300 RAM proximity probe and extension cable (If probe is 5 or 7 metres,
no extension cable is required), and a transmitter. Both systems provide two types of
output signals - a 4 to 20 mA current loop and a voltage signal.
Note: The 3300 NSv Probe and extension cable replaced and assumed the part
numbers of the 3300 RAM Probe and extension cable. The 3300 NSv Probe and
extension cable has blue coaxial cable with grey shrink at the connectors and the 3300
RAM Probe and extension cable has grey coaxial cable with no shrink at the
connectors. These products are identical in form, fit, and function.
The 990 Vibration Transmitter System measures the radial vibration of a shaft or other
part of a machine in relation to the location of the probe tip. The following equation
represents the relationship between the vibration and the loop current.
=
The 991 Thrust Transmitter System measures the distance between the target and a
reference (zero) point. The following equation represents the relationship between the
thrust position and the loop current.
=
Where Full Scale is 25 mils for the 25 - 0 - 25 mils thrust range or 0.6 mm for the 0.6 - 0
- 0.6 mm thrust range.
Both transmitters provide a voltage proportional to the distance between the target and
the probe tip. This voltage is available at the terminal strip and on the BNC connector
for use when gapping the probe and for diagnostic purposes. You may apply this
voltage to any battery powered instrumentation with a 1 MS or larger input impedance
or AC powered equipment when using test adapter part number 122115-01. The
phase of the Prox Out signal is inverted from the Bently Nevada standard of a signal
going positive when there is motion toward the probe. The Prox Out signal is not
isolated and a false alarm may result from connecting it directly to grounded AC
powered equipment. The test adapter provides isolation to avoid grounding problems,
changes the gap voltage to a negative voltage, and corrects the phase of the signal.
ITEM 2000
9
Maintenance and Troubleshooting
Maintenance
This section shows how to verify that the system is operating properly, adjust the
system, and identify parts of the system that are not working properly.
The transmitter system does not require verification at regular intervals. You should,
however, verify operation by using the scale factor verification on page 10 if any of the
following conditions occur:
! components of the system are replaced or disturbed
! the performance of the system changes or becomes erratic
! you suspect that the transmitter is not calibrated correctly
The adjustment procedures on pages 11 thru 16 are included for your information. For
target materials other than 4140 steel and for other special applications, contact your
local Bently Nevada office.
The scale factor verification procedure, the scale factor adjustment procedure, and the
zero/span adjustment procedure require the following instruments:
digital multimeter (2)
spindle micrometer
power supply
CAUTION
Electrostatic discharge on the exposed calibration resistor terminals can cause the
accuracy of the system to go out of specification, or cause the system to fail. Use
appropriate precautions for handling static sensitive devices.
The adjustment procedure also requires the following items:
variable resistor, 0 to 100 kS
vulcanizing compound (for example, Dow 3110 RTV)
soldering iron (with grounded tip) and soldering supplies
The scale factor verification and the scale factor adjustment procedure both use the
test setup as shown in the following figure:
ITEM 2000
ISF
n
'
Vdc
n
& Vdc
n&1
250 m
(
ASF '
Vdc
1625 m
& Vdc
250 m
1375 m
ASF '
Vdc
65 mil
& Vdc
10 mil
55 mil
ISF
n
'
Vdc
n
& Vdc
n&1
10 mil
(
Maintenance and Troubleshooting 990 Transmitter System Manual
10
n Adjust
Micrometer
to..
m or mil
Record
Voltages
Vdc
n
Calculate Scale Factor
ISF
n
(Incremental
Scale Factor)
ASF
(Average
Scale Factor)
1
2
3
4
5
6
7
250
500
750
1000
1250
1500
1625
10
20
30
40
50
60
65
____
____
____
____
____
____
____
_____
_____
_____
_____
_____
____* ____
Scale Factor Verification
1 2 3
Compensate for With the micrometer at the
mechanical backlash, intitial gap, adjust the probe Record voltages at
then adjust the position so that the voltage each gap
micrometer to the is 1.00 Vdc (Electrical Zero). increment, and
initial gap setting. calculate scale
factors.
4
* Calculate ISF for the increment between 1500 and 1625 m (60 - 65 mil) ISF by dividing by
125 m (5 mils).
ITEM 2000
11
If the incremental scale factor (ISF) or the average scale factor (ASF) of the system is out of
tolerance (refer to page 26), contact Bently Nevada Corporation for further information on
possible calibration problems or perform the following adjustment.
Scale Factor Adjustment Procedure
1 2 3
Remove label and vulcanizing in contact with the terminal across the calibration
compound. for less than 10 seconds. terminals.
Desolder calibration resistors.
Use a soldering iron with a
grounded tip and less than a
60 watt rating. Leave the iron Attach variable resistors
4 5 6
Compensate for mechanical
backlash, then adjust the
micrometer to the initial Adjust the probe gap to the Record the voltage at the
calibration gap. electrical zero voltage. initial calibration gap.
ITEM 2000
12
7 8 9
Change gap to second across Rcal-1 until Change gap to final
calibration gap. V = ( V + 6 0.03 ) Vdc. calibration gap.
Adjust the variable resistor
2 1
10 11 12
Adjust the variable resistor Remove variable resistors
across Rcal-2 until
V = ( V + 11 0.06 ) Vdc.
3 1
Repeat steps 4 through 10
until the variable resistors are
not changed to obtain V and
2
V
3.
13 14 15
Measure resistance of Solder correct resistors in
variable resistors. place. Reassemble transmitter.
ITEM 2000
13
Zero/Span Adjustment Procedure - Vibration
Follow these steps to adjust the zero and span for the 990 vibration transmitter.
1
Adjust zero potentiometer with no input signal.
2
Adjust span potentiometer with full scale input signal.
ITEM 2000
14
Zero/Span Adjustment Procedure - Thrust
You may adjust the 991 thrust transmitter zero and span by using either the probe input
(Mechanical method) or an external test signal (Test input method). After you install the
system at the machine, you may need to readjust the zero.
991 Mechanical Method
1 2
Set probe gap for a 6.5 Vdc signal measured Adjust the zero potentiometer to set the loop
between Prox Out and COM. current to 12 mA.
3 4
Set the probe gap for a full scale signal Adjust the span potentiometer to set the full
measured between Prox Out and COM. scale loop current.
ITEM 2000
15
991 Test Input Method
1 2
Short the test jumper pins together to enable
the test inputs. Set the DC test input voltage to 6.5 Vdc.
3 4
Adjust the zero potentiometer to set the loop Set the DC test input voltage to the full scale
current to 12 mA. voltage shown.
5 6
Adjust the span potentiometer to set the full Remove the short across the test jumper
scale loop current. pins.
ITEM 2000
16
Adjusting the 991 Zero Potentiometer at the Machine
1
With the rotor set against the active thrust shoe or in the center of the float (depending on your
procedure), gap the probe so that the voltage between Prox Out and COM is 6.5 0.4 Vdc.
2
If necessary, adjust the zero potentiometer until the loop current is 12 mA. Do not adjust the
span potentiometer.
Your may need to readjust the zero after you start the machine.
ITEM 2000
17
Troubleshooting
This section shows how to interpret a fault indication and isolate faults in an installed
transducer system. Before beginning this procedure, be sure the system has been
installed correctly and all connectors have been secured properly in the correct
locations.
When a malfunction occurs, locate the appropriate fault, check the probable causes for
the fault indication, and follow the procedure to isolate and correct the fault. Use a
digital multimeter to measure voltage and resistance. If you find faulty transducers,
please return them to the Product Repair Manager at Bently Nevada Corporation for
failure analysis.
The troubleshooting procedures use measured voltages as shown in the following
figure and table:
V
sig
Transmitter Power (-)
Transmitter Power (+)
V V
ps xmtr
Symbols for Measured Voltages
Symbol Meaning Voltage measured between...
V Signal voltage from the Prox out and Prox com
sig
transmitter
V Power supply voltage Power Supply (+) and
ps
Power Supply (-)
V Transmitter supply voltage Transmitter Power (+) and
xmtr
Transmitter Power (-)
Definitions
Symbol Definition
A > B "A" value is more positive than "B"
B < A "B" value is more negative than "A"
A = B "A" same value as "B"

ITEM 2000
18
Fault Type 1: V < 12 Vdc or V > 35 Vdc
xmtr xmtr
Possible Causes:
! Faulty power source
! Faulty field wiring
! Faulty Transmitter
V
ps
Measure V : Faulty
ps
Power
V < 12 Vdc or V > 35 Vdc Supply
ps ps
V
xmtr
Measure V : Faulty
xmtr
Field
V < 12 Vdc or V > 35 Vdc Wiring
xmtr xmtr
Faulty Transmitter
ITEM 2000
19
Fault Type 2: V = O Vdc
sig
Possible Causes:
! Incorrect power source voltage
! Short circuit in field wiring
! Short circuit at Transmitter terminal connection
Fault Type 1?
V
sig
Measure V : Short in
sig
Field
V = 0 Vdc? Wiring
sig
Test as Fault Type 3
ITEM 2000
20
Fault Type 3: 0 Vdc < V < 1 Vdc
sig
Possible Causes:
! Short circuit in the probe
! Short circuit in the extension cable
! Short circuit in a connector
! Probe is incorrectly gapped (too close to target)
! Probe is detecting other material than target, such as the counterbore or part
of the machine case
Fault Type 1?
V
sig
Measure V : Faulty
sig
Transmitter
0 Vdc < V < 1 Vdc
sig
Faulty Probe, cable or connector
See Fault Type 6
ITEM 2000
21
Fault Type 4: 13 Vdc < V
sig
Possible Causes:
! Probe is incorrectly gapped (too far from target)
! Open circuit in the probe
! Open circuit in the extension cable
! Open circuit in a connector

Fault Type 1?
V
sig
Short the BNJR connector
Measure V : Faulty
sig
Transmitter
0 Vdc < V < 1 Vdc?
sig
Faulty Probe, cable or connector
See fault type 6
ITEM 2000
22
Fault Type 5: V = V
sig xmtr
Possible Causes:
! Faulty field wiring
! Faulty transmitter
Fault Type 1?
V
sig
Measure V : Faulty
sig
Transmitter
V = V ?
sig xmtr
Faulty Field Wiring

ITEM 2000
23
Fault Type 6: Faulty probe, cable, or connector
Possible Causes:
! Short or open circuit in the probe
! Short or open circuit in the extension cable
! Short or open circuit in a connector
Inspect for clean connection: Clean connector
and retest
Dirty, rusty, or poor connection? original system
R
total
Measure resistance, R
total
Within specifications? Retest
5 m system: 5.3 S 0.7 S original
7 m system: 6.5 S 0.9 S system
Continued on next page
ITEM 2000
24
R
probe
Measure resistance, R
probe
Within specifications?
0.5 m Probe: 4.0 0.5 S Faulty
1.0 m Probe: 4.2 0.5 S Probe
R
shield
R
center
Measure Resistances, R and R
center shield
Faulty
Within specifications? Extension
See Cable Resistance, page 31 Cable
Retest original system
ITEM 2000
25
Fault Type 7: Supply Current < 3.6 mA
Possible Causes:
! Faulty transmitter
! Short or open circuit in the probe
! Short or open circuit in the extension cable
! Short or open circuit in a connector
! Probe is incorrectly gapped (too close to target)
! Probe is detecting other material than target such as the counterbore or part
of the machine case
! Thrust position is over range in the direction toward the probe (991 thrust
transmitter only)
Fault Type 1?
V
sig
Measure V
sig
See Fault
V < 1 Vdc Type 3
sig
Measure V
sig
See Fault
V > 13 Vdc Type 4
sig
Faulty Transmitter
ITEM 2000
ITEM 2000
ITEM 2000
ITEM 2000
ITEM 2000
ITEM 2000
ITEM 2000
ITEM 2000
ITEM 2000

Part number 147385-01 Specifications and Ordering Information Page 6 of 26
Revision A, February 2001
3300 NSv Proximity Probes:
330901 3300 NSv Probe, 1/4-28 UNF thread, without
armor
330902 3300 NSv Probe, 1/4-28 UNF thread, with
armor
330908 3300 NSv Probe, 3/8-24 UNF thread, without
armor
330909 3300 NSv Probe, 3/8-24 UNF thread, with
armor
Part Number-AXX-BXX-CXX-DXX-EXX
Option Descriptions
A: Unthreaded Length
Option: Note: Unthreaded length must be at l east 0.7 i nch
less than the case l ength.
Order i n i ncrements of 0.1 in
Length configurati ons:
Maximum unthreaded length: 9.2 in
Minimum unthreaded length: 0.0 i n
Example: 0 4 = 0.4 in
B: Overall Case Length
Option: Order i n i ncrements of 0.1 i n
Threaded length confi gurati ons:
Maximum case length: 9.9 in
Minimum case length: 0.8 in
Example: 2 4 = 2.4 in
C: Total Length
Option: 0 5 0.5 metre (20 i n)
1 0 1.0 metre (39 i n)
5 0 5.0 metres (16.4 feet)
7 0 7.0 metres (23.0 feet)
D: Connector and
Cabl e-Type Opti on: 0 0 No connector provided, stan-
dard cable
0 1 Mi niature coaxi al Cli ckLoc
connector wi th connector pro-
tector
0 2 Mi niature coaxi al Cli ckLoc
connector
E: Agency Approval
Option: 0 0 Not required
0 5 Mul tiple Approvals
3300 NSv Proximity Probes, Metric:
330903 3300 NSv Probe, M8 x 1 thread, without
armor
330904 3300 NSv Probe, M8 x 1 thread, with armor
330905 3300 NSv Probe, M10 x 1 thread, without
armor
330910 3300 NSv Probe, M10 x 1 thread, with armor
Part Number-AXX-BXX-CXX-DXX-EXX
Option Descriptions
A: Unthreaded Length
Option: Note: Unthreaded l ength must be at least 20 mm
less than the case length.
Order i n increments of 10 mm.
Length confi gurati on:
Maximum unthreaded length: 230
mm
Minimum unthreaded length: 0 mm
Example: 0 6 = 60 mm
B: Overal l Case Length
Option: Order i n increments of 10 mm.
Metric thread configurations:
Maximum length: 250 mm
Minimum length: 20 mm
Example: 0 6 = 60 mm
C: Total Length
1 0 1.0 metre (39 i n)
5 0 5.0 metres (16.4 feet)
7 0 7.0 metres (23.0 feet)
D: Connector and
Cabl e-Type Opti on: 0 0 No connector provi ded
0 1 Miniature coaxi al Cli ckLoc
connector wi th connector pro-
tector
0 2 Miniature coaxi al Cli ckLoc
connector
E: Agency Approval
Option: 0 0 Not requi red
ITEM 2000
Motor (X-Y): 05
Compressor (X-Y): 65
Compressor (Z): 15
Motor (X-Y): 40
Compressor (X-Y): 90
Compressor (Z): 40

BNC Part number 147385-01 Specifications and Ordering Information Page 7 of 26
3300 NSv Reverse Mount Probe
330906-02-12- CXX-DXX-EXX, 3/8-24 UNF threads
330907-05-30- CXX-DXX-EXX, M10 x 1 threads
Option Descriptions
C: Total Length
1 0 1.0 metre (39 i n)
5 0 5.0 metres (16.4 feet)
7 0 7.0 metres (23.0 feet)
D: Connector Opti on: 0 0 No connector provided
0 2 Mi niature Cli ckLoc coaxial
connector
E: Agency Approval
Note: For a shorter deli very ti me, order commonl y
stocked probes. Currently, stocked probes con-
sist of the fol lowi ng part numbers: 330901-00-24-
05-02-00, 330901-00-90-05-02-00, 330902-00-50-
05-02-00, 330902-00-95-05-02-00, 330903-00-02-
10-02-00, 330903-00-03-10-02-00, 330906-02-12-
05-02-00.
3300 XL NSv Proximitor Sensor
330980-AXX-BXX
Option Descriptions
A: Total Length and
Mounting Option: 5 0 5.0 metre (16.4 feet) system
length, panel mount
5 1 5.0 metre (16.4 feet) system
length, DIN mount
5 2 5.0 metre (16.4 feet) system
length, no mounti ng hardware
1
7 0 7.0 metres (23.0 feet) system
length, panel mount
length, DIN mount
length, no mounti ng hardware
1
B: Agency Approval
0 5 Mul tiple approval s
3300 NSv Extension Cable
330930-AXXX-BXX-CXX
Note: Make sure that the extension cabl e length
and the probe length, when added together, equal
the Proxi mi tor Sensor total length.
Option Descriptions
A: Cabl e Length
Option: 0 4 0 4.0 metres (13.1 feet)
0 4 5 4.5 metres (14.8 feet)
0 6 0 6.0 metres (19.7 feet)
0 6 5 6.5 metres (21.3 feet)
B: Connector and
Cabl e Option: 0 0 Wi thout stai nl ess steel armor
0 1 Wi th stainl ess steel armor, with
FEP jacket
0 2 Wi th stai nless steel armor,
without FEP jacket
0 3 Wi thout stai nl ess steel armor,
with connector protectors
0 4 Wi th stainl ess steel armor, with
FEP j acket, with connector pro-
tectors
0 5 Wi th stai nless steel armor,
without FEP jacket, with con-
nector protectors
C: Agency Approval
Option: 0 0 Not requi red
Accessories
147357-01 Manual
147347 Performance Speci fication
02120015 Bulk fiel d wire. 1.0 mm
2
(18 AWG),
3 conductor, twisted, shielded
cable with drain wire. Specify
length in feet.
138492-01 Replacement panel-mount mount-
ing pad
138493-01 Replacement DIN-mount mounting
pad
01609137 BNC (F) to banana pl ugs
01609138 Proximi tor Connector Test Pin
wi ring (two test pi ns to a BNC (F)
connector)
ITEM 2000

Figure 18 3300 NSv Proximity probes, Standard Mount
330901, -28 UNF-2A, without armor
330902, -28 UNF-2A, with armor
330903, M8x1 thread, wi thout armor
330904, M8x1 thread, wi th armor
330905, M10x1 thread, wi thout armor
330908, 3/8-24 UNF-2A, without armor
330909, 3/8-24 UNF 2A, wi th armor
330910, M10x1 thread, wi th armor
Figure 19 Installed Connector Protector s
Hex Nut
Wrench Flats
(0.207)
2.92 (0.115) Max.
Case Length "B"
5.26
Probe Tip
Total Length "C", +30%, -0%
Thread
Case
2.8 (0.11) Max. Outside Dia.
75 ohm Cable
Coaxial Connector
Miniature Male
7.23 (0.285) Outside
Dia. Maximum "D"
7.6 (0.30) Max. Outside Dia. of Armor
Unthreaded Length
"A"
3.23 (0.127)
Dia. Max.
ITEM 2000

Figure 20 3300 NSv Proximity Probes, Reverse Mount
330906, 3/8-24 UNF-2A threads
330907, M10x1 threads
Figure 21 330930, 3300 NSv Extension Cable
(0.207)
2.92 (0.115) Max.
Case Length "B"
5.26
Probe Tip
Unthreaded Length "A"
Total Length "C", +30%, -0%
7/16 or 10mm
Hex
Thread
Case
2.8 (0.11) outside Dia.
75 ohm Cable
Coaxial Connector
Miniature Male
7.23 (0.285) Outside
Dia. Maximum "D"
Dia. Max.
5.08 (0.20)
30.48 (1.20)
5.08 (0.20)
Max. Dia.
Uncoated Armor
FEP Coated or
Coaxial Connector
Miniature Female
Coaxial Cable
FEP Insulated
8.4 (0.33) Dia.
Stainless Steel Ferrules
Cable Length +20%, -0%
7.2 (0.285)
300 (11.8)
Armor Length:
(2.0)
51
Coaxial Connector
Miniature Male
Max. Dia.
7.2 (0.285)
less than cable length
(2.0)
51
(3.25)
82.6 82.6
(3.25)
2.80 (0.11) max. O.D.
7.6 (0.30) Max. O.D. of Armor
75 ohm cable
7.0 (0.275) Max. O.D. of Uncoated Armor
ITEM 2000

take reasonable precauti ons to avoid electro-
static di scharge during handl i ng.
Proximitor Sensor
The 3300 XL NSv Proxi mitor Sensor has simi l ar fea-
tures to those found in the 3300 XL 8 mm Proximitor Sen-
sor. Its thin design allows i t to be mounted in either a high-
density DIN-rail i nstal lati on or a more traditional panel
mount confi guration. Improved RFI/EMI immunity all ows
the 3300 XL NSv Proxi mitor Sensor to achieve Euro-
pean CE mark approvals without any special mounting con-
siderations. Thi s RFI immunity also prevents the
transducer system from being adversel y affected by nearby
high frequency radi o si gnals. SpringLoc terminal strips on
the Proxi mitor Sensor require no special i nstal lati on tool s
and facil itate faster, hi ghly robust fi el d wi ring connections.
Proximity Probe and Extension Cable
The 3300 NSv probe and extension cable are mechani-
cal ly and el ectri cal l y compatible and interchangeable with
our previous 3300 RAM proxi mity probe and extension
cabl e. The NSv probe has i ncreased chemical resi s-
tance compared to the 3300 RAM probe, al lowing it to be
used in many process compressor applications. The 3300
NSv probe also has superior si de-vi ew characteristi cs
compared to the 3000-series 190 probe when gappi ng the
3300 NSv probe at the same distance from the probe tar-
get.
The 3300 NSv probe comes i n varyi ng probe case confi g-
urations, i ncluding armored and unarmored -28,
3
8
-24,
M8 X 1 and M10 X 1 probe threads. The reverse mount
3300 NSv probe comes standard wi th either
3
8
-24 or
M10 X 1 threads. All components of the transducer system
have gold-pl ated brass Cl ickLoc connectors. ClickLoc
connectors l ock into place, preventing the connection from
loosening. The patented TipLoc molding method pro-
vides a robust bond between the probe tip and the probe
body. The probe cable is securely attached to the probe ti p
util izi ng our patented CableLoc design that provides 220
N (50 lb) pull strength.
Connector protectors are recommended for use on the
probe-to-extension cable connection, as well as on the
cabl e-to-Proximi tor Sensor connecti on. Connector pro-
tectors prevent most li quids from entering into the Click-
Loc connectors and adversely affecti ng the electrical
signal
2
.
Notes:
1 Proxi mi tor Sensors are suppl ied by defaul t from the factory
cal ibrated to AISI 4140 steel . Cal ibration to other target
materials is avai lable upon request.
2 Sili cone tape is also provided with each 3300 NSv exten-
si on cabl e and can be used instead of connector protectors.
Sili cone tape is not recommended in appl i cations where the
probe-to-extensi on cable connection wil l be exposed to tur-
bine oi l .
Specifications
Unl ess otherwise noted, the fol lowi ng specifications are for
a 3300 XL NSv Proximitor Sensor, extension cable and
probe between 0 C and +45C (+32F to +113F), with a -
24 Vdc power suppl y, a 10 k load, a Bentl y Nevada sup-
pli ed AISI 4140 steel target that i s 31 mm (1.2 in) diameter
or larger, and a probe gap of 1.0 mm (40 mil s). The system
accuracy and i nterchangeabi lity specifi cati ons do not apply
when using a transducer system calibrated to any target
other than a Bently Nevada AISI 4140 steel target.
Electrical
Proximitor Sensor
Input Accepts one noncontacting 3300
RAM or 3300 NSv Proxi mity
Probe and Extension Cabl e.
Power Requires -17.5 Vdc to -26 Vdc
wi thout barriers at 12 mA maximum
consumpti on, -23 Vdc to -26 Vdc
wi th barriers. Operation at a more
posi tive voltage than -23.5 Vdc can
resul t in reduced linear range.
Supply Sensitivity Less than 2 mV change in output
vol tage per vol t change in input
vol tage.
Output resistance 50
ITEM 2000
Probe dc resistance:
Extension cable dc
resistance: Center conductor: 0.220/m (0.067
/ft)
Shield: 0.066 /m (0.020 /ft)
Extension cable
capacitance: 69.9 pF/m (21.3 pF/ft) typi cal
Field wiring: 0.2 to 1.5 mm
2
(16 to 24 AWG)
[0.25 to 0.75 mm
2
(18 to 23 AWG)
wi th ferrul es]. Recommend using
three-conductor shi elded triad
cabl e. Maximum length of 305
metres (1,000 feet) between the
3300 XL NSv Proximi tor Sen-
sor and the monitor. See the fre-
quency response graphs Fi gure 16
and Fi gure 17 for si gnal rolloff at
high frequencies when using
longer fiel d wiring lengths.
Linear Range: 1.5 mm (60 mil s). Li near range
begi ns at approxi matel y 0.25 mm
(10 mi ls) from target and is from
0.25 to 1.75 mm (10 to 70 mils)
(approximatel y -1 to -13 Vdc).
Recommended Gap
Setting: 1.0 mm (40 mil s)
System performance over ambient temperature range
(0 C to 45 C):
Incremental Scale
Factor (ISF) 7.87 V/mm (200 mV/mi l) +12.5%/-
20% including i nterchangeabi lity
error when measured i n incre-
ments of 0.25 mm (10 mils) over
the 1.5 mm (60 mil) l inear range.
Deviati on from best fit
strai ght l ine (DSL) Less than 0.06 mm (2.3 mil s).
Frequency
Response: 0 to 10 kHz: +0, -3 dB typical, with
up to 305 metres (1000 feet) of
field wiring.
Target Size (flat
target): Mini mum: 8.9 mm (0.35 in) diame-
ter
Recommended mini mum: 13 mm
(0.5 i n) diameter
Axial posi tion measurements on
shaft diameters small er than 13mm
(0.5 i n) wi ll general ly result i n a
change in scale factor. Reducing
the gap between the probe and tar-
get wil l hel p li mit the change i n
scale factor. See Figure 12 for
addi tional i nformati on.
Shaft Diameter Mini mum (standard X-Y probe con-
figuration): 30 mm (1.2 in)
Mini mum (X-Y proximi ty probes
offset axiall y by 23 mm (0.9 in)): 20
mm (0.8 in)
Measurements on shaft di ameters
smal ler than 30 mm (1.2 in) usual ly
requi re close spacing of radial
vi bration or axi al positi on trans-
ducers with the potential for their
electromagnetic emitted fields to
interact with one another (cross-
tal k), resulting in erroneous read-
ings. To prevent cross-talk, main-
tai n mini mum separation of
transducer tips of at l east 25 mm
(1.0 i n) for axial posi tion measure-
ments or 23 mm (0.9 i n) for radial
vi bration measurements (see Fig-
ure 14 and Figure 15 for additional
information.) Radial vibration or
radial position measurements on
shaft diameters small er than 20
mm (0.8 in) will general ly result in
greater than a 10% change i n
Average Scale Factor (ASF). See
Figure 13 for additi onal informa-
tion.
Counterbore Mini mum: 9.5 mm (0.375 in)
Recommended mini mum: 13 mm
(0.5 i n)
Counterbores smal ler than 13 mm
(0.5 i n) generally resul t in a
change in scal e factor at far gaps.
Probe Length (m)
Resistance from the Center
Conductor to the Outer
Conductor (R
PROBE
) (ohms)
0.5 4.0 0.5
1.0 4.2 0.5
5.0 5.3 0.7
7.0 5.9 0.9
ITEM 2000
Reducing the gap between the
probe and the target wil l al low the
transducer system to mai ntain its
Average Scale Factor (ASF) over a
reduced li near range. See Fi gure
9 for additi onal information.
Effects of 60 Hz Magnetic Fields Up to 300 Gauss (5
metre system)
Output vol tage in mi l pp/gauss:
Electrical
Classification: Complies wi th the European CE
mark.
Hazardous Area Approvals
Multi ple approvals for hazardous
areas certified by Canadian Stan-
dards Associ ation (CSA/NRTL/C)
in North Ameri ca and by
BASEEFA/CENELEC i n Europe.
North America: Ex ia IIC T5; Cl ass I Zone 0 or Exi a
IIC T5 for Class 1 Divi sion 1;
Groups A, B, C, and D, when
install ed wi th i ntrinsical ly safe
zener barriers per drawing 141092
or when installed with galvanic iso-
lators.
ExnA IIC T5 Cl ass I Zone 2 or
ExnA IIC T5 for Cl ass I, Division 2,
Groups A, B, C, and D when
install ed wi thout barriers per draw-
ing 140979.
T
5
@ T
a
= -35C to +85C.
Europe: EExia IIC T5 for Zones 0, 1 and 2,
Group IIC, BASEEFA certifi cate
number BAS99ATEX1101, when
install ed wi th i ntrinsical ly safe
zener barriers or galvanic isola-
tors,
T5 @ Ta= -35C to +85C.
EEx nA for Zone 2, Group IIC,
BASEEFA certificate number
BAS99ATEX3100U.
Mechanical
Probe Tip Material: Polyphenyl ene sulfide (PPS).
Probe Case
Material: AISI 304 stainl ess steel (SST).
Probe Cable
Specifications: 75 coaxial, fluoroethyl ene pro-
pyl ene (FEP) insulated probe cable
in the following total probe lengths:
0.5, 1, 5, or 7 metres.
Extension Cable
Material: 75 coaxial, fluoroethyl ene pro-
pyl ene (FEP) insulated.
Proximitor Sensor
Material: A380 aluminum
System Length: 5 or 7 metres including extension
cabl e
Extension Cable
Armor (optional): Flexible AISI 302 SST wi th/wi thout
FEP outer jacket.
Tensile Strength
(maximum rated): 220 N (50 l b) probe case to probe
lead. 220 N (50 lb) at probe lead to
extension cable connectors. 220 N
(50 l b) probe case to stainless
steel armor.
Connector material: Gol d-plated brass
Gap
Proximitor
Sensor
Probe Ext. Cable
0.25 mm
(10 mil)
0.006 0.001 0.001
1.0 mm (40
mil)
0.007 0.002 0.001
1.75 mm
(70 mil)
0.008 0.002 0.003
ITEM 2000
Connector-to-connector torque
Recommended
torque: Finger tight
Maxi mum torque: 0.56 Nm (5 inlb)
Minimum Bend
Radius (with or
without sst armor): 25.4 mm (1.0 i n)
System Weight (typical) :
Probe: Approxi mately 14 to 150 g (0.5 to 5
oz)
Extension Cable: 45 g/m (0.5 oz/ft)
Armored Extension
Cable: 64 g/m (0.7 oz/ft)
Proximi tor Sensor: 255 g (9 oz)
Environmental Limits
Probe Temperature Range
Operating
Temperature: -34C to +177C (-30F to
+351F)
Storage Temperature: -51C to +177C (-60F to
+351F)
Note: Exposing the probe to temperatures below
-34C (-30F) for a sustai ned peri od of time may
cause premature fail ure of the pressure seal .
Extension Cable Temperature Range
Operating and
+351F)
Proximitor Sensor Temperature Range
Operating
Temperature: -35C to +85C (-31F to +185F)
+221F)
Relative Humidity: 100% condensing, non-submers-
ibl e when connectors are pro-
tected. Tested to IEC 68-2-3 damp
heat.
Probe Pressure: 3300 NSv probes are designed
to seal differential pressure
between the probe tip and case.
The probe sealing material con-
si sts of a Viton O-ri ng. Probes
are not pressure tested prior to
shi pment. Contact our custom
design department if you require a
test of the pressure seal for your
appl ication
Note: It i s the responsibility of the customer or
user to ensure that al l l iqui ds and gases are con-
tained and safely controll ed shoul d leakage occur
from a proximi ty probe. In additi on, solutions with
hi gh or low pH val ues may erode the ti p assembl y
of the probe causi ng media leakage into surround-
ing areas. Bentl y Nevada Corporation wi ll not be
held responsi bl e for any damages resulti ng from
leaki ng 3300 NSv Proximity Probes. In addi -
ti on, 3300 NSv Proximity Probes wi ll not be
replaced under the service pl an due to probe leak-
age.
Patents: 5,016,343
5,126,664
5,351,388
5,685,884
Components or procedures descri bed i n these patents
appl y to this product.
Probe case
torque:
Maximum Rated Recommended
-28 or M8x1 probe
cases
7.3 Nm
(65 inlb)
5.1 Nm
(45 inlb)
3/8-24 or M10x1
probe cases
33.9 Nm
(300 inlb)
11.3 Nm
(100 inlb)
3/8-24 or M10x1
probe cases first
three threads
22.6 Nm
(200 inlb)
7.5 Nm
(66 inlb)
Reverse mount
probes
22.6 Nm
(200 inlb)
7.5 Nm
(66 inlb)
ITEM 2000
SIMATIC HMI HMI devices MP 377, MP 377 PRO (WinCC flexible)
______________
______________
______________
______________
______________
______________
______________
______________
______________
______________
______________
______________
______________
______________
Preface
Overview

1
Safety instructions
and approvals

2
Planning application

3
Mounting and connecting

4
Operator controls
and displays

5
Configuring the
operating system

6
Commissioning a project

7
Operating a project

8
Operating alarms

9
Operating recipes

10
Maintenance and care

11
Technical specifications

12
Appendix

A
Abbreviations

B

SIMATIC HMI
HMI devices
MP 377, MP 377 PRO
(WinCC flexible)
10/2008
A5E01003518-03
Ordernumber: 6AV6691-1DR01-0AB0

ITEM 2500

Legal information
Legal information
Warning notice system
DANGER

WARNING

CAUTION

CAUTION

NOTICE
account.
property damage.
Qualified Personnel
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be adhered to. The information in the relevant documentation must be observed.
Trademarks
owner.
editions.

Siemens AG
Industry Sector
Postfach 48 48
90026 NRNBERG
GERMANY
Ordernumber: 6AV6691-1DR01-0AB0
11/2008
ITEM 2500

MP 377, MP 377 PRO (WinCC flexible)
Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0 3
Preface
Purpose of the operating instructions
These operating instructions provide information based on the requirements defined by
DIN EN 62079 for mechanical engineering documentation. This information relates to the
place of use, transport, storage, mounting, use and maintenance.
These operating instructions are intended for:
Users
Commissioning engineers
Maintenance personnel
Read especially the information in the section "Safety instructions" (Page 37).
The help integrated in WinCC flexible, the WinCC flexible Information System, contains
detailed information. The information system contains instructions, examples and reference
information in electronic form.
Basic knowledge required
General knowledge of automation technology and process communication is needed to
understand the operating instructions.
It is also assumed that those using the manual have experience in using personal computers
and knowledge of Microsoft operating systems.
Scope of the operating instructions
The operating instructions apply to the following HMI devices in conjunction with the
WinCC flexible software package:
MP 377 12" Touch
MP 377 12" Key
MP 377 15" Touch
MP 377 19" Touch
MP 377 PRO 15" Touch
Trademarks
The following designations marked with the symbol are registered trademarks of
Siemens AG:
HMI

SIMATIC

WinCC

SIMATIC MP 377

ITEM 2500
Preface

4 Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0
Position in the information landscape
These operating instructions form part of the SIMATIC HMI documentation. You can obtain
an overview of SIMATIC hardware and SIMATIC software products and SIMATIC systems
and information that can be called up in PDF format in various languages at the
following address:
"http://www.automation.siemens.com/simatic/portal/html_76/techdoku.htm"
The following designations are used in these operating instructions to represent
multiple HMI devices:
"MP 377" designates all MP 377 HMI devices.
"MP 377 mounting device" designates the following HMI devices:
MP 377 12" Touch
MP 377 12" Key
MP 377 15" Touch
MP 377 19" Touch
"MP 377 PRO" designates the following HMI devices:
Conventions
The following text notation will facilitate reading the Operating Instructions:

Notation Scope
"Add screen" Terms that appear in the user interface, for example, dialog
names, tabs, buttons, menu commands
Inputs required, for example limit values, tag values.
Path information
"File > Edit" Operational sequences, for example, menu commands, shortcut
menu commands
<F1>, <Alt+P> Keyboard operation
Please observe notes labeled as follows:

Note
Notes contain important information concerning the product, its use or a specific section of
the documentation to which you should pay particular attention.

Figures in this documentation
This documentation contains figures pertaining to the hardware described herein. Newer
versions of the HMI device may differ from these figures.
ITEM 2500
Preface

Representatives and office locations
If you have any further questions relating to the products described in this manual, please
contact your local representative at the Siemens branch nearest you.
Locate your contact person at "http://www.automation.siemens.com/partner".
Training center
Siemens AG offers a variety of training courses in order to familiarize you with automation
systems. Contact your regional Training Center or the central Training Center in D-90327
Nuremberg, Germany.
Internet: "http://www.sitrain.com"
Technical support
Technical support for all industry sector products is available as follows:
Using the web form to request support
"http://www.siemens.com/automation/support-request"
Additional information about our technical support is available on the Internet under
"http://support.automation.siemens.com".
Service & Support on the Internet
Service & Support provides additional comprehensive information on SIMATIC products
through online services at "http://support.automation.siemens.com":
The newsletter offers you the latest information about your products
A large document base is available using our Service & Support search engine
A forum for global exchange of information by users and experts
Current product information, FAQs and downloads
You local representative
Information about on-site services, repairs, spare parts, and more
Recycling and disposal
The HMI devices described in these operating instructions can be recycled due to the low
levels of pollutants. Contact a certified disposal service company for environmentally sound
recycling and disposal of your old devices.

ITEM 2500
Preface

ITEM 2500

Table of contents

Preface...................................................................................................................................................... 3
1 Overview.................................................................................................................................................. 13
1.1 Product overview .........................................................................................................................13
1.2 MP 377 mounting devices............................................................................................................15
1.2.1 Design of the MP 377 12" Touch.................................................................................................15
1.2.2 Design of the MP 377 12" Key.....................................................................................................17
1.3 MP 377 PRO................................................................................................................................23
1.3.1 Design of the MP 377 PRO 15" Touch ........................................................................................23
1.3.2 Structure of the basic adapter......................................................................................................24
1.4 Accessory kit ................................................................................................................................25
1.5 Accessories..................................................................................................................................26
1.6 The HMI device in the operating process ....................................................................................28
1.7 Functional scope with WinCC flexible..........................................................................................29
1.8 Software options ..........................................................................................................................32
1.9 Communication............................................................................................................................33
2 Safety instructions and approvals............................................................................................................ 37
2.1 Safety instructions........................................................................................................................37
2.2 Standards, certificates and approvals..........................................................................................39
2.3 Notes about usage.......................................................................................................................41
2.4 Electromagnetic compatibility ......................................................................................................42
2.5 Transport and storage conditions ................................................................................................44
3 Planning application................................................................................................................................. 45
3.1 Notes about usage.......................................................................................................................45
3.2 MP 377 mounting devices............................................................................................................47
3.2.1 Mounting positions and type of fixation........................................................................................47
3.2.2 Preparing for installation ..............................................................................................................48
3.2.3 Information on insulation tests, protection class and degree of protection..................................50
3.2.4 Rated voltages .............................................................................................................................50
3.3 MP 377 PRO................................................................................................................................51
3.3.1 Mounting positions.......................................................................................................................51
3.3.2 Preparing for installation ..............................................................................................................51
3.3.3 Information on insulation tests, protection class and degree of protection..................................52
3.3.4 Rated voltages .............................................................................................................................52
ITEM 2500
Table of contents

4 Mounting and connecting......................................................................................................................... 53
4.1 Checking the package contents.................................................................................................. 53
4.2 Installing the HMI device............................................................................................................. 54
4.2.1 Installing the MP 377 mounting device ....................................................................................... 54
4.2.2 Installing MP 377 PRO................................................................................................................ 58
4.3 Connecting the HMI device......................................................................................................... 61
4.3.1 Overview..................................................................................................................................... 61
4.3.2 Ports............................................................................................................................................ 62
4.3.3 Connecting the equipotential bonding circuit .............................................................................. 63
4.3.4 Connecting the power supply...................................................................................................... 65
4.3.5 Connecting an uninterruptible power supply............................................................................... 67
4.3.6 Connecting the PLC.................................................................................................................... 68
4.3.7 Connecting the configuration PC................................................................................................ 71
4.3.8 Connecting a USB device........................................................................................................... 74
4.3.9 Connecting a printer.................................................................................................................... 75
4.3.10 Connecting an audio device........................................................................................................ 76
4.4 Switching on and testing the HMI device.................................................................................... 77
4.5 Securing the cables..................................................................................................................... 79
4.5.1 Securing cables on the MP 377 mounting device....................................................................... 79
4.5.2 Securing cables on the MP 377 PRO......................................................................................... 79
4.6 Closing the housing rear wall of MP 377 PRO............................................................................ 80
5 Operator controls and displays ................................................................................................................ 81
5.1 Front operator controls................................................................................................................ 81
5.2 Inserting a memory card ............................................................................................................. 83
5.3 Securing memory card................................................................................................................ 84
5.4 Unplugging the memory card...................................................................................................... 85
5.5 Labeling the function keys on the MP 377 12" Key .................................................................... 86
6 Configuring the operating system............................................................................................................ 89
6.1 Loader ......................................................................................................................................... 89
6.2 Setting up and disabling SecureMode ........................................................................................ 94
6.3 Viewer ......................................................................................................................................... 95
6.4 Control Panel .............................................................................................................................. 96
6.4.1 Overview..................................................................................................................................... 96
6.4.2 Opening the Control Panel.......................................................................................................... 97
6.4.3 Reference for functions............................................................................................................... 98
6.4.4 Operating the Control Panel ....................................................................................................... 99
6.4.4.1 Overview..................................................................................................................................... 99
6.4.4.2 Operation using the touch screen............................................................................................. 100
6.4.4.3 Operation with the keyboard..................................................................................................... 102
6.5 Changing settings for operation................................................................................................ 106
6.5.1 Configuring the screen keyboard.............................................................................................. 106
6.5.2 Setting the character repeat...................................................................................................... 107
6.5.3 Setting the double-click............................................................................................................. 108
6.5.4 Calibrating the touch screen ..................................................................................................... 110
6.6 Setting up password protection................................................................................................. 112
ITEM 2500
Table of contents

6.7 Canceling password protection..................................................................................................113
6.8 Changing HMI device settings ...................................................................................................114
6.8.1 Setting the date and time...........................................................................................................114
6.8.2 Changing regional settings ........................................................................................................115
6.8.3 Backup registry information .......................................................................................................116
6.8.4 Changing monitor settings .........................................................................................................118
6.8.5 Setting the screen saver ............................................................................................................119
6.8.6 Changing the printer properties .................................................................................................120
6.8.7 Enabling sound and setting sound volume................................................................................122
6.8.8 Assigning sound to an event......................................................................................................124
6.8.9 Restarting the HMI device..........................................................................................................125
6.8.10 Displaying information about the HMI device ............................................................................127
6.8.11 Displaying system properties.....................................................................................................128
6.8.12 Displaying memory distribution..................................................................................................129
6.9 Setting storage location .............................................................................................................130
6.10 Setting the delay time ................................................................................................................131
6.11 Setting the uninterruptible power supply....................................................................................132
6.12 State of uninterruptible power supply ........................................................................................133
6.13 Enabling PROFINET IO.............................................................................................................134
6.14 Changing transfer settings.........................................................................................................136
6.14.1 Configuring the data channel .....................................................................................................136
6.14.2 Changing MPI/PROFIBUS DP settings .....................................................................................139
6.15 Configuring network operation...................................................................................................142
6.15.1 Overview of network operation ..................................................................................................142
6.15.2 Setting the device name of the HMI device ...............................................................................144
6.15.3 Changing the network configuration ..........................................................................................145
6.15.4 Changing the logon data............................................................................................................147
6.15.5 Changing e-mail settings ...........................................................................................................148
6.15.6 Changing Internet settings.........................................................................................................149
6.15.6.1 Changing general Internet settings............................................................................................149
6.15.6.2 Setting the proxy server .............................................................................................................150
6.15.6.3 Changing privacy settings..........................................................................................................150
6.15.6.4 Importing and deleting certificates .............................................................................................152
6.16 Saving to external storage device (backup)...............................................................................153
6.17 Restoring from external storage device.....................................................................................155
6.18 Activate memory management ..................................................................................................158
7 Commissioning a project ....................................................................................................................... 159
7.1 Overview....................................................................................................................................159
7.2 Operating modes .......................................................................................................................160
7.3 Using existing projects...............................................................................................................161
7.4 Data transmission options..........................................................................................................162
7.5 Transfer......................................................................................................................................163
7.5.1 Overview....................................................................................................................................163
7.5.2 Starting manual transfer.............................................................................................................163
7.5.3 Starting automatic transfer.........................................................................................................164
7.5.4 Starting backtransfer..................................................................................................................166
7.5.5 Testing a project ........................................................................................................................167
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Table of contents

7.6 Backup and restore................................................................................................................... 168
7.6.1 Overview................................................................................................................................... 168
7.6.2 Backup and restore using WinCC flexible................................................................................. 169
7.6.3 Backup and restore using ProSave .......................................................................................... 171
7.7 Updating the operating system................................................................................................. 173
7.7.1 Overview................................................................................................................................... 173
7.7.2 Resetting factory settings.......................................................................................................... 174
7.7.3 Updating the operating system using WinCC flexible............................................................... 175
7.7.4 Updating the operating system using ProSave......................................................................... 176
7.7.5 Resetting to factory settings with WinCC flexible ..................................................................... 177
7.7.6 Resetting to factory settings with ProSave ............................................................................... 180
7.8 Installing and removing options ................................................................................................ 182
7.8.1 Overview................................................................................................................................... 182
7.8.2 Installing and removing options using WinCC flexible.............................................................. 183
7.8.3 Installing and removing options using ProSave........................................................................ 185
7.9 Transferring and transferring back license keys ....................................................................... 186
7.9.1 Overview................................................................................................................................... 186
7.9.2 Transferring and transferring back license keys ....................................................................... 187
8 Operating a project ................................................................................................................................ 189
8.1 Overview................................................................................................................................... 189
8.2 Direct keys ................................................................................................................................ 192
8.3 Setting the project language ..................................................................................................... 193
8.4 Entries using the touch screen.................................................................................................. 193
8.4.1 Overview................................................................................................................................... 193
8.4.2 Entering and editing numerical values...................................................................................... 195
8.4.3 Entering and editing alphanumerical values ............................................................................. 197
8.4.4 Entering the date and time........................................................................................................ 199
8.4.5 Entering symbolic values .......................................................................................................... 199
8.4.6 Displaying infotext ..................................................................................................................... 200
8.5 Entries using the keys............................................................................................................... 201
8.5.1 Control keys .............................................................................................................................. 201
8.5.2 Example: enter characters using the alphanumeric keyboard.................................................. 204
8.5.3 Function keys............................................................................................................................ 204
8.5.4 General procedures .................................................................................................................. 205
8.5.5 Entering and editing numerical values...................................................................................... 205
8.5.6 Entering and editing alphanumerical values ............................................................................. 207
8.5.7 Entering the date and time........................................................................................................ 208
8.5.8 Entering symbolic values .......................................................................................................... 208
8.5.9 Displaying infotext ..................................................................................................................... 209
8.6 Bar and gauge........................................................................................................................... 210
8.7 Operating the switch ................................................................................................................. 211
8.8 Operating the trend view........................................................................................................... 212
8.9 Operating the slider control ....................................................................................................... 214
8.10 Operating the Status Force....................................................................................................... 216
8.10.1 Overview................................................................................................................................... 216
8.10.2 Touch operation ........................................................................................................................ 217
8.10.3 Key control ................................................................................................................................ 218
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Table of contents

8.11 Operating the Sm@rtClient view ...............................................................................................220
8.11.1 Overview....................................................................................................................................220
8.11.2 Touch operation.........................................................................................................................221
8.11.3 Key control .................................................................................................................................223
8.12 Project security ..........................................................................................................................224
8.12.1 Overview....................................................................................................................................224
8.12.2 User view ...................................................................................................................................226
8.12.3 User logon..................................................................................................................................227
8.12.4 User logoff..................................................................................................................................228
8.12.5 Creating users............................................................................................................................229
8.12.5.1 Creating users with touch operation ..........................................................................................229
8.12.5.2 Creating users with key operation..............................................................................................230
8.12.6 Changing user data....................................................................................................................233
8.12.6.1 Changing user data with touch operation ..................................................................................233
8.12.6.2 Changing user data with key operation .....................................................................................234
8.12.7 Deleting users ............................................................................................................................235
8.13 Closing the project .....................................................................................................................236
9 Operating alarms ................................................................................................................................... 237
9.1 Overview....................................................................................................................................237
9.2 Detecting queued alarms...........................................................................................................239
9.3 Message display ........................................................................................................................240
9.4 Displaying infotexts....................................................................................................................242
9.5 Acknowledge alarm....................................................................................................................243
9.6 Editing alarms ............................................................................................................................244
10 Operating recipes .................................................................................................................................. 245
10.1 Overview....................................................................................................................................245
10.2 Structure of a recipe...................................................................................................................246
10.3 Recipes in the project ................................................................................................................248
10.4 Recipe displays..........................................................................................................................250
10.5 Recipe values in the HMI device and the PLC ..........................................................................253
10.6 Operating the recipe view..........................................................................................................254
10.6.1 Overview....................................................................................................................................254
10.6.2 Creating a recipe data record ....................................................................................................255
10.6.3 Editing a recipe data record.......................................................................................................257
10.6.4 Deleting a recipe data record.....................................................................................................258
10.6.5 Synchronizing tags.....................................................................................................................259
10.6.6 Reading a recipe data record from the PLC..............................................................................260
10.6.7 Transferring a recipe data record to the PLC ............................................................................261
10.7 Operating the simple recipe view...............................................................................................262
10.7.1 Overview....................................................................................................................................262
10.7.2 Creating a recipe data record ....................................................................................................264
10.7.3 Editing a recipe data record.......................................................................................................265
10.7.4 Deleting a recipe data record.....................................................................................................266
10.7.5 Reading a recipe data record from the PLC..............................................................................267
10.7.6 Transferring a recipe data record to the PLC ............................................................................268
10.8 Importing a recipe data record...................................................................................................269
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10.9 Exporting a recipe data record.................................................................................................. 270
10.10 Examples .................................................................................................................................. 271
10.10.1 Entering a recipe data record.................................................................................................... 271
10.10.2 Manual production sequence.................................................................................................... 272
11 Maintenance and care ........................................................................................................................... 273
11.1 Maintaining and caring for the touch screen and keyboard overlay ......................................... 273
11.2 Clean screen on MP 377 Touch ............................................................................................... 274
11.3 Spare parts and repairs............................................................................................................. 274
12 Technical specifications......................................................................................................................... 275
12.1 Dimension drawings.................................................................................................................. 275
12.1.1 Dimension drawings of the MP 377 12" Touch......................................................................... 275
12.1.2 Dimension drawings of the MP 377 12" Key............................................................................. 276
12.1.5 Dimension drawings of the MP 377 PRO 15" Touch................................................................ 279
12.2 Specifications............................................................................................................................ 280
12.3 Bit assignment of the direct keys .............................................................................................. 282
12.4 Description of the ports ............................................................................................................. 283
12.4.1 Power supply............................................................................................................................. 283
12.4.2 X10/IF 1B (RS 422/RS 485)...................................................................................................... 283
12.4.3 X1 (PROFINET) ........................................................................................................................ 284
12.4.4 X20, X21 (USB)......................................................................................................................... 284
12.4.5 X40 (line out)............................................................................................................................. 285
A Appendix................................................................................................................................................ 287
A.1 ESD guideline ........................................................................................................................... 287
A.2 System alarms .......................................................................................................................... 289
B Abbreviations......................................................................................................................................... 321
Glossary ................................................................................................................................................ 323
Index...................................................................................................................................................... 329
ITEM 2500

Overview
1
1.1 Product overview
The Multi Panel MP 377 HMI devices are an innovative advanced development of
the 370 series.
In addition to the established display sizes of 12", 15", and 19", the product series was
expanded to include the Multi Panel MP 377 PRO 15" Touch offering all around IP65 degree
of protection. The distinguishing feature of the HMI devices is that they fulfill the increasing
demands for technical innovation especially in regard to display, performance and
extended applications.
Hardware equipment
The Multi Panel MP 377 has a TFT display with 64 K colors and improved performance
compared to predecessor devices. The Multi Panel MP 377 is based on Microsoft Windows
CE 5.0. Compared with previous devices, its multimedia functionality has been greatly
extended. Integration of the Microsoft Media Player allows the MP 377 to play videos.
Internet Explorer 6.0 for pocket PCs is pre-installed on the HMI devices and extends the
ways in which web pages can be displayed. Word documents, Excel spreadsheets and PDF
documents can be displayed with Microsoft Viewer.
The user memory has been expanded, and a retentive maintenance-free alarm buffer
integrated. A retentive memory for PLC data is provided to support WinAC MP.
Thanks to the wide range of devices, you can use the device best suited to your needs. The
MP 377 can be used for a wide range of applications, and offers high performance and a
favorable cost/performance ratio.
The HMI device has:
1 PROFIBUS interface
2 Ethernet ports for connection to PROFINET
2 USB 2.0 ports
1 slot for an SD memory card or multimedia card
1 CF card slot
1 TFT display with up to 64 K colors
The following extra software options have been added to the functions of the MP 377
as a "multifunctional platform":
WinCC flexible /Sm@rtService
WinCC flexible /Sm@rtAccess
WinCC flexible /OPC Server
WinCC flexible /ProAgent
WinCC flexible /Audit
WinAC MP 2007
ITEM 2500
Overview
1.1 Product overview
IP65 all-round
The Multi Panel MP 377 PRO, which features a housing with IP65 degree of protection, all
around protection against dust and water jets. The ready-to-use HMI device can be fixed
either from the top or the bottom to a support arm system or to a stand.
A basic adapter and adapter sets that can be ordered separately support fixing systems from
various manufacturers (including VESA standard for flat screens). The rear wall can be
removed quite easily. The interfaces of the HMI device can therefore be reached without any
problems. You do not require any special cables or connectors.
The Multi Panel MP 377 PRO is impressive not only due to ease of servicing but also
because of its sophisticated design and slimline device depth.

ITEM 2500
Overview
1.2 MP 377 mounting devices
1.2.1 Design of the MP 377 12" Touch
Front view and side view
3
1
2
5
4

Slot for an SD memory card or multimedia card
Slot for a CF memory card
Display/touch screen
Oblong holes for mounting clamps
Mounting seal
Bottom view
1
2

Ports
Oblong holes for mounting clamps
ITEM 2500
Overview
Rear view
3
2
1
4
5

Slot for an SD memory card or multimedia card
Rating label
Slot for a CF memory card
DIP switch
Interface name
See also
Ports (Page 62)
ITEM 2500
Overview
1.4 Accessory kit
1.4 Accessory kit
Accessory kit for MP 377 mounting device
The accessory kit contains the following:
Mains terminal for the power supply
Mounting clamps for mounting the HMI device
Additional documents may be enclosed with the accessory kit.
Accessory kit for MP 377 PRO
The accessory kit contains the following:
Mains terminal for the power supply
Basic adapter as a basic element for fixing to a support arm
Four screws for fixing the basic adapter to an adapter from an adapter set
Additional documents may be enclosed with the accessory kit.
ITEM 2500
Overview
1.5 Accessories
1.5 Accessories
Accessories are not included in the product package of the HMI device, but can ordered in
the Internet at "http://mall.automation.siemens.com".
RS 422 to RS 232 converter
The converter is required for the connection of controllers of other manufacturers. Connect
the RS 422 to RS 232 converter to the RS 422 / RS 485 interface. The converter converts
the input signals to RS-232 signals.
Order number for RS 422 to RS 232 converter: 6AV6 671-8XE00-0AX0.
90 elbow adapter
If space is limited, you can use an elbow adapter at the RS 422/RS 485 interface.
Order number for 90 elbow adapter: 6AV6 671-8XD00-0AX0.
Protective foil for HMI devices with touch screen
The protective foil prevents the touch screen from being scratched.
The protective foil can be ordered using the following order numbers:

HMI device Order no.
MP 377 12" Touch 6AV6 574-1AD00-4CX0
MP 377 15" Touch
6AV6 574-1AD00-4EX0
MP 377 19" Touch 6AV7 672-1CE00-0AA0
Clamping frame
A clamping frame is available for the MP 377 12" Touch. If the material thickness around the
mounting cutout is < 2 mm, the clamping frame allows IP65 degree of protection or
enclosure type 4X/Type 12 to be achieved.
Order number for clamping frame for MP 377 12" Touch: 6AV6 671-8XS00-0AX0.
Key labeling strips
For the MP 377 12" Key, a kit containing two sets of blank key labeling strips can be ordered.
Order number for key labeling strips: 6AV6 574-1AB00-2BA0.
ITEM 2500
Overview
1.5 Accessories
Service packages
The service packages include:
Mounting seals
Mounting clamps
Power supply terminal, 2-pin
Service packages can be ordered for the following HMI devices using the following
order numbers:

HMI device Order no.
MP 377 12" Key 6AV6 574-1AA00-2BX0
MP 377 12" Touch
MP 377 15" Touch
MP 377 19" Touch
6AV6 671-4XA00-0AX0
Basic adapter
One basic adapter is included in the delivery scope of the MP 377 PRO 15" Touch.
Order number for the basic adapter as accessory: 6AV7674-0KA00-0AA0.
Adapter sets for support arm systems
The following adapter sets can be ordered for the MP 377 PRO:

Adapter set Suitable for support arm systems Order no.
Adapter set
VESA75/VESA100
VESA75 and VESA100 compatible systems,
Rose GTN II support arm systems
6AV7674-0KF00-0AA0
Adapter set CP-L Rittal CP-L support arm systems 6AV7674-0KC00-0AA0
Adapter set PLUS Bernstein CS-3000 Coupler 48, Rolec tara Plus,
Rolec Quadro, Rittal CP-S, Rose GT48/2,
Rose GTK electronic
6AV7674-0KB00-0AA0
Memory card
Only use SD memory cards, CF memory cards or MultiMediaCards tested and approved by
Siemens AG.
SIMATIC PC USB flash drive
The SIMATIC PC USB flash drive is a mobile form of data storage with a high data
throughput, designed for industrial use.
ITEM 2500
Overview
1.6 The HMI device in the operating process
1.6 The HMI device in the operating process
The HMI device is part of the operating process. The following two phases are key to the
way the HMI device is integrated in the operating process:
Project design
Process management
Project design
Visualization of the operating process is known as project design. Project design comprises:
writing project data
saving project data
testing project data
simulating project data
Project design is undertaken independently of the HMI device and results in a project. Once
this has been generated, the project can be transferred to the HMI device to control the
operating process.
Configuring PC HMl device

Process management
Process management is marked by two-way communication between HMI device and
controller. This lays the foundations for operator control and monitoring.
Control 1
Control 2
HMl device

The operator can intervene in the operating process on the HMI device for control purposes.
The controller in turn supplies the results of the operating process which are displayed on
the HMI device.
ITEM 2500
Overview
1.7 Functional scope with WinCC flexible
The following tables show the objects that can be integrated in a project for an MP 377.

Note
The specified values are maximum values of the individual objects. Simultaneous use of
multiple objects with their maximum value can lead to problems in the active project.

Alarms

Object Specification MP 377
Number of discrete alarms 4 000
Number of analog alarms 200
Length of the alarm text 80 characters
Number of tags in an alarm Max. 8
Display Alarm line, Alarm
window, Alarm view
Acknowledge error alarm individually Yes
Acknowledge multiple error alarms
simultaneously (group acknowledgement)
16 alarm groups
Edit alarm Yes
Alarms
Alarm indicator Yes
ALARM_S Display S7 alarms Yes
Alarm buffer capacity 1024 alarms
Simultaneously queued alarm events Max. 500
View alarm Yes
Delete alarm buffer Yes
Alarm buffer, retentive
Print alarms line by line Yes
Tags, values and lists

Tags Quantity 2 048
Limit value monitoring Input/output Yes
Linear scaling Input/output Yes
Text lists Quantity 500
1)

Graphics lists Quantity 500
1)

1)
The maximum total of text and graphics lists is 500.
ITEM 2500
Overview
Screens

Quantity 500
Fields per screen 200
Tags per screen 400
Complex objects per screen
(for example, bars)
20
Screens
Template Yes
Recipes

Quantity 500
Data records per recipe 1000
Entries per recipe 1000
Recipe memory 128 Kb
Recipes
Location
1)
Memory card
USB memory stick
Network drive

1)
The number of recipe data records might be restricted by the capacity of the
storage medium.
Logs
Note
The HMI devices are suitable for the logging of relatively small volumes of data.
Manage the data in several adjacent archives in a segmented circular log. The use of a large
circular log has a negative effect on performance.

Number of logs 50
Number of partial logs in a segmented
circular log
400
Entries per log 10 000
Filing format CSV with ANSI
character set
Logs
Location
1)
Memory card
USB memory stick
Network drive

1)
The number of entries in the log may be restricted by the capacity of the
storage medium.
ITEM 2500
Overview
Safety

Number of user groups 50
Number of users 50
User view
Number of authorizations 32
Info texts

Length (no. of characters) 320
(depending on font)
For alarms Yes
For screens Yes
Info texts
For screen objects (for example, for I/O field,
switch, button, invisible button)
Yes
Additional functions

Screen settings Calibrating the touch screen
1)

Brightness setting
Yes
Yes
Language change Number of languages 16
User-specific extension of the functionality Yes VBScript
Number of scripts 100
Graphic objects Vector and pixel graphics Yes
Trends Quantity 400
Task planner Number of tasks 48
Text objects Quantity 30 000
PROFIBUS DP direct keys Yes Direct keys
PROFINET IO direct keys Yes

1)
MP 377 with touch screen only
ITEM 2500
Overview
1.8 Software options
1.8 Software options
The following software options are available for the MP 377:
WinCC flexible /Sm@rtService
The WinCC flexible /Sm@rtService option enables you to access a remote HMI device or
PC via Ethernet.
WinCC flexible /Sm@rtAccess
The WinCC flexible /Sm@rtAccess option enables you to set up communication between
different HMI systems.
WinCC flexible /Audit
The WinCC flexible /Audit option extends the HMI device to include functions for
recording operations in an audit trail and electronic signature.
WinCC flexible /OPC-Server (OPC XML)
The WinCC flexible /OPC-Server option enables you to create communications to
OPC-capable applications from an HMI device or PC via Ethernet.
WinAC MP 2007
WinAC MP 2007 is PLC software capable of running on the MP 377.
WinCC flexible /ProAgent
The WinCC flexible /ProAgent option enables you to extend the HMI device to include
specific and high-speed process fault diagnostics.
Uninterruptible Power Supply (UPS) with USB support
When interfacing an uninterruptible power supply, the HMI device is shut down in a
controlled manner after a buffer time in the event of a power failure. The MP 377 supports
SITOP DC UPS modules connected via the USB port.
Microsoft Excel Viewer
Microsoft Excel Viewer enables you to view Excel documents.
Microsoft PDF Viewer
Microsoft PDF Viewer enables you to view PDF documents.
Microsoft Word Viewer
Microsoft Word Viewer enables you to view Word documents.
ITEM 2500
Overview
1.9 Communication
1.9 Communication
Number of connections

Connection MP 377
Number using a bus connection 6
Number of connections based on "SIMATIC HMI HTTP Protocol" 8

NOTICE
Communication faults with PROFINET IO
When you release PROFINET IO in the HMI device's control panel, communication faults
may arise in the following cases:
Use of PLCs from other manufacturers
Use of SIMATIC 500/505 via NITP
Do not release PROFINET IO in the HMI device's control panel in the cases given.

ITEM 2500
Overview
1.9 Communication
PLCs
The following table shows the PLCs which can be used with the HMI devices and the
protocols or profiles which can be used.

PLC Protocol MP 377
SIMATIC S7 PPI
MPI
1)

PROFIBUS DP
PROFINET
Yes
SIMATIC S5 PROFIBUS DP Yes
SIMATIC 500/505 NITP
PROFIBUS DP
Yes
SIMATIC HMI HTTP Protocol HTTP/HTTPS (Ethernet) Yes
PLC series SLC500, SLC501, SLC502, SLC503,
SLC504, SLC505, MicroLogix and PLC5/11,
PLC5/20, PLC5/30, PLC5/40, PLC5/60, PLC5/80
DF1
2) 5) 6)

DH+ via KF2 module
3) 5) 6)

DH485 via KF3 module
4) 5) 6)

DH485
4) 6)

Yes Allen-Bradley
ControlLogix and CompactLogix PLC series
Ethernet/IP
Yes
GE Fanuc Automation PLC series 90-30, 90-70, VersaMax Micro
SNP
6)

Yes
LG Industrial Systems
(Lucky Goldstar)/IMO
PLC series GLOFA GM (GM4, GM6 and GM7),
Series G4, G6 and G7
Dedicated communication
6)

Yes
PLC series MELSEC FX and MELSEC FX0
FX
6)

Yes Mitsubishi Electric
PLC series MELSEC FX0, FX1n, FX2n, AnA,
AnN, AnS, AnU, QnA and QnAS
Protocol 4
6)

Yes
PLC series Modicon 984, TSX Quantum and
TSX Compact
Modbus RTU
5) 6)

Yes Modicon
(Schneider Automation)
PLC series Quantum, Momentum, Premium and
Micro
PLC series Compact and 984 via Ethernet bridge
Modbus TCP/IP (Ethernet)
Yes
ITEM 2500
Overview
1.9 Communication
PLC Protocol MP 377
OMRON PLC series SYSMAC C, SYSMAC CV, SYSMAC
CS1, SYSMAC alpha and CP
Hostlink/Multilink (SYSMAC Way)
6)

Yes
Telemecanique PLC series TSX 7 with P47 411, TSX 7 with
P47/67/87/107 420, TSX 7 with P47/67/87/107
425, module TSX SCM 21.6 with the specified
TSX 7 CPUs, TSX 17 with module SCG 1161,
TSX 37 (Micro) and TSX 57 (Premium)
Hostlink/Multilink (SYSMAC Way)
6)

Yes

1)
Not possible when connected to S7-212.
2)
Applies to controllers SLC503, SLC504, SLC505, PLC5, MicroLogix.
3)
Applies to controllers SLC504, PLC5 over DF1.
4)
Applies to controllers SLC500 to SLC 505 and MicroLogix.
5)
Only with converter RS 422-RS 232 6AV6 671-8XE00-0AX0 (option).
6)
PROFINET IO must be locked.

ITEM 2500
Overview
1.9 Communication
ITEM 2500

Safety instructions and approvals
2
2.1 Safety instructions
High frequency radiation
NOTICE
Unwanted operating states
High-frequency radiation, for example, from cellular phones, can trigger unwanted
operating states.

Proper use
WARNING
Commissioning the HMI device is prohibited until it has been absolutely ensured that the
machine in which the HMI device is to be installed complies with Directive 98/37/EC or
Directive 2006/42/EC as of December 29, 2009.

Hazardous areas
When operating the HMI device in hazardous areas the following warning applies.

WARNING
Explosion Hazard
Do not disconnect while circuit is live unless area is known to be non-hazardous.
Substitution of components may impair suitability for Class I, Division 2 or Zone 2.

ITEM 2500
2.1 Safety instructions
Working on the control cabinet
The following information applies to MP 377 mounting devices.

WARNING
Open equipment
The HMI device is open equipment. This means that the HMI device may only be mounted
in housings or cabinets, whereby the device can be operated from the front panel.
The cubicle or cabinet in which the HMI device is installed may only be accessed with a key
or tool and only by trained, authorized personnel.
Dangerous voltage
Opening the cabinet will expose high voltage parts. Contact with these parts could be fatal.
Always disconnect the cabinet from the mains before opening it.

ITEM 2500
2.2 Standards, certificates and approvals
Approvals
CAUTION
The following overview shows possible approvals.
The HMI device itself is certified as shown on the rear panel labels.

CE approval

The HMI device meets the general and safety-related requirements of the following EC
directives and conforms to the harmonized European standards (EN) for programmable logic
controllers published in the official gazettes of the European Union:
2004/108/EC "Electromagnetic Compatibility" (EMC Directive)
2006/95/EC "Electrical equipment for use within specific voltage limits" (Low-Voltage
Directive)
EC Declaration of Conformity
The EC Declarations of Conformity are available to the relevant authorities at the following
address:
Industry Sector
I IA AS RD ST PLC
P.O. Box 1963
D-92209 Amberg
ITEM 2500
UL approval

Underwriters Laboratories Inc., to
UL 508 (Industrial Control Equipment)
CSA C22.2 No. 142 (Process Control Equipment)
or

Underwriters Laboratories Inc., to
UL 1604 (Hazardous Location)
CSA-213 (Hazardous Location)
Approved for use in
Class I, Division 2, Group A, B, C, D or
Class I, Zone 2, Group IIC or
non-hazardous locations
FM approval (MP 377 mounting device only)
FM
APPROVED

Factory Mutual Research (FM) conforming to
Approval Standard Class Number 3611, 3600, 3810
Approved for use in
Class I, Division 2, Group A, B, C, D T4
Class I, Zone 2, Group IIC T4
Marking for Australia
N117

The HMI device fulfills the requirements of standard AS/NZS 2064 (Class A).
IEC 61131
The HMI device fulfills requirements and criteria to IEC 61131-2, Programmable Logic
Controllers, Part 2: Operating resource requirements and tests.
ITEM 2500
2.3 Notes about usage
Industrial applications
The HMI device is designed for industrial applications. It conforms to the following standards:
Requirements for emissions EN 61000-6-4: 2007
Requirements for interference immunity EN 61000-6-2: 2005
Use in residential areas
Note
The HMI device is not intended for use in residential areas. Operation of an HMI device in
residential areas can have a negative influence on radio/TV reception.

If the HMI device is used in a residential area, you must take measures to achieve Limit
Class B conforming to EN 55011 for RF interference.
Suitable measures for achieving the degree of noise suppression for Limit Class B include,
for example:
Installation of the HMI device in grounded control cabinets
Use of filters in electrical supply lines
Individual acceptance is required.
ITEM 2500
2.4 Electromagnetic compatibility
Introduction
The HMI device fulfills, among other things, the requirements of the EMC law pertaining to
the domestic European market.
EMC-compatible installation of the HMI device
The EMC-compliant installation of the HMI device and the application of interference-proof
cable is the basis for interference-free operation. The "Directives for interference-free
installation of PLCs" and the "PROFIBUS Networks" manual also apply for the installation of
the HMI device.
Pulse-shaped disturbance
The following table shows the electromagnetic compatibility of modules with regard to pulse-
shaped interference. The precondition for electromagnetic compatibility is that the HMI
device meets the specifications and guidelines for electrical installation.

Pulse-shaped disturbance Tested with Degree of
severity
Electrostatic discharge
in accordance with
IEC 61000-4-2
Air discharge: 8 kV
Contact discharge: 6 kV
3
Burst pulses
(high-speed transient
interference)
in accordance with
IEC 61000-4-4
2 kV power supply cable
2 kV signal cable, > 30 m
1 kV signal cable, < 30 m
3
High-power surge pulses in accordance with IEC 61000-4-5, external protective circuit required
(refer to the manual Automation System S7-300, Installation, "Lightning and
overvoltage protection" section)
Asymmetrical coupling 2 kV power cable
DC voltage with protective elements
2 kV signal/data cable, > 30 m,
with protective elements as required
3
Symmetrical coupling 1 kV power cable
DC voltage with protective elements
1 KV signal cable, > 30 m,
3
ITEM 2500
Sinusoidal interference
The following table shows the EMC behavior of the modules with respect to sinusoidal
interference. This requires the HMI device to meet the specifications and directives for
electrical installation.

Sinusoidal interference Test values Degree of
severity
HF radiation (in
electromagnetic fields) in
accordance with
IEC 61000-4-3
80% amplitude modulation at 1 kHz
with 10 V/m in the range of 80 MHz to 1 GHz
with 3 V/m in the range 1.4 GHz to 2 GHz
with 1 V/m the range 2 GHz to 2.7 GHz
10 V/m with 50% pulse modulation at 900 MHz
10 V/m with 50% pulse modulation at 1.89 GHz
3
RF interference current on
cables and cable shielding
conforming to IEC 61000-4-6
Test voltage 10 V, with 80% amplitude modulation
of 1 kHz in the 9 MHz to 80 MHz range
3
Emission of radio interference
The following table shows the unwanted emissions from electromagnetic fields in
accordance with EN 55011, Limit Value Class A, Group 1, measured at a distance of 10 m.

From 30 to 230 MHz < 40 dB (V/m) quasi-peak
From 230 to 1000 MHz < 47 dB (V/m) quasi-peak
Additional measures
If you want to connect an HMI device to the public power supply system, you must ensure
Limit Value Class B in accordance with EN 55022.
ITEM 2500
2.5 Transport and storage conditions
2.5 Transport and storage conditions
Mechanical and climatic conditions for transportation and storage
This HMI device meets the requirements for IEC 61131-2 relating to transport and storage
conditions. The following specifications apply to the transport and storage of an HMI device
in its original packaging.
The climatic conditions conform to the following standards:
IEC 60721-3-3, Class 3K7 for storage
IEC 60721-3-2, Class 2K4 for transport
Mechanical requirements conform to EC 60721-3-2, Class 2M2.

Type of condition Permitted range
Drop test (in transport package) 1 m
Temperature From 20 to +60 C
Atmospheric pressure From 1 080 hPa to 660 hPa,
corresponds to an elevation of 1000 to 3500 m
Relative humidity From 10 to 90%, without condensation
Sinusoidal vibration in accordance with
IEC 60068-2-6
5 to 9 Hz: 3.5 mm
9 Hz to 500 Hz: 9.8 m/s
2

Shock in accordance with IEC 60068-2-29 250 m/s
2
, 6 ms, 1000 shocks

NOTICE
Avoid dewing
If the HMI device is subjected to low temperatures or extreme fluctuations in temperature
during transportation, moisture could occur on or inside the HMI device. Dewing can occur.
This can cause malfunctions.
The HMI device must have acquired room temperature before it is put into operation. Do
not expose the HMI device to direct radiation from a heater in order to warm it up. If there is
condensation, wait approximately 4 hours until the HMI device has dried completely before
switching it on.

Proper transport and storage, installation and assembly as well as careful operation and
maintenance are required to ensure trouble-free and safe operation of the HMI device.
The warranty for the HMI device will be deemed void if these stipulations are not heeded.

ITEM 2500

3
Mechanical and climatic conditions of use
The HMI device is designed for use in a location protected from the effects of the weather.
The conditions of use meet the requirements for DIN IEC 60721-3-3:
Class 3M3 (mechanical requirements)
Class 3K3 (climatic requirements)
Use with additional measures
The HMI device should not be used at the following locations unless additional measures
are taken:
In locations with a high degree of ionizing radiation
In locations with severe operating conditions, for example, due to:
Corrosive vapors, gases, oils or chemicals
Electrical or magnetic fields of high intensity
In plants that require special monitoring - for example:
Elevators
Systems in especially hazardous rooms
Mechanical ambient conditions
The mechanical ambient conditions for the HMI device are specified in the following table in
terms of sinusoidal vibration.

Frequency range in Hz Constant Occasional
10 f 58 Amplitude 0,0375 mm Amplitude 0.075 mm
58 f 150 Constant acceleration 0,5 g Constant acceleration 1 g
Reducing vibrations
If the HMI device is subjected to greater shocks or vibrations, you must take appropriate
measures to reduce acceleration or amplitudes.
We recommend mounting the HMI device on damping materials (on rubber-metal vibration
dampers, for example).
ITEM 2500
Testing mechanical ambient conditions
The following table provides information on the type and scope of tests for mechanical
ambient conditions.

Tested for Test standard Comments
Vibrations Vibration test in accordance
with IEC 60068, part 26
(sinusoidal)
Type of vibration:
Transitional rate of the frequency:
1 octave/minute.
10 f 58,
Constant amplitude 0.075 mm
58 f 150,
constant acceleration 1 g,
with support arm 0.5 g on the basic adapter
Vibration duration:
10 frequency cycles per axis at each of the three
associated vertical axes
Shock Shock test in accordance
with IEC 60068, Part 2 27
Type of shock: Half-sine
Shock intensity:
Peak value 15 g, duration 11 ms
Direction of impact:
3 shocks in direction at each one of the three
associated vertical axes
Climatic ambient conditions
The following table shows the climatic ambient conditions for operation of the HMI device.

Ambient conditions Permitted range Comments
Temperature
Vertical installation
MP 377 12" Touch
MP 377 12" Key
MP 377 15" Touch
MP 377 19" Touch
Inclined installation
MP 377 12" Touch
MP 377 12" Key
MP 377 15" Touch
MP 377 19" Touch

From 0 to 50 C
From 0 to 50 C
From 0 to 50 C
From 0 to 50 C
From 0 to 45 C

From 0 to 40 C
From 0 to 40 C
From 0 to 35 C
From 0 to 35 C
From 0 to 45 C
MP 377 12" Touch,
MP 377 12" Key,
MP 377 15" Touch,
MP 377 19" Touch:
See section Mounting positions
and type of fixation (Page 47)
MP 377 PRO 15" Touch:
See section Mounting positions
(Page 51)
Relative humidity 10 to 90%, without condensation
Atmospheric pressure 1 080 to 795 hPa Corresponds to an elevation
of 1 000 m to 2 000 m
SO2: < 0.5 vpm;
Relative humidity < 60%,
no condensation
Test: 10 cm
3
/m
3
; 10 days Pollutant concentration
H2S: < 0.1 vpm;
Relative humidity < 60%,
no condensation
Test: 1 cm
3
/m
3
; 10 days
ITEM 2500
3.2.1 Mounting positions and type of fixation
Mounting position
The HMI device is suitable for installation in:
Mounting cabinets
Control cabinets
Switchboards
Consoles
In the following, all of these mounting options are referred to by the general term "cabinet".
The HMI device is self-ventilated and approved for vertical and inclined mounting in
stationary cabinets.
1 2 1
+

Mounting position Deviation from the vertical
Inclined 35
Vertical 0

CAUTION
Damage due to overheating
An inclined installation reduces the convection by the HMI device and therefore the
maximum permissible ambient temperature for operation.
If there is sufficient forced ventilation, the HMI device can also be operating in the
inclined mounting position up to the maximum permissible ambient temperature
for vertical installation.
Otherwise, the HMI device may be damaged and the approvals and warranty for the
HMI device may become void.

For information regarding the permissible ambient temperatures, refer to Notes about usage
(Page 45).
ITEM 2500
Mounting
Metal mounting clamps are provided for mounting. The mounting clamps hook into the
oblong holes on the HMI device.
2
1

Threaded pin
Hook
3.2.2 Preparing for installation
Select the mounting location of the HMI device
Points to observe when selecting the mounting location:
Position the HMI device so that it is not subjected to direct sunlight.
Position the HMI device such that it is ergonomically accessible for the user.
Choose a suitable mounting height.
Ensure that the air vents of the HMI device are not covered as a result of the mounting.
Note the permissible mounting positions.

NOTICE

Stability of the mounting cutout
The material in the area of the mounting cutout must provide sufficient strength to
guarantee the enduring and safe mounting of the HMI device.
The force of the clamps or operation of the device may not lead to deformation of the
material in order to achieve the degrees of protection described below.

Degrees of protection
The protection ratings are only ensured if the mounting cutout conforms to the following:
Material thickness at the mounting cutout for IP65 degree of protection or for
enclosure type 4X/type 12 (indoor use only): 2 mm to 6 mm
Permitted deviation from plane at the mounting cutout: 0.5 mm
This condition must be fulfilled for the mounted HMI device.
Permissible surface roughness in the area of the seal: 120 m (Rz 120)
A clamping frame is additionally available for mounting the MP 377 12" Touch to panels with
a material thickness < 2 mm at the mounting cutout. The frame enables IP65 degree of
protection or enclosure type 4X/type 12 to be achieved.
ITEM 2500
Dimensions of the mounting cutout
The following table shows the dimensions of the required mounting cutout:

Mounting cutout MP 377 12" Touch MP 377 12" Key MP 377 15" Touch MP 377 19" Touch
Width 310
+1
mm 450
+1
mm 367
+1
mm 449
+1
mm
Height 248
+1
mm 290
+1
mm 289
+1
mm 379
+1
mm
HMI device depth,
not including front
panel
72 mm 59 mm 72 mm 75 mm

Note
You can insert an MP 377 12" Key into the mounting cutout of the following HMI devices:
MP 370 12" Key
MP 277 10" Key
MP 270 10" Key
OP 270 10"
You can insert an MP 377 12" Touch into the mounting cutout of the following HMI devices:
MP 370 12" Touch
MP 277 10" Touch
MP 270 10" Touch
OP 270 10"
You can insert an MP 377 15" Touch into the mounting cutout of the following HMI device:
MP 370 15" Touch

Maintaining clearances
The HMI device must be installed with the following clearances:
50 mm above and below the mounting cutout respectively for ventilation
15 mm to the right and left of the mounting cutout respectively for suspending the
mounting clamps for mounting
At least 10 mm behind the rear panel of the HMI device

NOTICE

Ensure that the maximum ambient temperature is not exceeded when mounting the
device in a cabinet and especially in a closed enclosure.

ITEM 2500
3.2.3 Information on insulation tests, protection class and degree of protection
Test voltages
Insulation strength is demonstrated in the type test with the following test voltages in
accordance with IEC 61131-2:

Circuits with a nominal voltage of Ue to
other circuits or ground
Test voltage
< 50 V 500 V DC
Protection class
Protection Class I in accordance with IEC 60536, i.e. PE/ground terminal to profile rail
required!
Protection against foreign objects and water

Degree of protection in accordance with
IEC 60529
Explanation
Front When mounted:
IP65
Enclosure Type 4X/Type 12 (indoor use only)
Rear panel IP20
Touch protection test with standard test probes. There is
no protection against ingress by water.
The degree of protection at the front can only be guaranteed if the mounting seal is installed
flush to the mounting cutout.
3.2.4 Rated voltages
The table below shows the rated voltage and the corresponding tolerance range.

Rated voltage Tolerance range
+24 VDC 19.2 to 28.8 V (+/20%)
ITEM 2500
3.3 MP 377 PRO
3.3 MP 377 PRO
3.3.1 Mounting positions
Mounting position
The HMI device is self-ventilated and approved for vertical and inclined mounting.
1 2 1
+

Mounting position Deviation from the vertical
Inclined 35
Vertical 0
3.3.2 Preparing for installation
Select the mounting location of the HMI device
Points to observe when selecting the mounting location:
Position the HMI device so that it is not subjected to direct sunlight.
Position the HMI device such that it is ergonomically accessible for the user. Choose a
suitable mounting height.
Observe the permissible mounting positions for the HMI device.
ITEM 2500
3.3 MP 377 PRO
3.3.3 Information on insulation tests, protection class and degree of protection
Test voltages
Insulation strength is demonstrated in the type test with the following test voltages in
accordance with IEC 61131-2:

Circuits with a nominal voltage of Ue to other
circuits or ground
Test voltage
< 50 V 500 VDC
Protection class
Protection Class I in accordance with IEC 60536, i.e. PE/ground terminal to
profile rail required!
Protection against foreign objects and water
The following degree of protection applies to the HMI device:

Device side Degree of protection in accordance with IEC 60529
all sides IP65
Enclosure Type 12 (indoor use only)
Enclosure Type 4X/Type 12 (indoor use only)
3.3.4 Rated voltages
The table below shows the rated voltage and the corresponding tolerance range.

Rated voltage Tolerance range
+24 VDC 19.2 to 28.8 V (+/20%)
ITEM 2500

4
4.1 Checking the package contents
Check the package content for visible signs of transport damage and for completeness.

NOTICE
Damaged parts
A damaged part will cause the HMI device to malfunction.
Do not install parts damaged during shipment. In the case of damaged parts, contact your
Siemens representative.

The following is included in the product package of the MP 377 mounting device:
HMI device
Accessory kit with mounting clamps and mains terminal
The following is included in the product package of the MP 377 PRO:
HMI device
Basic adapter for fixing to a support arm
Four screws for fitting the basic adapter
Mains terminal
Additional documents may be included in the product package of all HMI devices.
The documentation belongs to the HMI device and is required for subsequent
commissioning. Retain all enclosed documentation for the entire service life of the HMI
device. You must pass on the enclosed documentation to any subsequent owner or user of
the HMI device. Make sure that every supplement to the documentation that you receive is
stored together with the operating instructions.
ITEM 2500
4.2 Installing the HMI device
4.2.1 Installing the MP 377 mounting device
Requirement
All packaging components and protective foils should be removed from the HMI device.
To install the HMI device, you need the mounting clamps from the accessory kit. The
mounting seal must be fitted on the HMI device. If the mounting seal is damaged, order a
replacement seal. The mounting seal is part of the associated service pack.
To ensure the necessary degree of protection on the HMI device, the mounting clamps must
observe the positions listed below.
The following photo shows how positions 1 to 10 are counted.
1
10
2
3

ITEM 2500
Positions of mounting clamps on the MP 377 12" Touch
The following figure shows the counting direction for the insertion of the mounting clamps.

The following table shows the positions of the mounting clamps on the MP 377 12" Touch.
Observe the counting direction.

Page Number of mounting
clamps
Position 1 Position 2 Position 3
Top 3 2 11 20
Right 3 2 9 16
Bottom 3 2 11 20
Left 3 2 9 16
Positioning the mounting clamps on the MP 377 12" Key
A total of 10 mounting clamps are needed for mounting. Fit mounting clamps
in all the cutouts.
ITEM 2500
Positioning the mounting clamps on the MP 377 15" Touch
The following figure shows the counting direction for the insertion of the mounting clamps.

The following table shows the positioning of the mounting clamps on the MP 377 15" Touch.
Observe the counting direction.

Page Number of
mounting clamps
Position 1 Position 2 Position 3 Position 4
Top 4 2 9 17 24
Right 3 3 10 17
Bottom 4 2 9 17 24
Left 3 3 10 17
Positions of the mounting clamps on the MP 377 19" Touch
The positions of the mounting clamps are marked by stamps on the cutouts.
The following diagram shows examples of these stamps.
1

Stamps identifying the position of a mounting clamp
A total of 18 mounting clamps are needed for mounting. Fit mounting clamps in all the
stamped cutouts.
ITEM 2500
Procedure
NOTICE
Installation of the HMI device
Always mount the HMI device according to the instructions in this manual.
Risk of guaranteed level of protection not being met
If the mounting seal is damaged or protrudes beyond the HMI device, the level of protection
is not ensured.
Check the fit of the mounting seal.

Note
Tighten the threaded pins of the mounting clamps until the HMI device is flush with the
surface of the control cabinet. Alternatively, tighten the mounting clamps using a maximum
torque of 0.2 Nm.

Proceed as follows:
1. Check that the mounting seal is fitted on the HMI device.
Do not install the mounting seal turned inside out. This may cause leaks in
the mounting cutout.
2. Insert the HMI device into the mounting cutout from the front.
3. Insert a mounting clamp into the cutout provided on the HMI device.
1
2

4. Fasten the mounting clamp by tightening the threaded pin .
5. Repeat steps 3 and 4 for all mounting clamps.
6. Check the fit of the mounting seal.
If necessary, repeat steps 1 to 6.
ITEM 2500
Result
The HMI device is mounted and the relevant level of protection is ensured at the front.
See also
Accessory kit (Page 25)
Accessories (Page 26)
Information on insulation tests, protection class and degree of protection (Page 50)
4.2.2 Installing MP 377 PRO
Requirement
All packaging components and protective foils should be removed from the HMI device.
To install the HMI device, you need the basic adapter and an adapter set from the
accessories.
The following cables are fed through the stand or the support arm to which the HMI device
will be fixed:
Equipotential bonding cable
Power supply cable
Data cables, such as PROFINET, USB

NOTICE

Warranty endangered
If you install the HMI device not in accordance with the specifications given in these
operating instructions, the warranty for the HMI device will become void.
Always install the HMI device according to these operating instructions.
IP65 degree of protection at risk
If there are no seals on the adapters or these are damaged, then IP65 degree of
protection is at risk. Check the condition and seating of the seals.
If the seal on the rear panel of the housing is damaged, it can be repaired. For a repair
scenario, follow the procedure described in the section "Spare parts and repairs
(Page 274).

Note
The warranty for the IP65 degree of protection assumes that the support arm or the stand
also complies with IP65.

ITEM 2500
Procedure
This section describes how to install the device on a support arm system. Installation on a
stand is carried out analogously.
Proceed as follows:
1. Remove the 10 screws of the housings rear panel using a size 2 Allen wrench.
1
2
3
5
7
6
6
4

2. Remove the rear panel of the housing and store it in a secure location.
3. Fasten the support arm head to the adaptor plate using the four M6 x 12 screws
from the accessory kit of the adapter set. Ensure that the seal is properly seated.
4. Fasten the base adapter to the adaptor plate using the four M6 x 12 screws from
the accessory kit of the adapter set. Ensure that the seal is properly seated.

NOTICE

Do not exceed the permissible torque
If you fasten the screw with a torque > 1.2 Nm, the threads in the housing may be
damaged.
Alternatively, tighten the screws using a maximum torque of 1.2 Nm.

5. Fasten the base adapter to the mechanical interface using the four screws of the
cover. Ensure that the seal is properly seated.
ITEM 2500
6. Fasten the HMI device to the support arm .
In doing so, ensure that all connections are fed (without damage) through the adapter into
the inside of the HMI device.
7. If you want to connect the cables at a later point in time, fasten the housing rear panel
to the HMI device.
Result
The HMI device is fitted and can be connected electrically.
See also
Accessory kit (Page 25)
ITEM 2500
4.3 Connecting the HMI device
4.3.1 Overview
Requirement
The HMI device must be mounted according to the specifications of
these operating instructions.
Always use shielded standard cables for the data cable.
Additional information is available in the catalog and online order system at
"http://mall.automation.siemens.com".
Connection sequence
Connect the HMI device in the following sequence:
1. Equipotential bonding
2. Power supply
Perform a power-up test to ensure the power supply is connected with
the correct polarity.
3. PLC
4. Configuring PC as necessary
5. I/Os as necessary

NOTICE

Damage to the HMI device
If you do not keep to the connection sequence you could damage the HMI device.
Ensure you connect the HMI device in the sequence stipulated above.

Disconnect the HMI device by completing the above steps in reverse order.
Connecting the cables
When connecting the cables, ensure that the contact pins are not bent. Secure the cable
connectors by screwing the connector onto the socket.
Provide adequate strain relief for the cables. For this purpose, the MP 377 PRO contains a
strain relief bar below the ports on the rear of the HMI device.
ITEM 2500
4.3.2 Ports
The following figure shows the ports of the HMI device MP 377.
1 2 3 4 6 5

Power supply connector
RS-422/RS-485 port X10 / IF1b
PROFINET, 2 ports X1 P1 and X1 P2
USB, ports X20 and X21
Line in and micro
Line out
Connect PROFIBUS DP or MPI to the X10 / IF1b port.
You can affix the USB and PROFINET connecting cables to the rear panel of the HMI device
with cable ties.
See also
Design of the MP 377 12" Touch (Page 15)
Design of the MP 377 12" Key (Page 17)
Design of the MP 377 PRO 15" Touch (Page 23)
ITEM 2500
4.3.3 Connecting the equipotential bonding circuit
Differences in electrical potential
Differences in electrical potential can develop between spatially separated plant
components. Such electrical potential differences can lead to high equalizing currents over
the data cables and therefore to the destruction of their interfaces. Equalizing currents
can develop if the cable shielding is terminated at both ends and grounded to different
plant parts.
Differences in potential may develop when a system is connected to different
mains supplies.
General requirements for equipotential bonding
Differences in potential must be reduced by means of equipotential bonding in order to
ensure trouble-free operation of the relevant components of the electronic system. The
following must therefore be observed when installing the equipotential bonding circuit:
The effectiveness of equipotential bonding increases as the impedance of the
equipotential bonding conductor decreases or as its cross-section increases.
If two plant parts are interconnected by means of shielded data cables and their shielding
is bonded at both ends to the grounding/protective conductor, the impedance of the
additionally installed equipotential bonding cable must not exceed 10% of the
shielding impedance.
The cross-section of an equipotential bonding conductor must be capable of handling the
maximum equalizing current. Experience has shown that equipotential bonding
conductors with a minimum cross-section of 16 mm should be fitted between the control
cabinets or the ground point of the supporting arm or the stand for PRO HMI devices.
Use equipotential bonding conductors made of copper or galvanized steel. Establish a
large surface contact between the equipotential bonding conductors and the
grounding/protective conductor and protect these from corrosion.
Use a suitable cable clip to clamp the shield of the data cable flush to the equipotential
bonding rail. Keep the length of cable between the HMI device and the equipotential
bonding rail as short as possible.
Route the equipotential bonding conductor and data cables in parallel and with minimum
clearance between these.
ITEM 2500
Wiring diagram
1
2
3
4
5 7 6
3
8
6
8
4

Chassis terminal on the HMI device, example
Equipotential bonding conductor cross-section: 4 mm
2

Control cabinet
Equipotential bonding conductor cross-section: min. 16 mm
2

Ground connection
Cable clip
Equipotential bonding rail
Parallel routing of the equipotential bonding conductor and data cable

CAUTION
Damage to the interface modules possible
Cable shielding is not suitable for equipotential bonding.
Use only the prescribed equipotential bonding conductors. The equipotential bonding
conductor must not be less than 16 mm. The interface modules may otherwise be
damaged or destroyed.

ITEM 2500
4.3.4 Connecting the power supply
Wiring diagram
The following figure shows the connection between the power supply and HMI device.
MP 377 12 Touch
MP 377 12 Key
MP 377 15 Touch
MP 377 19 Touch
MP 377 PRO 15 Touch

Note when connecting
The mains terminal for connecting the power supply is contained in the accessory kit. The
mains terminal is designed for cables with a maximum cross-section of 1.5 mm.
ITEM 2500
Connecting the mains terminal
NOTICE
Damage
Do not tighten the screws of the power supply terminal if it is plugged into the HMI device.
The pressure from the screwdriver may otherwise damage the HMI device socket.
Only connect the wires when the mains terminal is withdrawn.

GND
+24 VDC

Connect the power supply terminal to the cables of the power supply as shown in the figure
above. Ensure that the lines are connected properly to the correct terminals. Refer to the
label for the contact pins on the rear of the HMI device.
Reverse polarity protection
The HMI device is equipped with a reverse polarity protection circuit.
Connecting the power supply
CAUTION
Safe electrical isolation
Use only 24 VDC power supply units with safe electrical isolation in accordance with
IEC 60364-4-41 or HD 384.04.41 (VDE 0100, Part 410), e.g. to PELV standard.
The supply voltage must be within the specified voltage range. Otherwise, malfunction at
the HMI device cannot be ruled out.
Applies to non-isolated plant configurations:
Connect the GND 24 V connection from the 24 V power supply output to equipotential
bonding for uniform reference potential. You should always select a central point
of termination.

See also
Connecting an uninterruptible power supply (Page 67)
ITEM 2500
4.3.5 Connecting an uninterruptible power supply
Connection graphic
The following figure shows the connection between the uninterruptible power supply and
HMI device. The uninterruptible power supply is connected to the 24-V input and one of the
HMI device's USB ports.
When connected to the HMI device's USB port, the following uninterruptible power supplies
are supported:
SITOP DC UPS modules as of a rated power value of 6 A, e.g. 6EP1931-2DC42
Uninterruptible power supply
MP 377 PRO 15 Touch
MP 377 12 Touch
MP 377 12 Key
MP 377 15 Touch
MP 377 19 Touch

Note
Observe all the notes relating to connecting a power supply.

See also
Connecting the power supply (Page 65)
ITEM 2500
4.3.6 Connecting the PLC
Wiring diagram
The following figure shows the connection between the PLC and HMI device.
MP 377 12 Touch
MP 377 12 Key
MP 377 15 Touch
MP 377 19 Touch
MP 377 PRO 15 Touch
SlMATlC S7
SlMATlC 500/505
SlMATlC S7
SlMATlC S5
SlMATlC 500/505
RS 232
RS 485
RS 422/RS 485
RS 422
RS 485
PROFlNET (Ethernet/LAN)
PROFlNET
RS 485
RS 232
RS 422
RS 485
PLC
1
PLC
1
PLC
1
PLC
1
1
PLC of other manufacturer

ITEM 2500
NOTICE
Approved cable
If you do not use approved cables to connect a SIMATIC S7 controller,
you may experience malfunctions.
Only use approved cables to connect a SIMATIC S7 controller.

Standard cables are available for the connection. You can find additional information on this
in the Internet at "http://mall.automation.siemens.com".
Connecting PROFINET
NOTICE
Damage to the HMI device
Only connect the HMI device to public Ethernet networks using a switch
or comparable device.
PROFINET IO communication
For instructions regarding the installation of PROFINET networks, refer to the
"PROFINET System Description" manual.

Note the following for the MP 377 PRO 15" Touch:
Use an angled tool, such as an Allen wrench, to loosen the latch of the RJ45 connector
for PROFINET.

ITEM 2500
Configuring an RS-422/RS-485 port
A DIP switch S1 for the configuration of the RS-422/RS-485 port is located on the rear of
the HMI device.
In the factory state, the DIP switch is set for communication with the SIMATIC S7 PLC
via RS 485.

Note
Note the diagrams of DIP switch settings on the rear panel of the HMI device.

The following table shows the DIP switch settings. The send and receive direction is toggled
internally using the RTS signal.

Communication Switch setting Meaning
4 3 2 1
ON

No RTS on connector,
During data transfer between the PLC and HMI device
During data transfer between the HMI device and PC
(delivery condition)
4 3 2 1
ON

RTS on pin 4, same as PLC,
for example for commissioning
RS 485
4 3 2 1
ON

RTS on pin 9, same as programming device,
for example for commissioning
RS 422
4 3 2 1
ON

RS-422 port is active.
ITEM 2500
4.3.7 Connecting the configuration PC
Wiring diagram
The following figure shows the connection between the configuring PC and HMI device.
MP 377 PRO 15 Touch
RS 232
RS 485
USB
PROFlNET
RS 485
MP 377 12 Touch
MP 377 12 Key
MP 377 15 Touch
MP 377 19 Touch

The ports are described in the specifications.
For the RS-485 to RS-232 conversion, you can order the PC/PPI cable from Siemens AG
using order number 6ES7 901-3CB30-0XA0.
ITEM 2500
Configuring the PC/PPI cable
Use the DIP switches to configure the transfer rate of the PC/PPI cable.

Note
Set a lower bit rate if the connection is lost during the operating system update. If you use
a higher bit rate, you must use the PC/PPI cable version 3 or higher. The version code is
printed on the cable ("E stand 3," for example, corresponds to version 3).

1 2

DIP switch
LEDs
Set DIP switches 1 to 3 to the same bit rate as in WinCC flexible. DIP switches 4 to 8
must be set to "0".
1
1
0
2 3 4 5 6 7 8
1

DIP switch
The following bit rates can be set:

Bit rate in Kbps DIP switch 1 DIP switch 2 DIP switch 3
115.2 1 1 0
57.6 1 1 1
38.4 0 0 0
19.2 0 0 1
9.6 0 1 0
4.8 0 1 1
2.4 1 0 0
1.2 1 0 1
In the figure, the bit rate is set to 115.2 Kbps.
ITEM 2500
NOTICE
USB connection sequence
Observe the following sequence when connecting by USB:
1. HMI device
2. PC
USB host-to-host cable
Use only the driver for the USB host-to-host cable that is included in the WinCC flexible
package. Never use the driver supplied with the USB host-to-host cable.

Note
Updating the operating system
If there is no serviceable HMI device image on the HMI device, you can only update the
operating system by restoring the factory setting. When restoring the factory settings,
connect the PC to the HMI device by PROFINET.
HMI device changeover
If you connect more than one HMI device with the same IP address in succession to a single
configuring PC, you need to ping the configuring PC once from the HMI device on each
changeover of the HMI device.

Note for MP 377 PRO 15" Touch
Use an angled tool, such as an Allen wrench, to loosen the latch of the RJ45 connector
for PROFINET.

ITEM 2500
4.3.8 Connecting a USB device
Below are examples of devices you can connect to the USB port of the HMI device:
External mouse
External keyboard
Printer
USB memory stick
Industrial USB Hub 4
Industrial USB hub 4 can be obtained using order number 6AV6671-3AH00-0AX0.
NOTICE
Functional problem with USB port
If you connect an external device with a 230-V power supply to the USB port without using
an non-insulated installation, you may experience functional problems.
Ensure a non-insulated installation.
Excessive rated load on port
A USB device with too high a power load may possibly cause functional problems.
Observe the values for the maximum load of the USB interface. You will find the values in
the section "Technical specifications" (Page 284).

ITEM 2500
4.3.9 Connecting a printer
Wiring diagram
The following figure shows the connection between the printer and HMI device.
MP 377 PRO 15 Touch
USB
PROFlNET
MP 377 12 Touch
MP 377 12 Key
MP 377 15 Touch
MP 377 19 Touch

ITEM 2500
NOTICE
Data exchange cables
If you use cables without a metallic netting shield between the HMI device and printer,
you may experience functional problems.
Only use cables with metal-braided shielding grounded at both ends for connecting the
HMI device and printer.

Note
Some printers may require the ASCII character set used in the project to also be defined on
the printer.

You can find the list of current printers and required settings for HMI devices in the Internet
at "http://support.automation.siemens.com/WW/view/en/11376409".
Observe the supplied printer documentation when you connect the printer.
4.3.10 Connecting an audio device
You can connect an active speaker or another audio amplifier to the HMI device's
"Line Out" port.

Note
The "Micro" and "Line In" ports are provided for future applications.

The microphone and audio source share one port.
ITEM 2500
4.4 Switching on and testing the HMI device
Procedure
Proceed as follows:
1. Switching on the power supply.
The screen lights up after power is switched on. A progress bar is displayed
during startup.
If the HMI device fails to start, you have probably crossed the wires on the mains
terminal. Check the connected wires and change their connection. The Loader opens
after the operating system has started.

The HMI device automatically switches to "Transfer" mode during initial startup under the
following conditions:
No project is loaded on the device.
At least one data channel has been configured.
During this process the following dialog appears:

2. Press "Cancel" to stop the transfer.
ITEM 2500
Result
The Loader appears again.

Note
When restarting the system, a project may already be loaded on the HMI device. The project
will then start after an adjustable delay or when you press the "Start" button.
Use the relevant operating element to close the project.
Refer to your plant documentation to find any additional information on this topic.

Function test
Perform a function test following commissioning. The HMI device is fully functional when one
of the following states is indicated:
The "Transfer" dialog is displayed.
The Loader is displayed.
A project is started.
Shutting down the HMI Device
Terminate the project at the HMI device before switching it off.
You have the following options for switching off the HMI device:
Switch off the power supply.
Remove the mains terminal from the HMI device.
See also
Configuring the data channel (Page 136)
ITEM 2500
4.5 Securing the cables
4.5 Securing the cables
4.5.1 Securing cables on the MP 377 mounting device
After the power-on test, to ensure strain relief, use cable ties to secure the connected cables
to the marked fixing elements.
Fastening element

4.5.2 Securing cables on the MP 377 PRO
After the power-on test, use cable ties to secure the connected cables to the marked clasps
to ensure strain relief.
Clasps

ITEM 2500
4.6 Closing the housing rear wall of MP 377 PRO
4.6 Closing the housing rear wall of MP 377 PRO
Requirement
All cables are connected.
Procedure
Proceed as follows:
1. Check that the seal is properly seated on the housing.

NOTICE

IP65 degree of protection at risk
If the seal on the rear wall of the housing is damaged, the IP65 degree of protection is at
risk. This is a repair case. Proceed as described in the section Spare parts and repairs
(Page 274).

2. Position the housing rear wall on the housing.
Ensure the housing rear wall cannot fall down.

NOTICE

Do not exceed the permissible torque
If you tighten up the screws with a torque of > 1.2 Nm, you could damage the thread in
the housing.
Alternatively, tighten the screws using a maximum torque of 1.2 Nm.

3. Use an Allen key, size 2, to remove the 10 screws of the housing rear wall.
1
1
1

ITEM 2500

Operator controls and displays
5
5.1 Front operator controls
MP 377 Touch
1

Display with touch screen
The MP 377 Touch is operated via the touch screen. All operating elements required for
operator input are displayed on the touch screen once the HMI device has started.

NOTICE
Unintentional action possible
Do not carry out several operations simultaneously. You may otherwise trigger an
unintentional action.
Always touch only one operating element on the screen
Damage to the touch screen possible
Never touch the touch screen with pointed or sharp objects. Avoid applying excessive
pressure to the touch screen with hard objects. Both these will substantially reduce the
useful life of the touch screen and even lead to total failure.
Always operate the HMI touch screen with your fingers or with a touch pen.

ITEM 2500
5.1 Front operator controls
MP 377 12" Key
1
2
5
3
1
4
4

Function keys with LED
System keys - alphanumeric keys
Display
System keys control keys
System keys - cursor keys
The MP 377 12" Key is operated using the system keys and the function keys.
The function assigned to a specific function key is defined during configuration. The function
keys have no function prior to the project being opened.

NOTICE
Unintentional action possible
Do not carry out several operations simultaneously. You may otherwise trigger an
unintentional action.
Do not press more than two keys simultaneously
Damage to the keyboard possible
Using hard instruments to press the keys considerably reduces the service life of the
key mechanism.
Only use your fingers to operate the HMI device keys.

ITEM 2500
5.2 Inserting a memory card
5.2 Inserting a memory card
Introduction
The following can be saved to the memory card of the HMI device:
Backup of the HMI device
Logs
Recipes
Operating system
Applications
Other data such as video files, Word, Excel or PDF files
The memory card can be inserted during operation.

Note
The multimedia card of the SIMATIC S7 PLC cannot be used.

Procedure
Proceed as follows:
1. Insert the memory card into the relevant slot.
When inserting the memory card, please note that it can only be inserted in the slot when
the front side of the memory card is visible.

2. Check that the memory card is properly seated.
See also
Securing memory card (Page 84)
ITEM 2500
5.3 Securing memory card
5.3 Securing memory card
Introduction
The HMI device is designed for the tough conditions experienced in industry. Therefore use
the locking bracket to secure the memory card in its slot.
Requirements
A memory card has been inserted.
Procedure
Proceed as follows:
1. Loosely screw in the Torx screw .
2
1

2. Place the locking bracket against the memory card.
3. Tighten the Torx screw .
Result
The memory card is secure.
ITEM 2500
5.4 Unplugging the memory card
5.4 Unplugging the memory card
Introduction
The memory card can be unplugged during operation. Do not remove the memory card while
data is being accessed by an application, e.g. during backup or recipe transfer.
Procedure
NOTICE
Loss of data possible
The data on the memory card is lost if you attempt to remove it while the HMI device is
accessing its data.
Do not remove the memory card while data is being accessed. Observe the corresponding
alarms on the screen.

Proceed as follows:
1. Unplug the memory card from the memory card slot.
2. Store the memory card in a safe place.
ITEM 2500
5.5 Labeling the function keys on the MP 377 12" Key
Introduction
You can label the function keys as required for your project. Use the labeling strips for
this purpose.
Preprinted key labeling strips may be ordered as accessories,
see section Accessories (Page 26).

Note
Do not write on the keyboard to label the function keys.

Printing labeling strips
WinCC flexible comes with a range of labeling strip templates. You can find additional
information on the location of the templates in the WinCC flexible online help.
Any printable and writable foil can be used as labeling strips. You can use transparency film,
the keyboard membrane of the HMI device is printed on the reverse side. Use transparent
foil so that the LEDs of the function keys can be seen.
The permitted thickness of the labeling strip is 0.13 mm. Paper labeling strips
are inappropriate.
Dimensions of the labeling strip for the MP 377 12" Key
Area which can be written and printed on
245
9.4 20.6 20.6 20.6 20.6 20.6 20.6 20.6
17
2 x 45
1
17
1
17
68
2 x 45
9.4 21
17

ITEM 2500
Procedure
Proceed as follows:
1. Edit and then print the template.
You can also print blank templates and label them manually.
2. Apply a fixing spray film to the labeling strips.
The fixing spray ensures that the text is water resistant and does not smear, and that the
printer ink on the keyboard membrane does not run.
3. Cut out the labeling strip.
Ensure that the corners are cut according to the diagram shown above as this makes it
easier to slide them into the slot.
4. Remove any existing labeling strips.

Note
Wait for the printed labeling strips to dry before you insert them.

5. Slide the labeling strips into the slot .
1
2

6. Slide the labeling strips into the slot up to the stop.
The labeling strip will protrude approximately 3 cm from the slot. The template
dimensions for the labeling strips are designed so that the labeling is correctly placed for
the function keys. It is not necessary to secure the labeling strip.
When mounting the HMI device, ensure that the labeling strips do not become jammed
between the mounting cut-out and the HMI device.

ITEM 2500
ITEM 2500

Configuring the operating system
6
6.1 Loader
Overview
The following figure shows the Loader. The header line contains details of the loader
version. These details are not shown in the following figure.

The Loader buttons have the following functions:
Press the "Transfer" button to set the HMI device to "Transfer" mode.
The transfer mode can only be activated when at least one data channel has been
enabled for the transfer.
Press the "Start" button to start the project on the HMI device.
If you do not perform an operation, the project on the HMI device will automatically start
after a delay.
Press the "Control Panel" button to open the control panel of the HMI device.
You can change various settings in the Control Panel, for example, the transfer settings.
Press the "Taskbar" button to activate the taskbar with the Windows CE start menu open.
ITEM 2500
6.1 Loader
The following figure shows the open start menu.

Depending on the software installed, other symbols may be displayed in the
desktop's status bar.
Open Loader
The following options are available to open the Loader:
The Loader appears briefly after starting the HMI device.
The Loader appears when the project is closed.
If configured, use the relevant operating element to close the project.
For further information on this, refer to your plant documentation.
Key operation in the Loader
The following table shows the key combinations for navigating in the Loader.

Key combination Function
, ,
TAB

The next or previous entry is selected.
ENTER
or
} {

The selected button is operated.
ITEM 2500
6.1 Loader
Key operation in the Windows CE interface
The following table shows the key combinations for navigating in the user interface.

CTRL
+
ESC

The taskbar is activated with the open Windows CE start menu.
ALT
+
ESC

The next active program is displayed.
ALT
+
TAB

The Task Manager is opened.
Key operation in the Explorer
The following table shows the key combinations for navigating in the Explorer.

TAB

Toggles the active window.
Toggles between the Windows CE Desktop and the window.
F
N
+
HOME

Selects the first entry.
F
N
+
END

Selects the last entry.
CTRL
+
B A

Selects everything, if the left LED of the key
A-Z
lights up
ALT

Activates the menu bar.

Changes to the higher level.
ALT
+
CTRL

Opens the shortcut menu.
ALT
+
ENTER

Displays the properties.
ITEM 2500
6.1 Loader
Protection against unauthorized use
You can protect the control panel against unauthorized access by using a password.
You can also protect the taskbar and the Desktop with the help of SecureMode. If the
HMI device is protected, "secure mode" is displayed on the Windows CE desktop.
You can find additional information on this in the section "Setting up and disabling
SecureMode (Page 94)".
The "Transfer" and "Start" buttons can always be used without having to enter a password.
Password protection prevents maloperation. This increases the security of the system
or equipment because settings for the current project can only be changed after entering
the password.

NOTICE
If the password is no longer available, you can only cancel password protection by updating
the operating system. All data on the HMI device will be deleted when you update the
operating system.
Back up the HMI device's data.

Internet Explorer
Internet Explorer for Windows CE is installed on the HMI device.

ITEM 2500
6.1 Loader

Note
Internet Explorer for Windows CE and the Internet Explorer version which can run on a PC
differ in terms of functionality.
Internet Explorer for Windows CE has separate proxy settings that are independent of the
settings in the control panel of the HMI device.
You can find additional information at the Microsoft Website.

Media Player
Media Player for Windows CE is installed on the HMI device. Media Player is used, for
example, to play video sequences for maintenance and servicing.

Media Player supports the following formats:
WMA
MPEG

Note
Media Player for Windows CE and the Media Player version that can run on a PC differ in
terms of functionality.
You can find additional information at the Microsoft Website.

ITEM 2500
6.2 Setting up and disabling SecureMode
6.2 Setting up and disabling SecureMode
Overview
You can protect the control panel against unauthorized access with a password. You can
also protect the taskbar and the Desktop with the help of the SecureMode.
Function of SecureMode
You set up SecureMode by setting up a password in the control panel. SecureMode is then
automatically activated. The label "secure mode" is displayed in the Windows CE Desktop.
If you now want to use a function on the taskbar or Desktop, you have to enter the password.
When you have entered the password, the label "secure mode" is no longer displayed. All
the functions of the taskbar and Desktop can now be used freely. To reactivate SecureMode,
double-click the icon on the Desktop. The "secure mode" label is displayed again. The
HMI device is protected again.
Canceling SecureMode
To completely cancel SecureMode, delete the password.
ITEM 2500
6.3 Viewer
6.3 Viewer
Introduction
You can use ProSave to install viewers for various data formats. You can tell which viewers
are installed by a symbol on the desktop and from the Start menu under "Programs".
The following viewers can be installed:

Viewer Icon
PDF Viewer

Word Viewer

Excel Viewer

Functional scope
The viewers can read and print the following file formats:

Viewer Readable file formats
PDF Viewer PDF
Word Viewer DOC, RTF
Excel Viewer XL*
All viewers share a Zoom function. The Excel Viewer also offers the following functions:
Switch between spreadsheet tabs
Split the spreadsheet
Change line height and column width
ITEM 2500
6.4 Control Panel
6.4 Control Panel
6.4.1 Overview
The HMI device's Control Panel is similar to the control panel on a PC.
The Control Panel looks like this:

The control panel can be used to modify the following settings:
Date and time
Screen saver
Regional settings
Transfer settings
Network settings
Delay time
Password
ITEM 2500
6.4 Control Panel
6.4.2 Opening the Control Panel
Introduction
The HMI device Control Panel can be opened as follows:
Independently of a running project
Press the "Control panel" button in the loader.
By calling up from the Windows CE start menu.
With active project
An operating element must be configured to open the control panel for this purpose.
Procedure open the Control Panel via the Start menu
Proceed as follows:
1. Open the Windows CE start menu.
Procedure using the keys:
Select the
ESC
+
CTRL
key combination.
Procedure using the touch screen:
Press the key twice on the alpha-numeric VDU keyboard.
2. Select "Settings > Control panel".
Result
The control panel is opened.
ITEM 2500
6.4 Control Panel
6.4.3 Reference for functions
Overview of functions
The following table shows the settings in the Control Panel.

Icon Functions Tab / entry

Saving and restoring with external storage device

Importing, displaying and deleting certificates "Stores"

Setting the date and time "Date/Time"

Configuring the screen keyboard
Changing the browser startup page and general
browser settings
"General"
Changing connection and proxy server settings "Connection"
Changing cookie settings "Privacy"

Changing privacy settings "Advanced"

Setting the character repeat for the keyboard "Repeat"

Setting the double-click "Double-Click"
Parameterizing the LAN connection "ERTEC400"
Setting the IP address "ERTEC400 Ethernet Driver'
Settings"
"IP Address"
Set name server "ERTEC400 Ethernet Driver'
Settings"
"Name Servers"

Changing the logon data "Identification"
Backup registry information "Persistent Storage"
Changing monitor settings "Display"
Displaying information about the HMI device "Device"
Restarting the HMI device "Device"
Touch screen calibration
1)
"Touch"

Activate memory management "Memory Monitoring"

Changing password protection "Password Settings"

Changing the printer properties

Changing the PROFINET IO setting
Changing regional settings "Regional Settings"
Changing the number format "Number"
Changing the currency format "Currency"
Changing the time format "Time"

Changing the date format "Date"
ITEM 2500
6.4 Control Panel
Icon Functions Tab / entry
Changing transfer settings "MPI"

Changing the PROFIBUS DP transfer settings "PROFIBUS"

Setting the screen saver
Reducing the backlighting

Displaying the system information "General"
Displaying memory information "Memory"
Setting the device name of the HMI device "Device Name"
Configuring the data channel "Channel"

Setting the delay time "Directories"
Setting the uninterruptible power supply "Configuration"
State of uninterruptible power supply "Current Status"
Setting operation feedback with key and
touch screen operation
Setting operation feedback with key operation
Setting acoustic signal for inadvertent operations
"Volume"

Assigning sounds to events. "Sounds"

Changing e-mail settings
2)
"Email"

1)
Only with MP 377 Touch
2)
Additional tabs may appear in the "WinCC flexible Internet Settings" dialog. This depends on
the options that have been enabled for network operation in the project.
6.4.4 Operating the Control Panel
6.4.4.1 Overview
Operator input options
The hardware of the HMI device determines, which of the following operator control options
are available:
Touch screen
The operating elements shown in the dialogs are touch-sensitive. Touch objects are
basically operated in the same way as mechanical keys. You activate operating elements
by touching them with your finger. To double-click them, touch an operating element
twice in succession.
HMI device keyboard
The operating elements shown in the dialogs are selected and operated using the keys of
the HMI device.
External USB keyboard
External USB mouse
ITEM 2500
6.4 Control Panel
Entries using an external keyboard
An external keyboard can be used to operate the Control Panel in exactly the same way as
the HMI device keyboard. Use the keys of the external keyboard which correspond to the
HMI device keys in the description.
Operator entries using an external mouse
An external mouse can be used to operate the Control Panel in exactly the same way as the
HMI device touch screen. Click the described operating elements with the mouse.
6.4.4.2 Operation using the touch screen
Introduction
The control panel is operated with the HMI device touch screen or a connected mouse.
Requirements
An active project has been terminated. The Loader appears.
Procedure
Proceed as follows to change settings in the Control Panel:
1. Open the Control Panel with the "Control Panel" button.
2. To open the required dialog, double-click its symbol.
3. Change the tab as required.
4. Make the necessary changes.
Touch the corresponding input object.
Use the screen keyboard of the HMI device to enter the new values in the text boxes.
Touch a button to operate it.
Touch the selection box to open a drop down list box. Touch the required entry from
the drop down list box.
Touch the check box to activate or deactivate a check box.
Touch a radio button to select it.
5. Confirm the selection with the button or abort the entry with the button.
The dialog closes.
6. Close the Control Panel with the " " button.
The Loader appears.
ITEM 2500
6.4 Control Panel
Input with the screen keyboard
A screen keyboard is available for data input. The screen keyboard is displayed as
soon as you touch a text box. You can also call up the screen keyboard directly from
the Control Panel.
Display methods for the screen keyboard
You can change the display method for the screen keyboard and fix the position on the
screen. Confirm the entry with the button or abort the entry with the key. Either
action closes the screen keyboard.
Numerical screen keyboard

Alphanumerical screen keyboard

The alphanumerical keyboard is organized in the following two layers:
Normal level
Shift level
Reduced screen keyboard

ITEM 2500
6.4 Control Panel
Changing the display of the screen keyboard

Key Functions

Switching between the numerical and alphanumerical keyboard

Switching between the normal level and Shift level of the alphanumerical
screen keyboard

Switchover to special characters

Switching from full display to reduced display

Switching from reduced display to full display

Close the screen keyboard
6.4.4.3 Operation with the keyboard
Introduction
The Control Panel is operated with the system keys of the HMI device.
Requirements
An active project has been terminated. The Loader appears.
Procedure
Proceed as follows to change settings in the Control Panel:
1. Open the Control Panel.
2. Select the "Control Panel" button in the loader using the cursor keys.
3. Press
ENTER
.
The Control Panel is opened.
4. Select the symbol of the required dialog with the cursor keys.
5. Press
ENTER
to open the dialog.
6. Change the tab as required.
Press
TAB
until the name of the tab is selected. Now switch between the tabs using
the cursor keys.
7. Use the
TAB
key to return to the input area.
ITEM 2500
6.4 Control Panel
8. Make the necessary changes.
To do this, highlight the corresponding input object using the
TAB
key.
Use the system keys of the HMI device to enter the new values in the text boxes.
To operate a button, select the button with the cursor keys and then press
ENTER
.
Open the drop down list boxes with the key combination
ALT
+ .
Select the required entry from the drop down list box using the cursor keys.
Confirm the selected entry by pressing
ENTER
.
Press
} {
to activate or deactivate a check box.
Select a radio button from a group using the cursor keys.
9. Confirm your entries with
ENTER
or discard your entries with
ESC
.
If you have selected an input object, you first have to complete entry.
The dialog closes.
10. Close the Control Panel.
Press the
ALT
key to do this.
The control panel menu is opened.
11. Select the "Close" entry using the cursor keys.
12. Press
ENTER
.
The Loader appears.
ITEM 2500
6.4 Control Panel
Control keys
The following tables show the control keys used to select and operate the control panel.
Select operating elements

Key Functions Description
TAB

SHIFT
+
TAB

Tabulator Selects the next/previous operating element in the
tab sequence.

Cursor keys Selects the next operating element to the left, right,
above or below the current screen object.
Navigates in the operating element.

Using operating elements

HOME

Scroll back Scrolls back a page in a list.
F
N
+
HOME

Scroll to the beginning Scrolls to the beginning of a list.
END

Scroll forward Scrolls one page forward in a list.
F
N
+
END

Scroll to the end Scrolls to the end of a list.
ENTER

ENTER key Operates a button.
Accepts and ends an entry.
ESC

Cancel Deletes the characters of a value entry and
restores the original value.
Closes the active dialog.
INS
DEL

Delete characters Deletes the character to the right of the current
cursor position.

Delete characters Deletes the character to the left of the current
cursor position.
ALT
+
Open drop down list box Opens a drop down list box.
CTRL
+
ENTER

Accept value Accepts the selected value in the drop down list
box without closing the list.
ITEM 2500
6.4 Control Panel
Enter key combinations

Key Functions Purpose
A-Z

Toggle key assignment Toggles the assignment for a key with
multiple assignment.
No LED is lit
The number assignment is enabled. Pressing
the button once toggles to letter assignment.
An LED is lit
The left or right letter assignment is enabled.
Each time the key is pressed, the system toggles
between the left letter assignment, the right letter
assignment and the number assignment.
SHIFT

Toggle between upper-case
and lower-case
Used in key combinations, for example for entering
upper-case letters.
F
N

Switch to additional
key assignment
Some of the keys contain a blue imprinted key
assignment, for example the "%" character.
Used in key combinations for the blue
key assignment.
CTRL

General control function Used in key combinations
ALT

ITEM 2500
6.5 Changing settings for operation
6.5.1 Configuring the screen keyboard
Introduction
The details provided below will explain how the screen keyboard can be
displayed and positioned.
Requirements
You have opened the "Siemens HMI Input Panel - Options" dialog with
the "InputPanel" icon.
1
2
3

Check box for displaying the button in the screen keyboard
Button for displaying the screen keyboard
Button for saving the screen keyboard settings
Procedure
Proceed as follows:
1. If you want to change the size of the screen keyboard, activate the "Show Resize Button"
check box.
The button is displayed in the screen keyboard awaiting opening.
2. If you want to prevent the size of the screen keyboard from being changed,
deactivate the "Show Resize Button" check box.
The button is removed from the screen keyboard awaiting opening.
3. Use the "Open Input Panel" button to open the screen keyboard.
4. If you want to switch between the numerical and alphanumerical screen keyboard,
press the key.
ITEM 2500
5. If you want to change the position of the screen keyboard, use the mouse pointer to
select a free space between the keys.
Release the mouse pointer when the required position has been reached.
6. If you want to increase or decrease the size of the keyboard screen, place your mouse
pointer over the button .
7. Adapt the screen keyboard size by dragging it to size with the mouse pointer.
8. Release the mouse pointer when the required size has been reached.
9. If you want to save the settings, press the "Save" button.
10. Confirm your entries.
The dialog closes.
Result
The screen keyboard settings have been modified.
6.5.2 Setting the character repeat
Introduction
The details provided below will explain how to set the character repetition and the associated
delay for the keyboard and/or screen keyboard.
Requirements
You have opened the "Keyboard Properties" dialog with the "Keyboard" icon.
1
4
3
2

Check box for activating the character repeat
Slider control and buttons for the delay time before character repeat
Slider control and buttons for the rate of the character repeat
Test field
ITEM 2500
Procedure
Proceed as follows:
1. If you want to enable character repetition, activate the "Enable character repeat"
check box.
2. If you want to change the delay, press a button or the slider in the "Repeat delay" group.
Moving the slider to the right will shorten the delay. Moving to the left will extend
the delay.
3. If you want to change the repeat rate, press a button or the slider in the
"Repeat rate" group.
Moving the slider to the right will shorten the repeat rate. Moving to the left will extend the
repeat rate.
4. Check the settings.
Procedure using the touch screen:
Touch the test field.
The screen keyboard opens.
Move the screen keyboard as needed.
Procedure using the keys:
Select the test field.
5. Press an alphanumeric key and keep the key pressed down.
Check the implementation of the character repetition and the rate of the character
repetition in the test field.
6. If the settings are not perfect, correct them.
The dialog closes.
Result
The character repetition and delay are set.
6.5.3 Setting the double-click
Introduction
You can start applications in the Control Panel and in Windows CE with a double-click.
A double-click corresponds to two brief touches in sequence.
In the "Mouse Properties" dialog, make the following adjustments for touch screen operation
and operation with external mouse:
Interval between touch contacts on the touch screen
Interval between mouse clicks
ITEM 2500
Requirements
You have opened the "Mouse Properties" dialog with the "Mouse" icon.
2
1

Pattern
Icon
Procedure
Proceed as follows:
1. Click the pattern twice.
After the second click, the colors of the pattern will be reversed and the white fields will
change to gray. The time before the second click is saved.

2. Check the double-click.
Click on the icon twice in succession to do this. If the double-click is recognized,
the icon is displayed as follows:

3. If the settings are not perfect, correct them.
To do this, repeat steps 1 to 2.
The dialog closes.
Result
The double-click adjustment is completed.
ITEM 2500
6.5.4 Calibrating the touch screen
Introduction
Depending on the mounting position and viewing angle, it is possible that parallax may occur
when operating the touch screen. In order to prevent any operating errors as a result,
calibrate the touch screen again in the startup phase or during runtime.
Requirements
You have opened the "OP Properties" dialog "Touch" tab with the "OP" icon.

Procedure
Proceed as follows:
1. Click on the "Recalibrate" button.
The following dialog opens:
Carefully press and briefly hold stylus on the center of
the target. Repeat as the target moves around the screen.
1

2. Briefly touch the middle of the calibration crosshairs .
The calibration crosshairs is then displayed at four more positions.
ITEM 2500
3. Briefly touch the middle of the calibration crosshairs for each position.
Once you have touched all the positions of the calibration crosshairs,
the following dialog appears:
New calibration settings have been measured.
Tape the screen to register saved data.
Wait for 30 seconds to cancel saved data and
keep the current setting.
Time limit: 30 sec

4. Touch the touch screen.
The calibration is saved. The "OP Properties" dialog, "Touch" tab is displayed again.
If you do not touch the touch screen within the time shown, your original setting will
be retained.
5. Close the dialog.
Result
The HMI device touch screen is calibrated.
ITEM 2500
6.6 Setting up password protection
6.6 Setting up password protection
Introduction
You can protect access to the Control Panel and the Windows CE taskbar with a password.
Requirements
You have opened the "Password Properties" dialog with the "Password" icon.

NOTICE
Password not available
If the password is no longer available, you will have to wait for the operating system to be
updated again.
Change settings in the Control Panel
Use the Windows CE taskbar
All data on the HMI device will be deleted when you update the operating system!
Therefore use the password to protect against loss.

Note
The following characters cannot be used in passwords:
Blank
Special characters * ? . % / \ ' "

Procedure
Proceed as follows:
1. Enter a password in the "Password" text box.
2. Repeat the password entry in the "Confirm password" text box.
The dialog closes.
Result
You cannot open the Control Panel or Windows CE taskbar without entering a password.
ITEM 2500
6.7 Canceling password protection
6.7 Canceling password protection
Requirements
You have opened the "Password Properties" dialog with the "Password" icon.

Procedure
Proceed as follows:
1. Delete the entries in the "Password" and "Confirm password" text boxes.
The dialog closes.
Result
Password protection for the Control Panel and Windows CE taskbar is canceled and they
can be freely accessed.
ITEM 2500
6.8 Changing HMI device settings
6.8.1 Setting the date and time
Introduction
You can set the date and time on the HMI device. The HMI must be restarted in
the following cases:
You have changed the time zone setting
You have changed the "Daylight savings time currently in effect" check box setting.
Requirements
You have opened the "Date/Time Properties" dialog with
the "Date/Time Properties" icon.
1
2
5
3
4

Time zone selection box
Input field for the time
Date selection box
"Daylight savings" check box
Button for applying changes
Procedure
Proceed as follows:
1. Select the appropriate time zone for the HMI device from the "Time Zone" selection field.
2. Touch the "Apply" button to confirm your entry.
The time of day shown in the "Current Time" field is adjusted correspondingly to the
selected time zone.
3. Set the date in the selection box.
4. Set the current time of day in the "Current Time" text box.
ITEM 2500
5. Confirm your input by clicking on the "Apply" button.
The values you have set are now in effect.

Note
The system does not automatically switch between winter and summer time.

6. If you want to switch from winter to summer time, activate the
"Daylight savings time currently in effect" check box.
When you press the "Apply" button, the time is brought forward by one hour.
7. If you want to switch from summer to winter time, deactivate the
"Daylight savings time currently in effect" check box.
When you press the "Apply" button, the time is taken backward by one hour.
The dialog closes.
Result
The settings for the data and time of day have now been changed.
Internal clock
The HMI device has an internal buffered clock.
Synchronizing the date and time with the PLC
The date and time of the HMI device can be synchronized with the PLC if this has been
configured in the project and the PLC program.
Further information on this subject is available in the "WinCC flexible" system manual.

NOTICE
Time-dependent reactions
You have to synchronize the date and time when time-controlled responses are triggered in
the PLC by the HMI device.

6.8.2 Changing regional settings
Introduction
In different countries, for example, the date, time and decimal points are displayed
differently. You can adjust this display to meet the requirements of different regions.
The country-specific settings apply to the current project. If the project language is changed,
the country-specific settings are also changed.
ITEM 2500
Requirements
You have opened the "Regional and Language Settings" dialog with
the "Regional Settings" icon.
1

Region selection box
Procedure
Proceed as follows:
1. Select the region from the selection box.
2. Change to the "Number", "Currency", "Time" and "Date" tabs and set the selection boxes
to the desired settings.
The dialog closes.
Result
The HMI device's regional settings have been changed.
6.8.3 Backup registry information
Registry information and temporary data
You can install and uninstall your own programs on the HMI devices under Windows CE.
You must save the registry settings after installation or uninstallation.
You can save the following data to the flash memory:
Registry Information
Temporary files
Restoring the file system of a memory card
If memory cards are used, the file system on the memory card may become damaged,
perhaps due to a power failure. The HMI device detects the defective file system on start-up
or when the memory card is inserted. The HMI device can restore the file system
automatically or on request.
ITEM 2500
Requirements
You have opened the "OP Properties" dialog, "Persistant Storage" tab with
the "OP" icon.
2
1
3
4
5

Significance of the text:
Saves the current registry information to the flash memory. The HMI device loads the saved
registry information the next time it boots.
Button for saving registry information
Button for saving temporary files
Significance of the text:
Saves all the files in temporary storage to the flash memory (for example, from the "Program
Files" directory). These files are written back when the HMI device is started. The "\Temp"
directory is not saved.
Automatically restores the file system on the memory card when the HMI device starts up and
when a memory card is inserted.
Procedure
Proceed as follows:
1. If you want the system to be restored automatically, activate the "Automatically repair file
system errors ..." check box.
If the check box is unchecked, the system is only restored once prompted to do so.
2. Click on the necessary buttons.
The dialog closes.
Result
The HMI device uses the saved registry information the next time it starts. The temporary
files are copied back.
ITEM 2500
6.8.4 Changing monitor settings
Requirements
You have opened the "OP Properties", dialog "Display" tab with the "OP" icon.

Procedure
Proceed as follows:
1. If you want to increase the brightness, press the "UP" button.
2. If you want to decrease the brightness, press the "DOWN" button.
The dialog closes.
Result
The screen settings have been changed.
ITEM 2500
6.8.5 Setting the screen saver
Introduction
You can set the following time intervals on the HMI device:
For the automatic activation of the screen saver
For the automatic reduction in the screen's backlighting
When you do not undertake an operation within the configured interval, the configured
function will be activated automatically.
The screen saver and the reduced screen backlighting functions are switched back off by
means of the following actions:
By pressing any key
By touching the touch screen
The function associated to the key or button will not be executed by this.

NOTICE
Reduce backlighting
The brightness of the backlighting decreases incrementally during its operational life.
In order to not shorten the operational lifetime of the backlighting unnecessarily,
activate the backlighting reduction.
Activating the screen saver
Screen contents may occasionally leave a burn-in effect in the background if they appear
too long.
This burn-in effect will automatically disappear after a certain amount of time if the
screensaver is activated, for example. The longer the same content is displayed on the
screen, the longer it will take for the burn-in effect to disappear.
Generally, you should always activate the screen saver.
When the screen saver is active, the backlighting is reduced at the same time.

ITEM 2500
Requirement
You have opened the "Screensaver" dialog with the "ScreenSaver" icon.
1
2
3

Time interval in minutes until backlighting is reduced
Period of time in minutes before the screen saver is activated
Radio buttons for the screensaver
Procedure
Proceed as follows:
1. Enter the interval in minutes after which the backlighting is to be reduced.
Entering "0" will deactivate the backlighting reduction.
2. Enter the number of minutes before the screen saver is to be activated.
The minimum time is 5 minutes and the maximum time is 71582 minutes. Entering "0"
disables the screen saver.
3. Select either the screen saver or an empty screen.
If you want the screen saver to function, activate the "Standard" radio button.
If you do not want the screen saver to function, activate the "Blank Screen"
radio button.
The dialog closes.
Result
The screen saver and the reduced backlighting for the HMI device is set.
6.8.6 Changing the printer properties
Introduction
The HMI device can print on local printers or network printers. You can print hardcopies and
reports on a network printer. Line printing of alarms is not possible on a network printer.
You can find the list of current printers and required settings for HMI devices in the Internet
at "http://support.automation.siemens.com/WW/view/en/11376409".
ITEM 2500
Requirement
You have opened the "Printer Properties" dialog with the "Printer" icon.
1
2
3
4
5
6
7

Selection box for the printer
Interface selection box
Network address of the printer
Paper format selection box
Group orientation with radio buttons for print orientation
Print quality check box
Color printing check box
Procedure
Proceed as follows:
1. Select a printer from the "Printer Language" selection box.
2. Select the port for the printer from the "Port" selection box.
3. If you wish to print via the network, enter the printer's network address in
the "Network" text box.
4. Select the paper format from the"Paper Size" selection box.
5. Activate a radio button in the "Orientation" group.
"Portrait" for portrait
"Landscape" for landscape
6. Select the print quality.
Select the "Draft Mode" check box if you wish to print in draft mode.
Clear the "Draft Mode" check box if you wish to print with higher quality.
7. If the printer selected can print in color and you wish it to do so,
activate the "Color" check box.
The dialog closes.
Result
The settings for the printer have now been changed.
ITEM 2500
6.8.7 Enabling sound and setting sound volume
Introduction
You can activate an acoustic feedback for keyboard and touch screen operations. With each
touch or activation of a key, a sound is emitted.
Requirements
You have opened the "Volume & Sounds Properties" dialog, "Volume" tab with
the "Volume & Sounds" icon.
3
2
1
4
5
6

Acoustic warnings and system events
Program-specific sounds
Notification sounds
Acoustic feedback when using keys
Acoustic feedback when using touch screen
Keys and controller for setting volume for the "Enable sounds for" group

Note
If you deactivate the settings under "Enable sounds for", no more acoustic signals will be
emitted during inadvertent operations.

ITEM 2500
Procedure
Proceed as follows:
1. Activate the check boxes needed in the "Enable sounds for" group.
If no check boxes are activated, no acoustic feedback will be output.
2. If you want signaling for entries to be audible, activate the following check box:
With key control: "Hardware buttons".
With touch control: "Screen taps".
3. Use the "Loud" and "Soft" radio buttons to select between loud and quiet signaling.
4. If you want to change the volume for acoustic messages, use the controller or "Loud" and
"Soft" keys to do this.
The dialog closes.
Result
The properties of the acoustic operation feedback are now set up.
ITEM 2500
6.8.8 Assigning sound to an event
Introduction
When acoustic feedback is activated, a sound is used to report an event. You can select the
sound to reflect the event.
Requirements
A loudspeaker is connected to the HMI device.
You have opened the "Volume & Sounds Properties", dialog "Sound" tab with
the "Volume & Sounds" icon.

Procedure
Proceed as follows:
1. Select a suitable sound from the "Event" group.
The sound selected is displayed in the "Sound" group in the associated list box.
2. If you want to listen to the sound, press the " " button.
The sound is output by a loudspeaker connected to the HMI device. Use the button
to stop the output.
3. If you haven't managed to find a suitable sound, you can use the "Browse" button to
switch to a folder of your choice.
The sound selected is displayed in the "Sound" group in the associated list box.
The dialog closes.
Result
The sound is set for acoustic feedback on operations.
ITEM 2500
6.8.9 Restarting the HMI device
Introduction
You can restart the HMI device or reset the factory settings before rebooting. Further
information on this can be found in the section "Resetting factory settings (Page 174)".
Required restart
The HMI device must be restarted in the following cases:
You have activated or deactivated the PROFINET IO direct keys.
You have changed the time zone setting.
You have changed the automatic daylight savings and standard setting

NOTICE

Data loss when the HMI device is restarted
All volatile data is lost when the HMI device is restarted.
Check the following:
The project on the HMI device is complete.
No data is being written to the flash memory.

The HMI device must be restarted in the following cases:
Requirement
You have opened the "OP Properties" dialog box, "Device" tab, by touching
the "OP" icon.
1

Button for restarting the HMI device
If you want to reset the HMI device to the factory settings: the HMI deice is connected to
a configuration PC via PROFINET.
ITEM 2500
Procedure
1. If you want to restart the HMI device, press the "Reboot" button.
The following message is displayed:
1
2 3

If you run this function, all data which has not been backed up will be lost. Please close all
applications before restarting.
Button for reset to factory settings and subsequent restart
Button for restart
2. Press one of the buttons.
If you want to restart the HMI device, press the "Reboot" button.
The HMI device restarts without delay.
If you want to reset the HMI device to the factory settings and then restart, press the
"Prepare for Reset" button.
You are given the option of resetting the HMI device to the factory settings through
ProSave. The HMI device then restarts.
If you do not want to restart the HMI device, press the "No" button.
The message closes. There will be no restart.
Result
The HMI device starts.
ITEM 2500
6.8.10 Displaying information about the HMI device
Introduction
You will need the device-specific information if you contact Technical Support.
Requirement
You have opened the "OP Properties" dialog box, "Device" tab, by touching
the "OP" icon.
The following figure applies to the MP 377 15" Touch. The data displayed are device-specific
and may therefore deviate from that of your HMI device.
1
2
3
4
5
6
7

HMI device name
Version of the HMI device image
Version of the boot loader
Boot loader release date
Size of the internal flash memory in which the HMI device image and project are stored
MAC address of the HMI device
See section "Restarting HMI device"
The HMI device-specific information is displayed in the "Device" tab.

Note
The size of internal flash memory is not equivalent to application memory available for a
project.

See also
Restarting the HMI device (Page 125)
ITEM 2500
6.8.11 Displaying system properties
Introduction
The general system-specific information provides you with information about the processor,
operating system and memory.
Requirements
You have opened the "System Properties", dialog "General" tab with the "System" icon.
The data displayed are device-specific and may therefore deviate from that of
your HMI device.
2 1

Copyright to Microsoft Windows CE
Details on processor and size of internal Flash memory
Displaying system properties
The system properties are displayed. This dialog is read-only. Close the dialog.
ITEM 2500
6.8.12 Displaying memory distribution
Introduction
The "Memory" system-specific information provides you with information about the
distribution and size of the memory in the HMI device.

NOTICE
"Memory" tab
Do not change the memory distribution in the "Memory" tab.
Applies for the usage of options:
An alteration to the memory distribution may be necessary. Please refer to the
accompanying documentation for further information.

Requirements
You have opened the "System Properties", dialog "Memory" tab with the "System" icon.

Procedure
1. Determine the HMI device's current memory structure
2. Close the dialog.
ITEM 2500
6.9 Setting storage location
6.9 Setting storage location
Introduction
There are various storage locations available for storing the compressed source file of your
project. The following describes how you can set the storage location.
Requirements
You have opened the "Transfer Settings", dialog "Directories" tab with
the "Transfer" icon.
2
1
3

Directory where the project file is saved
Directory where the compressed source file of your project is saved
Storage location and initialization file of the HMI device for process operation

NOTICE
Settings under "Project File" and "Path"
The project may not open the next time the HMI device is started if changes are made in
the "Project File" and "Path" text boxes.
Do not change the entries in the "Project File" and "Path" text boxes.

Procedure
1. Select a memory location from the "Project Backup" text box.
The external memory card or the location in the data network can be defined as the
storage location. During the next backup process, the project's source file is stored in the
specified location.
The dialog closes.
Result
The storage location for the HMI device is now set.
ITEM 2500
6.10 Setting the delay time
6.10 Setting the delay time
Introduction
Once the HMI device has been switched on, a project can be started after a delay. The
Loader is displayed during the delay time.
Requirements
You have opened the "Transfer Settings", dialog "Directories" tab with
the "Transfer" icon.

NOTICE
Settings under "Project File" and "Path"
The project may not open the next time the HMI device is started if changes are made in
the "Project File" and "Path" text boxes.
Do not change the entries in the "Project File" and "Path" text boxes.

Procedure
1. Select the desired delay time in seconds from the "Wait [sec]" selection box.
With the value "0", the project starts immediately. It is then no longer possible to call the
Loader after switching on the HMI device. If you still wish to access the Loader, an
operating element must be configured to close the project.
The dialog closes.
Result
The delay time for the HMI device is now set.
See also
Overview (Page 163)
ITEM 2500
6.11 Setting the uninterruptible power supply
6.11 Setting the uninterruptible power supply
Introduction
UPS monitoring is an option you load as an add-on with ProSave.
A UPS ensures that the HMI device is shut down in a controlled manner after a buffer time in
the event of a power failure. This avoids the loss of data.
The following uninterruptible power supplies are supported:
SITOP DC UPS modules as of a rated power value of 6 A, e.g. 6EP1931-2DC42
Connect the UPS to the 24-V input and a USB port. Configure the USB port
for UPS monitoring.
Requirements
You have opened the "UPS Properties", dialog "Configuration" tab with the "UPS" icon.
2
4
3
1

Text box for the time after which the "Battery mode activated" message is displayed
Check box for enabling battery mode
Text box for the time after which the "Faulty port" message is displayed
Check box for the "Faulty port" message
Procedure
Proceed as follows:
1. If you want to enable battery mode, activate the "Battery mode" check box.
2. Enter the time for terminating applications in the "min" and "s" text boxes.
You will receive a message when UPS takes effect. Applications such as HMI Runtime
and WinAC MP are then terminated depending on the time entered.
3. If the port to which the UPS is connected is faulty and you therefore want to receive a
message, activate the "Port disturbed" check box.
4. Select the message you want from the list box.
5. Enter the time after which the "Faulty port" message is displayed in the "min" and
"s" text boxes.
ITEM 2500
6.12 State of uninterruptible power supply
Result
Port monitoring for the UPS is set.
See also
State of uninterruptible power supply (Page 133)
6.12 State of uninterruptible power supply
Introduction
If you have connected a UPS to a USB port, you can display the monitoring state of this port.
Requirements
You have opened the "UPS Properties", dialog "Current status" tab with the "UPS" icon.
1

The "UPS program is not running. No current status available." message appears when the
UPS is not connected.
Procedure
Proceed as follows:
1. Installing the UPS monitoring software.
2. Connect the UPS.
3. If you want to update the monitoring state, press the "Update" button.
The message is changed according to the current setting. The message will remain
unchanged if no check boxes in the "Configuration" tab have been activated.
Result
The current monitoring state for the UPS is displayed.
See also
Setting the uninterruptible power supply (Page 132)
ITEM 2500
6.13 Enabling PROFINET IO
PROFINET IO
If the HMI device is connected to the PLC via PROFINET, function keys or buttons, for
example, can be configured as PROFINET IO direct keys. If PROFINET IO direct keys are
used in the project, they must be enabled.

Note
If you enable PROFINET IO direct keys, you cannot use the RS 422/RS 485 port
for serial communication.
PROFINET IO direct keys and PROFIBUS DP direct keys are mutually exclusive.

Requirements
You have opened the "PROFINET" dialog with the "PROFINET" icon.
2
3
1

Activating or deactivating the PROFINET IO direct keys
Text box for the device name
MAC address of the HMI device

NOTICE
Inconsistent device name
If the device name does not match the device name entered in the HW Config of STEP 7,
the direct keys do not work.
Use the device name from the HW Config of STEP 7. This device name does not
correspond to the device name used under Windows CE.

ITEM 2500
Within the ETHERNET data network, the device name must be unique and satisfy the DNS
conventions. These include:
Restriction to 127 characters in total (letters, digits, hyphen or point)
A name component within the device name, e.g. a string between two points, may not
exceed 63 characters.
Special characters such as umlauts, brackets, underscores, slashes, spaces etc. are not
permitted. The hyphen is the one exception.
The device name must not start or end with a the "-" character.
The device name must not take the form n.n.n.n (n = 0 to 999).
The device name must not start with the character sequence "port-xyz-" (x, y, z = 0 to 9).
Procedure
Proceed as follows:
1. If you want to enable the PROFINET IO direct keys, activate the "PROFINET IO enabled"
check box.
2. Enter the device name of the HMI device.
The dialog closes.
Result
The PROFINET IO direct keys are enabled.
ITEM 2500
6.14 Changing transfer settings
6.14.1 Configuring the data channel
Introduction
If you block all data channels, the HMI device is protected against unintentional overwriting
of the project data and HMI device image.

Note
A project can only be transferred from the configuring PC to the HMI device when at least
one of the data channels is enabled on the HMI device.

Requirements
The "Transfer Settings" dialog, "Channel" tab has been opened with the
"Transfer Settings" icon.
1
2
3

Group for the data channel 1 (Channel 1)
Group for the data channel 2 (Channel 2)
Button for the "MPI/DP-Transfer Settings" and/or "Network and Dial-Up Connections" dialog

WARNING
Unintentional transfer mode
Unintentional transfer mode could cause unintentional actions to be triggered in the plant.
Ensure that the configuring PC does not inadvertently switch the HMI device to transfer
mode during the open project.

ITEM 2500
NOTICE
"Remote control" for "Channel 1"
If the "Remote Control" check box is activated during "Online" operating mode, the X10 port
cannot be used for communication.
The "Remote Control" check box must be deactivated for "Online" operating mode. Once
the serial transfer is complete, in the "Channel 1" group you must therefore deactivate the
"Remote Control" check box.
Transfer mode using "Channel 2"
When the project on the HMI device starts, transfer parameters, e.g. HMI device address,
for MPI/PROFIBUS DP are overwritten with the values from the project.
You can change the settings for the transfer via "Channel 2".
The following steps are required:
Close the project.
Change the settings on the HMI device.
Then return to "Transfer" mode.
The next time the project is started on the HMI device, the settings will be overwritten by
the values from the project.

Note
If the HMI device is in "Transfer" mode while changes are made to the transfer settings,
the settings only go into effect after the transfer function is restarted.
This may occur if the Control Panel is opened to change the transfer properties in
an active project.

ITEM 2500
Procedure
Proceed as follows:
1. If you want to enable a data channel, activate the "Enable Channel" check box in the
"Channel 1" or "Channel 2" group.
In the "Channel 1" group, the RS-422/RS-485 port is enabled for the serial data transfer.
The network port is enabled in the "Channel 2" group.
2. If you want to enable the automatic transfer, activate the associated "Remote Control"
check box.
3. If you have enabled the data channel for "Channel 2", select the log from
the selection box.
4. Enter further parameters if required.
Applies to "MPI/PROFIBUS DP":
Press the "Advanced" button to switch to the "S7-Transfer Settings" dialog box.
You can change the settings for MPI/PROFIBUS DP there.
Confirm your entries.
The "S7-Transfer Settings" dialog box closes.
Applies to "ETHERNET":
Use the "Advanced" button to change to "Network&Dial-Up Connections".
Open the "ERTEC400" entry. You can change the TCP/IP settings there.
Confirm your entries.
Close "Network&Dial-Up Connections".
Applies to "USB":
No settings are needed for "USB".
The dialog closes.
Result
The data channel is configured.
See also
Overview (Page 163)
Backup and restore using WinCC flexible (Page 169)
Backup and restore using ProSave (Page 171)
Changing MPI/PROFIBUS DP settings (Page 139)
Changing the network configuration (Page 145)
ITEM 2500
6.14.2 Changing MPI/PROFIBUS DP settings
Introduction
The communication settings for MPI or PROFIBUS DP are defined in the HMI device project.
In the following cases, the transfer settings might have to be changed:
The first time the project is transferred
If changes are made to the project but are only applied later

NOTICE

Transfer mode using MPI/PROFIBUS DP
The bus parameters are read from the project currently loaded on the HMI device.
The settings for MPI/PROFIBUS DP transfer can be modified. The following steps
are required:
Close the project.
Change the settings on the HMI device.
Then return to "Transfer" mode.
The changed MP/PROFIBUS DP settings will be overwritten in the following cases:
The project is started again
A project is transferred and started
Transfer settings
If the HMI device is in "Transfer" mode while changes are made to the transfer settings,
the settings only go into effect after the transfer function is restarted.

Requirements
You have opened the "S7-Transfer Settings" dialog with
the "S7-Transfer Settings" icon.
2
1

Network selection
Button for opening the properties dialog
ITEM 2500
Procedure
Proceed as follows:
1. Select a network.
2. Use the "Properties" button to open the "MPI" or "PROFIBUS" dialog.

2
1
5
4
3

2
1
5
4
3
6
7

The HMI device is the only master on the bus.
Bus address of the HMI device
Time-out
Data transmission rate in total network
Highest station address in the network
Profile
Button for displaying the bus parameters
3. If there are several masters connected on the bus, deactivate the "Panel is the only
master on the bus" check box.
4. Enter the bus address for the HMI device in the "Address" text box.

NOTICE

The bus address in the "Address" text box must be unique throughout the
MPI/PROFIBUS DP network.

5. Select the transmission rate from the "Transmission Rate" text box.
6. Enter the highest station address on the bus in the "Highest Station Address" or
"Highest Station" text box.
7. Select the desired profile from the "Profile" selection box.
ITEM 2500
8. If you want to view the profile data, press the "Busparameter" button of
the PROFIBUS dialog.
The profile data are displayed. The "Profile" dialog is read-only.

NOTICE

The bus parameters must be the same for all stations in
the MPI/PROFIBUS DP network.

9. Close the "Profile" dialog.
The dialog closes.
Result
The MPI/PROFIBUS DP settings of the HMI device have been changed.
See also
ITEM 2500
6.15 Configuring network operation
6.15.1 Overview of network operation
Introduction
You can connect the HMI device to a PROFINET network via the Ethernet port.

NOTICE
The HMI device only has client functionality in the PC network. This means that users can
access files of a node with TCP/IP server functionality from the HMI device via the network.
However, you cannot, for example, access files of the HMI device from a PC via
the network.

Note
Information on communication using SIMATIC S7 via PROFINET is provided in the
"WinCC flexible communication" user manual.

The connection to a network offers, for example, the following options:
Printing via a network printer
Saving, exporting and importing of recipe data records on or from a server
Setting up of message and data archives
Transferring a project
Saving data
Addressing
Within a PROFINET network, computers are usually addressed using computer names.
These device names are translated from a DNS or WINS server to TCP/IP addresses.
This is why a DNS or WINS server is needed for addressing via computer names when
the HMI device is in a PROFINET network.
The corresponding servers are generally available in PROFINET networks.

Note
The use of TCP/IP addresses to address PCs is not supported by the operating system.

Consult your network administrator if you have questions in this regard.
ITEM 2500
Printing via a network printer
The HMI device's operating system does not support line by line alarm logging via a network
printer. All other printing functions, for example, hardcopy or logs, are available without
restriction via the network.
Preparation
Before beginning the configuration, request the following network parameters from your
network administrator.
Does the network use DHCP for dynamic assignment of network addresses?
If not, get a new TCP/IP network address for the HMI device.
Which TCP/IP address does the default gateway have?
If a DNS network is used, what are the addresses of the name server?
If a WINS network is used, what are the addresses of the name server?
General procedure for configuring the network
The HMI device must be configured prior to network operation. The configuration is basically
divided into the following steps:
Proceed as follows:
1. Enter the device name of the HMI device.
2. Configure the network address.
3. Set the logon information.
4. Save the settings.
ITEM 2500
6.15.2 Setting the device name of the HMI device
Introduction
The HMI device uses the device name to identify itself in the communication network.
Requirements
You have opened the "System Properties", dialog "Device Name" tab with
the "System" icon.
1
2

Device name of the HMI device
Description for the HMI device (optional)

Note
To activate the network functions, enter a unique computer name in the "Device name"
text box.

Procedure
Proceed as follows:
1. Enter the device name for the HMI device in the "Device name" text box.
2. If necessary, enter a description for the HMI device in the "Device description" text box.
The dialog closes.
Result
The device name for the HMI device is now set.
ITEM 2500
6.15.3 Changing the network configuration
Introduction
You can change the network settings for the LAN connection under
"Network&Dial-Up Connections".
Requirements
You have opened the following display using the "Network&Dial-Up Connections" icon.

ITEM 2500
Procedure
Proceed as follows:
1. Open the "ERTEC400" entry.
The "'ERTEC400 Ethernet Driver' Settings" dialog is opened.

2. If you need automatic issuing of addresses, select the "Obtain an IP address via DHCP"
radio button.
3. If you need manual issuing of addresses, select the "Specify an IP address" radio button.
4. If you have selected manual issuing of addresses, enter the corresponding addresses in
the "IP Address", "Subnet Mask" text boxes and if necessary in "Default Gateway".
5. If a name server is used in the network, change to the "Name Servers" tab.

6. Enter the respective addresses in the text boxes.
The dialog closes.
8. Close the "Network&Dial-Up Connections" display.
The Control Panel is displayed again.
Result
The LAN connection parameters for the HMI device have been changed.
See also
ITEM 2500
6.15.4 Changing the logon data
Introduction
Windows CE uses this information to gain access to the network resources. Enter the user
name, password and domain you have received from your administrator.
Requirements
You have opened the "Network ID" dialog with the "Network ID" icon.

Procedure
Proceed as follows:
1. Enter the user name in the "User name" text box.
2. Enter your password in the "Password" text box.
3. Enter the domain name in the "Domain" text box.
The dialog closes.
Result
The logon information has now been set.
ITEM 2500
6.15.5 Changing e-mail settings
Requirements
You have opened the "WinCC flexible Internet Settings" dialog with the
"WinCC Internet Settings" icon.
1
2
3

Setting the SMTP server
Name for the sender
E-mail account

Note
Additional tabs may appear in the "WinCC flexible Internet Settings" dialog. This depends on
the options that have been enabled for network operation in the project.

Procedure
Proceed as follows:
1. Specify the SMTP server.
Activate the "Use the default of the project file" radio button if you want to use the
SMTP server configured in the project.
Deactivate the "Use the default of the project file" radio button if you do not want to
use the SMTP server configured in the project. Specify the required SMTP server.
2. Enter the name for the sender in the "Sender" text box.
3. Enter the e-mail account for your e-mail in the "Authentication" text box.
Some e-mail providers only allow you to send mail if you specify the e-mail account. The
"Authentication" text box can remain empty if your e-mail provider allows you to send mail
without checking the account.
The dialog closes.
Result
The e-mail settings have been changed.
ITEM 2500
6.15.6 Changing Internet settings
6.15.6.1 Changing general Internet settings
Requirements
You have opened the "Internet Options", dialog "General" tab with
the "Internet Options" icon.

Note
Do not change the settings in the "User Agent" field.

Procedure
Proceed as follows:
1. Enter the homepage for the Internet browser in the "Start Page" text box.
2. Enter the address of the required search engine in the "Search Page" text box.
3. Enter the required cache memory size in the "Cache" text box.
4. If you want to delete the cache memory, press the "Clear Cache" button.
5. If you want to delete the history, press the "Clear History" button.
The dialog closes.
Result
The general parameters for the Internet browser have been set.
ITEM 2500
6.15.6.2 Setting the proxy server
Requirements
You have opened the "Internet Options", dialog "Connection" tab with

Procedure
Proceed as follows:
1. Select the "Use LAN (no autodial)" check box.
2. If you are using a proxy server, in the "Network" group, activate the
"Access the Internet using a proxy server" check box.
Specify the address of the proxy server and the port.
3. If you want to bypass the proxy server for local addresses, activate the
"Bypass proxy server for local addresses" check box.
The dialog closes.
6.15.6.3 Changing privacy settings
Cookies and encryption
Cookies are pieces of information sent by a web server to a browser. In the event of
subsequent access to the web server, the cookies are sent back. This enables information to
be stored between the accesses.
In order to ensure a high level of privacy, data are sent via the Internet in encrypted form.
Common encryption protocols include SSL and TLS. You can activate or deactivate the
usage of encryption protocols.
The required settings can be obtained from your network administrator.
ITEM 2500
Requirements
You have opened the "Internet Options" dialog, "Privacy" tab with

Procedure
Proceed as follows:
1. Select the required cookie behavior by means of the radio buttons.
"Accept"
Cookies are stored without request.
"Block"
Cookies will not be stored.
"Prompt"
Cookies will be stored on request.
2. If you want allow cookies which are restricted to a single session, activate the
"Always allow session cookies" check box.
3. Change to the "Advanced" tab.

4. Activate the required encryption protocol.
The dialog closes.
Result
The logon information has now been set.
ITEM 2500
6.15.6.4 Importing and deleting certificates
Overview
You can import, view and delete certificates that have been imported for the HMI device.
The certificates differ in the following ways:
Certificates that you trust
Own certificates
Other certificates
You can import additional certificates and delete certificates that are not required.
The required settings can be obtained from your network administrator.
Requirements
You have opened the "Certificates" dialog with the "Certificates" icon.

Procedure
Proceed as follows:
1. Select the type of certificate from the selection box:
"Trusted Authorities"
"My Certificates"
"Other Certificates"
2. If required, start the importing process with the "Import" button.
A dialog with source details will open.
3. If required, delete certificates with the "Remove" button.
Mark the desired certificate.
4. If you want to list the properties of the certificate marked, press the "View" button.
The dialog closes.
Result
The changes to the certificates have been undertaken.
ITEM 2500
6.16 Saving to external storage device (backup)
Introduction
A backup involves copying the operating system, applications and data from the internal in
flash memory of the HMI device to an external storage device.
The following external storage devices are possible:
External memory
USB memory stick
Requirements
The HMI device features an external storage device with sufficient free space.
You have opened the "Backup/Restore" dialog with the "Backup/Restore" icon.

Procedure - using a memory card for the first time
NOTICE
The first time you use a memory card the HMI device will request that you format the card.
Save a backup copy of memory card data to a PC before formatting.

Proceed as follows:
1. Cancel the formatting procedure by pressing "ESC".
2. Remove the memory card from the HMI device.
3. Save a backup copy of vital data to a PC.
4. Insert the memory card into the HMI device.
5. Format the memory card on the HMI device.
ITEM 2500
Procedure
Proceed as follows:
1. Press the "BACKUP" button to open the "Select Storage Card" dialog.
The "--- no storage card available ---" message appears if there is no external memory
in the HMI device or if this memory is defective. Insert an external memory or a
different one.
2. Select the external memory for backup from the "Please select a Storage Card" list box.
3. Click on the "Start Backup" button.
The HMI device checks the external memory.
If the "This storage card..." message appears, an external memory with a greater memory
capacity is needed. Acknowledge this message. Backup is aborted. Insert an external
memory with a greater memory capacity and restart the backup process.
If the "You may have an old backup on the storage card. Do you want to delete it?"
message appears, there is already a backup on the external memory. If you do not want
to overwrite the backup, press the "No" button. Otherwise click on the "Yes" button.
Several messages are displayed in sequence during the backup process:
Saving registry data
Copy files
A progress bar shows the status of the backup process. When the backup process is
completed, the following message is displayed:
"The operation completed successfully."
4. Acknowledge this message.
The dialog closes.
Result
The HMI device data is now saved on the external memory.
ITEM 2500
6.17 Restoring from external storage device
Introduction
A restore operation deletes the old data from flash memory of the HMI device on
confirmation. The data stored on the external memory is then copied to the internal flash
Flash memory.
Requirements
The external memory holding the backed up data is inserted in the HMI device.
You have opened the "Backup/Restore" dialog with the "Backup/Restore" icon.

NOTICE

All data on the HMI device will be deleted during a restore operation. License keys are
deleted after counter-inquiry.
Back up the HMI device's data before restoring if required.
External memory with data backup
If several external memories with data backups are plugged in, the data cannot
be restored.
Remove the external memory with the data backups not needed.

ITEM 2500
Procedure
Proceed as follows:
1. Press the "RESTORE" button to open the "Storage Card" dialog.
2
1

No storage card available
Only one storage card containing backup is allowed. No storage card detected. Insert a
storage card and press the "Refresh" button.
2. Select the external memory with the backup from the "Storage Card with Backup
detected" selection box.
The "--- no storage card available ---" message appears if there is no external memory in
the HMI device or if this memory is defective.
3. If the "--- no storage card available ---" message appears, press the "Cancel" button.
Restoring is then aborted.
Insert a memory card or a different one.
Click on the "Refresh" button.
The content of the selection box will be changed.
Select the external memory with the backup from the "Storage Card with Backup
detected" selection box.
4. Click on the "Start Restore" button.
Restoring is started.
ITEM 2500
5. The data to be restored is checked.
The following messages are displayed in sequence during the check.
"Starting Restore"
"Checking data"
When the data has been checked, the following message is displayed:
"You are starting RESTORE now. All files (except files on storage cards) and the registry
will be erased. Are you sure?"
The message means that the restore process can be started. All files files except
those located on the external memory will be deleted. Tab entries are also deleted.
Are you sure?
6. If you do not want to allow the data to be deleted from the HMI device, abort the restore
process by pressing the "ESC" button.
7. Start to restore the data by selecting "Yes".
The following messages are displayed in sequence during the restore:
"Deleting files on flash"
"Restore CE Image"
A progress bar shows the status of the restore process.
When restore is completed, the following message is displayed:
"Restore succesfully finished. Press ok, remove your storage card and
reboot your device."
8. Remove the external memory.
9. Acknowledge this message.
The HMI device starts.
Result
The data from the external memory is now on the HMI device.

Note
Calibrating the touch screen
After the reset, you may have to recalibrate the touch screen.

ITEM 2500
6.18 Activate memory management
6.18 Activate memory management
Memory management
Provided the memory management is activated, the HMI device will automatically close the
project if the memory needs reorganizing during an active project.
The project is shut down and the HMI device will display a message. You have to restart
the project.

NOTICE
Memory management
If you do not activate memory management, undefined states can occur during the runtime
of the project.
Active memory management from the "OP Properties" dialog.

Requirements
You have opened the "OP Properties" dialog, "Memory Monitoring" tab with
the "OP" icon.
1
2
3

Maximum memory used since the HMI device was last switched on
Percentage of memory currently used
Activate memory management
Procedure
Proceed as follows:
1. If you want to enable memory management, activate the check box.
If memory management is active and there is not enough working memory, the
SIMATIC HMI runtime and therefore the current project will be closed.
The dialog closes.
Result
Memory management is activated.
ITEM 2500

7
7.1 Overview
Configuration phase
A project the process image of the working process is produced during configuration
to visualize automated working processes. The process displays for the project contain
displays for values and messages which provide information about process statuses.
The process control phase follows the configuration phase.
Process control phase
The project must be transferred to the HMI device if it is to be used in process control.
Another precondition for process control is that the HMI device is connected online to a
controller. Current working processes - operating and observing - can then be subject to
process control.
Transferring the project to the HMI device
You can transfer a project to an HMI device as follows:
Transfer from the configuring PC
Restore from a PC using ProSave
In this case, an archived project is transferred from a PC to the HMI device.
The configuration software need not be installed on this PC.
Commissioning and recommissioning
Initial and re-start-ups differ in the following respects:
When the HMI device is commissioned there is no project at first.
The HMI device is also in this state after the operating system has been updated.
When recommissioning, any project already on the HMI device is replaced.
ITEM 2500
7.2 Operating modes
7.2 Operating modes
Operating modes
The HMI device may be in the following operating modes:
Offline
Online
Transfer
"Offline mode" and "Online mode" can be set on both the configuring PC and the HMI
device. To set these modes on the HMI device, use a corresponding operating element
of the project.
Changing the operating mode
The configuration engineer must have configured an appropriate operating element to allow
a change of the operating mode on the HMI device during ongoing operation.
Further information on this may be available in your plant documentation
"Offline" operating mode
In this mode, there is no communication between the HMI device and PLC. Although the
HMI device can be operated, it cannot exchange data with the PLC.
"Online" operating mode
In this mode, the HMI device and PLC communicate. You can operate the plant on the HMI
device according to your system configuration.
"Transfer" mode
In this mode, you can transfer a project from the configuring PC to the HMI device or backup
and restore HMI device data, for example.
The following options are available for setting "Transfer" mode on the HMI device:
When the HMI device starts up
Start "Transfer" mode manually in the HMI device Loader.
During ongoing operation
Start the "Transfer" mode manually within the project using an operating element. The
HMI device toggles to "Transfer" mode when automatic mode is set and a transfer is
initiated on the configuring PC.
See also
ITEM 2500
7.3 Using existing projects
7.3 Using existing projects
The following table shows how you can reuse existing projects, while observing
the screen size:

HMI device in the existing project New HMI device
MP 370 12" Touch MP 377 12" Touch
MP 370 12" Key MP 377 12" Key
MP 370 15" Touch MP 377 15" Touch, MP 377 PRO 15" Touch
The following cases are possible:
1. Project exists in ProTool
Migrate the project to WinCC flexible and then replace the HMI device.
2. Project exists in WinCC flexible
Carry out an HMI device switch in WinCC flexible.
If you migrate existing projects from HMI devices with a different screen size, images which
have already been configured are converted during the migration.
Further information on the subject can be found in the WinCC flexible Online Help or in the
"WinCC flexible Migration" manual.
ITEM 2500
7.4 Data transmission options
7.4 Data transmission options
Overview
The following table shows the options for data transfer between the MP 377 and
the configuring PC.

Type Data channel MP 377
Serial
1)
Yes
MPI/PROFIBUS DP Yes
USB Yes
Backup
PROFINET Yes
Serial
1)
Yes
MPI/PROFIBUS DP Yes
USB Yes
Restoring
PROFINET Yes
Serial
1)
Yes
MPI/PROFIBUS DP Yes
USB Yes
PROFINET Yes
PROFINET with restore to
factory setting
Yes
Serial
1)
Yes
MPI/PROFIBUS DP Yes
USB
2)
Yes
Transferring a project
PROFINET Yes
Serial
1)
Yes
MPI/PROFIBUS DP Yes
USB Yes
Installing or removing an option
PROFINET Yes
Serial
1)
Yes
MPI/PROFIBUS DP Yes
USB Yes
License key transferring or
transferring back
PROFINET Yes

1)
Applies when PC/PPI cable 6ES7 901-3CB30-0XA0 is used
2)
You must not connect the HMI device to a USB 2.0 hub.
See also
Overview (Page 163)
ITEM 2500
7.5 Transfer
7.5 Transfer
7.5.1 Overview
Transfer
Transfer the executable project from the configuring PC to the HMI device.
You can start the "Transfer" mode manually or automatically on the HMI device.
Transferred data is written directly to the internal flash memory on the HMI device. For the
transfer, you use a data channel which you have to configure before starting a transfer.
Backtransfer
You have the option to transfer the compressed project file together with the runtime project
to the HMI device. If necessary, the compressed project file can be transferred back to the
configuring PC and edited.
The HMI device must be equipped with an external memory card to which the compressed
project file can be saved.

NOTICE
Compressed project file
WinCC flexible does not check whether the compressed project file stored on the HMI
device corresponds to the existing runtime project.

See also
Setting the delay time (Page 131)
Data transmission options (Page 162)
7.5.2 Starting manual transfer
Introduction
You can manually switch the HMI device to "Transfer" mode as follows:
With a configured operating element during ongoing operation.
In the Loader of the HMI device.
ITEM 2500
7.5 Transfer
Requirements
The project "*.hmi" is opened in WinCC flexible.
The HMI device is connected to a configuring PC.
The data channel is configured on the HMI device.
The HMI device is in "Transfer" mode.
Procedure
Proceed as follows:
1. On the configuring PC, select the "Transfer settings" command in the menu "Project >
Transfer" in WinCC flexible.
The "Select devices for transfer" dialog opens.
2. Select the HMI device in the left area of the dialog.
3. Select the type of connection between the HMI device and the configuring PC.
Set the connection parameters.
4. Set the transfer parameters in the right area of the dialog.
5. If you wish to transfer the compressed project file together with the runtime project to the
HMI device:
Select the "Enable backtransfer" check box.
6. Start transfer in WinCC flexible with "Transfer".
The configuring PC checks the connection to the HMI device. The project is transferred to
the HMI device. If the connection is not available or is defective, an error message is
displayed on the configuring PC.
Result
When the transfer is completed successfully, the project can be found on the HMI device.
The transferred project is then started automatically.
7.5.3 Starting automatic transfer
Introduction
If automatic transfer is activated, the HMI device automatically changes into "Transfer" mode
during operations as soon as a transfer starts on the configuring PC connected.

Note
With automatic transfer, the HMI device only changes into "Transfer" mode when the project
is running on the HMI device.

Automatic transfer is particularly suited for the test phase of a new project since transfer is
completed without interfering with the HMI device.
ITEM 2500
7.5 Transfer

NOTICE
If the automatic transfer has been activated on the HMI device and a transfer is initiated on
the configuring PC, the project currently running is automatically stopped. The HMI device
then automatically switches to "Transfer" mode.
After the commissioning phase, deactivate the automatic transfer so that the HMI device
cannot be inadvertently switched to transfer mode. The transfer mode can trigger
unintentional actions in the device.
You can issue a password in the control panel to restrict access to the transfer settings and
thus avoid unauthorized modifications.

Requirements
The project *.hmi is opened in WinCC flexible.
The automatic transfer is activated in the data channel for the transfer.
The project is started on the HMI device.
Procedure
Proceed as follows:
1. On the configuring PC, select the "Transfer settings" command in the menu "Project >
Transfer" in WinCC flexible.
The "Select devices for transfer" dialog opens.
2. Select the HMI device in the left area of the dialog.
4. Set the transfer parameters in the right area of the dialog.
5. If you wish to transfer the compressed project file together with the runtime project to the
HMI device:
Select the "Enable backtransfer" check box.
6. Start transfer in WinCC flexible with "Transfer".
The configuring PC checks the connection to the HMI device. The HMI device shuts
down the current project and automatically switches to "Transfer" mode. The project is
transferred to the HMI device. If the connection is not available or is defective, an error
message is displayed on the configuring PC.
Result
When the transfer is completed successfully, the project can be found on the HMI device.
The transferred project is then started automatically.
ITEM 2500
7.5 Transfer
7.5.4 Starting backtransfer
Requirements
No project is open in WinCC flexible.
The HMI device is in "Transfer" mode.
The memory card containing the compressed project file is inserted into the HMI device.
Procedure
Proceed as follows:
1. On the configuring PC, select the "Communication settings" command in the menu
"Project > Transfer" in WinCC flexible.
The "Communication Settings" dialog opens.
2. Select the type of HMI device.
4. Close the dialog with "OK".
5. Select the "Transfer" > "Backtransfer" command in the "Project" menu.
The "Backtransfer" dialog opens.
6. Click "OK" to start the backtransfer process.
The configuring PC checks the connection to the HMI device. The compressed project file
is transferred back from the HMI device to the configuring PC. If the connection is not
available or is defective, an error message is displayed on the configuring PC.
Result
After successful backtransfer, the project is opened on the configuring PC in WinCC flexible.
ITEM 2500
7.5 Transfer
7.5.5 Testing a project
Introduction
There are two options to test a project:
Test the project on the configuring PC
You can test a project at a configuring PC, using a simulator. For detailed information,
refer to the "WinCC flexible" user manual and to the WinCC flexible Online Help.
Offline testing of the project on the HMI device
Offline testing means that communication between the HMI device and PLC is down
while the test is being carried out.
Online testing of the project on the HMI device
Online testing means that the HMI device and PLC communicate with each other
during testing.
Perform the tests, starting with the "Offline test", followed by the "Online test".

Note
You should always test the project on the HMI device on which the project will be used.

Check the following:
1. Check the correct layout of the screens
2. Check the screen navigation
3. Check the input objects
4. Enter the tag values
The test increases the certainty that the project will run error-free on the HMI device.
Requirements for offline testing
The project has been transferred to the HMI device.
The HMI device is in "Offline" mode.
Procedure
In "Offline" mode, you can test individual project functions on the HMI device without them
being affected by the PLC. PLC tags, therefore, are not updated.
Test the operating elements and visualization of the project as far as possible without
connecting to the PLC.
Requirements for online testing
The project has been transferred to the HMI device.
The HMI device is in "Online" mode.
ITEM 2500
7.6 Backup and restore
Procedure
In "Online" mode, you can test individual project functions on the HMI device without them
being affected by the PLC. PLC tags are updated in this case.
You have the option to test all communication-dependent functions, for example alarms, etc.
Test the operating elements and views of the project.
7.6.1 Overview
Backup and restore
You can back up and restore the following data in the internal flash memory of the
HMI device with a PC:
Project and HMI device image
Password list
Recipe data
License keys
Use one of the following tools for backup and restore:
WinCC flexible
ProSave

Note
Alternatively, use the control panel to back up to an external memory device.

General information
NOTICE
Power failure
If a complete restore operation is interrupted due to power failure on the HMI device, the
operating system of the HMI device may be deleted! In this case, you have to reset the HMI
device to its factory settings.
Compatibility conflict
If a message is output on the HMI device warning of a compatibility conflict during the
restore operation, the operating system must be updated.

See also
Saving to external storage device (backup) (Page 153)
ITEM 2500
7.6.2 Backup and restore using WinCC flexible
Requirements
No project is open on the configuring PC in WinCC flexible.
The HMI device is connected to this configuring PC.
Procedure for backup
Proceed as follows:
5. Select the "Backup" command in the menu "Project > Transfer" in WinCC flexible.
The "Backup Settings" dialog opens.
6. Select the data to be backed up.
7. Select a destination folder and a file name for the "*.psb" backup file.
8. Set "Transfer" mode on the HMI device.
If automatic transfer mode is enabled on the HMI device, the HMI device automatically
sets "Transfer" mode when a backup is initiated.
9. Start the backup operation in WinCC flexible with "OK" on the configuring PC.
Follow the instructions in WinCC flexible.
A status view opens to indicate the progress of the operation.
Result
The system outputs a message when the backup is completed.
The relevant data is now backed up on the configuring PC.
ITEM 2500
Procedure for restore
Proceed as follows:
4. Set the connection parameters.
6. Select the "Restore" command in the menu "Project > Transfer" in WinCC flexible.
The "Restore Settings" dialog opens.
7. Select the "*.psb" backup file to be restored from the "Open" field.
You can see the HMI device for which the backup file was created and the type of backup
data the file contains.
If automatic transfer mode is enabled on the HMI device, the device automatically sets
"Transfer" mode when a restore operation is initiated.
9. Start the restore operation in WinCC flexible with "OK" on the configuring PC.
If there are license keys both on the HMI device and in the backup, a dialog will appear.
Use this dialog to establish whether you want to overwrite the license keys or abort the
restore process.
If necessary, abort the backup and first back up the HMI device's license keys.
Then restart the restore process.
Result
When the restore is successfully completed, the data backed up on the configuring PC is
now on the HMI device.
See also
Transferring and transferring back license keys (Page 186)
Operating modes (Page 160)
ITEM 2500
7.6.3 Backup and restore using ProSave
Requirements
The HMI device is connected to a PC on which ProSave is installed.
Procedure for backup
Proceed as follows:
1. From the Windows Start menu, start ProSave on the PC.
2. Select the HMI device type in the "General" tab.
3. Select the type of connection between the HMI device and the PC.
4. Select the data to be backed up in the "Backup" tab.
5. Select a destination folder and a file name for the "*.psb" backup file.
If automatic transfer mode is enabled on the HMI device, the HMI device automatically
sets "Transfer" mode when a backup is initiated.
7. Start the backup operation in ProSave with "Start Backup".
Follow the instructions in ProSave.
Result
The system outputs a message when the backup is completed.
The relevant data is now backed up on the PC.
ITEM 2500
Procedure for restore
Proceed as follows:
5. Select the "*.psb" backup file to be restored from the "Restore" tab.
You can see the HMI device for which the backup file was created and the type of backup
data the file contains.
"Transfer" mode when a restore operation is initiated.
7. Start the restore operation in ProSave on the PC with "Start Restore".
If there are license keys both on the HMI device and in the backup, a dialog will appear.
Use this dialog to establish whether you want to overwrite the license keys or abort the
restore process.
If necessary, abort the backup and first back up the HMI device's license keys.
Then restart the restore process.
8. Follow the instructions in ProSave.
Result
When the restore is successfully completed, the data backed up on the PC is now on
the HMI device.
See also
Operating modes (Page 160)
Transferring and transferring back license keys (Page 186)
ITEM 2500
7.7 Updating the operating system
7.7.1 Overview
A compatibility conflict may occur when transferring a project to the HMI device. This is
caused by different versions of the configuration software used and the HMI device image
available on the HMI device. If there are different versions, the transfer is aborted. A
message indicating a compatibility conflict is displayed on the configuration PC.
There are two ways to match the versions:
Update the HMI device image if the project was created with the most recent version of
the configuration software.
Transfer a matching version of the HMI device image if you do not want to adapt the
project for the HMI device to the most recent version of the configuration software
for the project.

NOTICE

Data loss
All data on the HMI device, such as the project and licenses, will be deleted when you
update the operating system.

Note
When WinAC MP is used, all data channel parameters are reset.

Note
After the update, you may have to recalibrate the touch screen.

ITEM 2500
7.7.2 Resetting factory settings
In ProSave or WinCC flexible, you can update the operating system with or without resetting
to factory settings.
Updating the operating system without resetting to factory settings
First, switch into "Transfer" mode on the HMI device or use the automatic transfer
function if the project is active. Then start the operating system update in ProSave
or WinCC flexible.
Updating the operating system with resetting to factory settings

NOTICE

Loss of license keys
The license keys on the HMI device will be deleted when resetting to factory settings.
The license keys on the HMI device will be retained when updating the operating system
without resetting to factory settings.

NOTICE

Data channels
When resetting to factory settings, all data channel parameters are reset. The transfer
can only be started following reconfiguration of the data channels.

Note
You have to perform an operating system update with reset to factory settings if the
HMI device does not yet have an operating system or if the HMI device's operating
system is corrupt.

First, start the operating system update in ProSave or WinCC flexible and switch the
power on the HMI device off and on again when prompted.
ITEM 2500
7.7.3 Updating the operating system using WinCC flexible
Requirements
Procedure
Proceed as follows:
1. On the configuring PC, select the "Communication settings" command from the
"Projekt > Transfer" menu in WinCC flexible.
6. In WinCC flexible, select the command "OS Update" from the "Projekt > Transfer" menu.
7. In "Image path", select the HMI device image file "*.img".
The HMI device image files are available under "WinCC flexible Images" in the
WinCC flexible installation folder or on the WinCC flexible installation CD.
In the output area, you are provided information on the version of the HMI device image
file after it is opened.
8. Switch into "Transfer" mode on the HMI device.
If you have activated automatic transfer mode for the HMI device, the device
automatically switches to "Transfer" mode when an update is initiated.
9. In WinCC flexible, select "Update OS" on the configuring PC to run the operating
system update.
10. Follow the instructions in WinCC flexible.
During the operating system update a status view opens to indicate progress.
Result
A message is displayed when the operating system update is successfully completed.
This operation has deleted the project data from the HMI device.
ITEM 2500
7.7.4 Updating the operating system using ProSave
Requirements
Procedure
Proceed as follows:
5. Select the "OS Update" tab.
7. Switch into "Transfer" mode on the HMI device.
If you have activated automatic transfer mode for the HMI device, the device
automatically switches to "Transfer" mode when an update is initiated.
8. Select "Update OS" n the PC to run the operating system update.
Result
This operation has deleted the project data from the HMI device.
ITEM 2500
7.7.5 Resetting to factory settings with WinCC flexible
Requirements
The HMI device is connected to this configuration PC over the standard Ethernet cable.
Have the MAC address of the Ethernet interface on your HMI device to hand.
The MAC address is displayed briefly when the HMI device is turned on.
The MAC address is displayed in the "PROFINET" dialog in the Control Panel.
Procedure - Setting the PC interface
1. Select "Start > Control Panel > Set PG / PC interface" on the configuration PC.
2. Select "S7ONLINE (STEP7) -> TCP / IP" from the "Application access point" area.
3. Select the interface which is connected to the HMI device from the "Interface
parameterization used" area.
ITEM 2500
Procedure - Restoring factory settings
Proceed as follows:
2. Select the HMI device type from the "General" tab, and select "Ethernet" from the
"Connection" area.
3. Enter an IP address.

Note
Possible address conflicts with incorrect IP address
Do not use a dynamic IP configuration for "Reset to factory settings".
Specify a unique IP address in which the configuration PC is located. For the duration of
the update process, the HMI device is automatically assigned to the specified address.
If the HMI device has already been used with WinCC flexible or ProSave you can use the
existing IP address for "Reset to factory settings."

5. In WinCC flexible, select the command "Update OS" in the "Project > Transfer" menu.
6. Activate the "Reset to factory settings" check box.
A text box opens where you can enter the MAC address.
7. Enter the HMI device's MAC address in the text box.
ITEM 2500
9. In WinCC flexible, select "Update OS" on the configuring PC to run the operating
system update.
10. In the Control Panel of the HMI device, open the "OP Properties" dialog and select the
"Device" tab.
11. Click on the "Reboot" button.
A query is opened.
12. Click on the "Prepare for Reset" button.
13. On the configuration PC, follow the instructions in WinCC flexible.
Result
This operation has deleted the project data from the HMI device. The factory settings
are reset.

Note
If you can no longer call the Control Panel on the HMI device, as the operating system is
missing, switch off the HMI device. Then reset to factory settings and restart the HMI device.
If the HMI device doesnt start up, switch it off and then on again.

Note

ITEM 2500
7.7.6 Resetting to factory settings with ProSave
Requirement
The HMI device is connected over the Ethernet to a PC on which ProSave is installed.
Have the MAC address of the Ethernet interface on your HMI device to hand.
The MAC address is displayed briefly when the HMI device is turned on.
The MAC address is displayed in the "PROFINET" dialog in the Control Panel.
Procedure - Setting the PC interface
1. Select "Start > Control Panel > Set PG / PC interface" on the configuration PC.
2. Select "S7ONLINE (STEP7) -> TCP / IP" from the "Application access point" area.
3. Select the interface which is connected to the HMI device from the "Interface
parameterization used" area.
Procedure - Restoring factory settings
Proceed as follows:
2. Select the HMI device type from the "General" tab, and select "Ethernet" from
the Connection area.
3. Enter an IP address.

Note
Possible address conflicts with incorrect IP address
Do not use a dynamic IP configuration for "Reset to factory settings".
Specify a unique IP address of the subnet in which the configuration PC is located. For
the duration of the update process, the HMI device is automatically assigned to the
specified address of ProSave.
If the HMI device has already been used with WinCC flexible or ProSave you can use the
existing IP address for "Reset to factory settings."

ITEM 2500

4. Change to the "OS Update" tab.
5. Activate the "Reset to factory settings" check box.
A text box opens where you can enter the MAC address.
6. Enter the HMI device's MAC address in the text box.
8. Select "Update OS" on the PC to start the "Reset to factory settings" process.
9. In the Control Panel of the HMI device, open the "OP Properties" dialog and select
the "Device" tab.
10. Click on the "Reboot" button.
A query is opened.
11. Click on the "Prepare for Reset" button.
ITEM 2500
7.8 Installing and removing options
Result
This operation has deleted the project data from the HMI device. The factory settings
are reset.

Note
If you can no longer call the Control Panel on the HMI device, as the operating system is
missing, switch off the HMI device. Then reset to factory settings and restart the HMI device.
If the HMI device doesnt start up, switch it off and then on again.

Note

7.8.1 Overview
Installing and removing options
You can install options on the HMI device, for example, additional programs developed
especially for the HMI device.
You can also remove the option from the HMI device again.

Note
License key
A license key may be needed to run an option. The license key unlocks the option for use.

ITEM 2500
7.8.2 Installing and removing options using WinCC flexible
Requirements
Procedure for installing an option
Proceed as follows:
3. Select the type of connection between the HMI device and the configuring PC, then set
the connection parameters.
5. Select the "Options" command in the menu "Project > Transfer" in WinCC flexible.
6. Select the desired option under "Available options".
"Transfer" mode when the installation of an option is initiated.
8. Start the installation of the option in WinCC flexible on the configuring PC with
the ">>" button.
A status display appears indicating the progress of the installation.
Result
The option has now been installed on the HMI device.
ITEM 2500
Procedure for removing an option
Proceed as follows:
3. Select the type of connection between the HMI device and the configuring PC, then set
the connection parameters.
5. Select the "Options" command in the menu "Project > Transfer" in WinCC flexible.
6. Press the "Device status" button to update the display.
7. Select the desired option under "Installed options".
"Transfer" mode when the removal of an option is initiated.
9. Start the removal of the option in WinCC flexible on the configuring PC with
the "<<" button.
A status display appears indicating the progress of the removal.
Result
The option has now been removed on the HMI device.
ITEM 2500
7.8.3 Installing and removing options using ProSave
Requirements
Procedure for installing an option
Proceed as follows:
3. Select the type of connection between the HMI device and the PC, then set the
connection parameters.
4. Select the "Options" tab.
5. Select the desired option under "Available options".
"Transfer" mode when the installation of an option is initiated.
7. Start the installation of the option in ProSave with the ">>" button.
A status display appears indicating the progress of the installation.
Result
The option has now been installed on the HMI device.
ITEM 2500
7.9 Transferring and transferring back license keys
Procedure for removing an option
Proceed as follows:
3. Select the type of connection between the HMI device and the PC, then set the
connection parameters.
4. Select the "Options" tab.
5. Press the "Device status" button to update the display.
6. Select the desired option under "Installed options".
"Transfer" mode when the removal of an option is initiated.
8. Start the removal of the option in ProSave with the "<<" button.
A status display appears indicating the progress of the removal.
Result
The option has now been removed on the HMI device.
7.9.1 Overview
Transferring and transferring back license keys
With the purchase of an optional package, you obtain a specific user license with an
associated license key. Once you have installed an option, transfer a license key to the
HMI device. The license key unlocks an option for use.
You can also transfer back the license key from the HMI device to the storage location.

Note
You only transfer license keys with the Automation License Manager or WinCC flexible.

ITEM 2500
7.9.2 Transferring and transferring back license keys
Requirements
When transferring or transferring back using WinCC flexible:
The storage location and the license key awaiting transfer are ready.
Procedure for transferring a license key
Proceed as follows:
1. Switch to "Transfer" mode on the HMI device.
2. When transferring using WinCC flexible:
Select the "License Keys" command in the menu "Project > Transfer".
The Automation License Manager opens.
When transferring using the Automation License Manager:
Start the Automation License Manager via the Windows Start menu.
3. In the Automation License Manager, select the command "Connect HMI device" in the
menu "Edit > Connect target system".
The "Connect Target System" dialog opens.
4. Under "Device Type", select the appropriate HMI device type.
5. Select the type of connection from the "Connection" box.
7. Select "OK".
The connection to the HMI device is established. The connected HMI device is displayed
in the left window of the Automation License Manager.
8. In the left window, select the source drive.
The right window displays the available license keys.
9. Drag one or more license keys from the right window and drop them on the HMI device in
the left window.
The license keys are then transferred to the HMI device.
Result
The license key is transferred from the storage location to the HMI device.
ITEM 2500
Procedure for transferring a license key back
Proceed as follows:
1. Switch to "Transfer" mode on the HMI device.
2. When transferring back using WinCC flexible:
Select the "License Keys" command in the menu "Project > Transfer".
The Automation License Manager opens.
When transferring back using the Automation License Manager:
Start the Automation License Manager via the Windows Start menu.
3. In the Automation License Manager, select the command "Connect HMI device" in the
menu "Edit > Connect target system".
The "Connect Target System" dialog opens.
4. Under "Device Type", select the appropriate HMI device type.
5. Select the type of connection from the "Connection" box.
7. Select "OK".
The connection to the HMI device is established. The connected HMI device is displayed
in the left window of the Automation License Manager.
8. In the left window, select the HMI device.
The right window displays the available license keys.
9. Drag one or more license keys from the right window and drop them on the destination
drive in the left window.
The license keys are transferred back to the storage location.
Result
The license key is transferred back from the HMI device to the storage location.

ITEM 2500

Operating a project
8
8.1 Overview
Configuration and process control phase
HMI devices can be used to operate and monitor tasks in process and production
automation. The plant screens on the HMI devices are used to provide a clear overview
of the active processes.
The HMI device project, which includes the plant screens, is created during the configuration
phase. The configuration engineer defines which tasks the HMI device has in the process
and defines the following in detail:
Which process data is displayed on the individual HMI device
Which plant components are controlled by this HMI device
The configuration engineer stores this information in the project's screens. The project is
transferred to the HMI device during commissioning.
After transfer to the HMI device, current processes can be operated and monitored in the
project's screens. The screens enable you to observe, for example, operational states,
current process data and faults in a plant. Operating elements which are used to operate the
process, for example buttons, I/O fields and alarm windows, are displayed in the screens.
The hardware of the HMI device determines which of the following operator control options
are available:
Touch screen
The operating elements shown in the dialogs are touch-sensitive. Touch objects are
basically operated in the same way as mechanical keys. You activate operating elements
by touching them with your finger. To double-click them, touch an operating element
twice in succession.
HMI device keyboard
The operating elements shown in the screens are selected and operated using the keys
of the HMI device.
External keyboard, connected via USB
External mouse, connected via USB

CAUTION

Do not use any pointed or sharp objects when operating the touch screen. Otherwise
this may damage the plastic membrane of the touch screen.

The following provides instructions for operating a project with the touch screen
and the keyboard.
ITEM 2500
Operating a project
8.1 Overview
Operating a project with an external keyboard
An external keyboard can be used to operate a project in exactly the same way as with the
HMI keyboard or screen keyboard.

Note
The function keys of the external keyboard are disabled.

Use the other keys of the external keyboard, which correspond to the HMI device keys
in the description.
Operating a project with an external mouse
An external mouse can be used to operate a project in exactly the same way as with the
HMI touch screen. Click the described operating elements with the mouse.
Unintentional actions
CAUTION
Do not carry out several operations simultaneously. You may otherwise trigger
unintentional actions.
With touch control:
Always touch only one operating element on the screen
With key control:
Do not press more than two keys simultaneously

Observing the plant documentation
Some operations with the project may require in-depth knowledge about the specific plant on
the part of the operator. Proceed with caution, for example, when you use jog mode. Further
information on this may be available in your plant documentation.
Operation feedback from operating elements
The HMI device provides operation feedback as soon as it detects that an operating element
has been selected. This operation feedback is independent of any communication with the
PLC. Therefore, this operation feedback does not indicate whether the relevant action is
actually executed or not.
ITEM 2500
Operating a project
8.1 Overview
Optical feedback from operating elements
The operating element receives the focus and is selected. The configuration engineer can
also configure the selection of an operating element so that it deviates from the standard.
Further information on this may be available in your plant documentation.
The type of optical feedback depends on the operating element:
Buttons
The HMI device outputs different views of the "Pressed" and "Unpressed" states,
provided the configuration engineer has configured a 3D effect:
"Pressed" state:

"Unpressed" state:

The configuration engineer determines the appearance of a selected field, for example,
line width and color for the focus.
Invisible buttons
By default, invisible buttons are not displayed as pressed when they are touched.
No optical operation feedback is provided in this case.
The configuration engineer may, however, configure invisible buttons so that their outline
appears as lines when touched. This outline remains visible until you select another
operating element.
I/O fields
When you select an I/O field, the content of the I/O field is displayed against a colored
background. With touch operation, a screen keyboard is displayed for the entering
of values.
Acoustic feedback from operating elements
As soon as the HMI device detects a touch of the touch screen or that a key has been
pressed, an acoustic signal is issued. You can activate or deactivate this acoustic
operation feedback.

Note
The acoustic feedback is only possible if you interact with the project directly on the touch
screen or press one of the keys of the HMI device. If you use an external mouse or keyboard
for interaction, no acoustic signal is issued.

Acoustic signal for inadvertent operations
If you try to enter an invalid character, the HMI device issues an acoustic signal in
accordance with the setting.
ITEM 2500
Operating a project
8.2 Direct keys
8.2 Direct keys
Introduction
Direct keys on the HMI device are used to set bits in the I/O area of a SIMATIC S7.
Direct keys enable operations with short reaction times that are, for example,
a jog mode requirement.

NOTICE
Direct keys are still active when the HMI device is in "offline" mode.

NOTICE
If you operate a function key with direct key functionality in a running project, the direct key
function is always executed, independent of the current screen contents.

Note
You can only use direct keys when there is a connection via PROFIBUS DP or
PROFINET IO.
Direct keys result in additional basic load on the HMI device.

Direct keys
The following objects can be configured as a direct key:
Buttons
Function keys
You can also define image numbers in the case of HMI devices with touch operation. In this
way, the project engineer can configure the direct keys on an image-specific basis.
Further information on configuring direct keys can be found in the
"WinCC flexible Communication" system manual.
ITEM 2500
Operating a project
8.3 Setting the project language
8.3 Setting the project language
Introduction
The HMI device supports multilingual projects. You must have configured a corresponding
operating element which lets you change the language setting on the HMI device
during runtime.
The project always starts with the language set in the previous session.
Requirements
The required language for the project must be available on the HMI device.
The language switching function must be logically linked to a configured operating
element such as a button.
Selecting a language
You can change project languages at any time. Language-specific objects are immediately
output to the screen in the new language when you switch languages.
The following options are available for switching the language:
A configured operating element switches from one language to the next in a list
A configured operating element directly sets the desired language
8.4 Entries using the touch screen
8.4.1 Overview
Screen keyboard
When you touch an operating element requiring entry on the HMI device touch screen,
a screen keyboard appears. The screen keyboard is displayed in the following cases:
An I/O field is selected for input
A password must be entered for accessing a password-protected function
The screen keyboard is automatically hidden again when input is complete.
Based on the configuration of the operating element, the system displays different screen
keyboards for entering numerical or alphanumerical values.

Note
The screen keyboard display is independent of the configured project language.

ITEM 2500
Operating a project
General procedure
The operating elements of a screen are operated by touching the touch screen.
Proceed as follows:
1. Touch the desired operating element within the screen.
2. Depending on the operating element, perform further actions. Detailed descriptions can
be found under the respective operating element.
Examples:
I/O field: Enter numerical, alphanumeric or symbolic values in the I/O field
Symbolic I/O field: Select an entry from the drop down list box
Slider control: Move the slider control
Procedure for text boxes
Values are entered in the project text boxes. Based on your configuration, the values are
saved to tags and transferred, for example, to the PLC.
Proceed as follows:
1. Touch the desired text box within the screen.
The screen keyboard opens.
Depending on your configuration, you can enter values in the text box in
the following manner:
Numerical values, for example decimal numbers, hexadecimal numbers, binary values
Alphanumerical values, for example digits and letters
Date/time
2. Enter the value.
3. Confirm your entry with or discard your entry with the button .
ITEM 2500
Operating a project
8.4.2 Entering and editing numerical values
Numerical screen keyboard
When you touch an operating element for numerical input on the HMI-device touch screen,
the numerical screen keyboard appears. This is the case, for example, for a text box. The
screen keyboard is automatically hidden again when input is complete.

Note
Opened screen keyboard
PLC job 51 "Select screen" has no effect while the screen keyboard is open.

Formats for numerical values
You can enter values in numerical text boxes based on the following formats:
Decimal
Binary
Hexadecimal

Note
Entry of hexadecimal values
When you enter values in hexadecimal format, the alphanumerical screen
keyboard opens.

Checking numerical value limits
Tags can be assigned limit values. If you enter a value that lies outside of this limit, it will not
be accepted, for example, 80 with a limit value of 78. In this case the HMI device will deliver
a system alarm, if an alarm window is configured. The original value is displayed again.
Decimal places of numerical values
The configuration engineer can define the number of decimal places for a numerical text box.
The number of decimal places is checked when you enter a value in this type of I/O field.
Decimal places in excess of the limit are ignored
Empty decimal places are filled with "0"
ITEM 2500
Operating a project
Procedure
Numerical values can be entered character-by-character via the buttons on the numerical
screen keyboard.
Proceed as follows:
1. Touch the desired operator control on the screen.
The numerical screen keyboard opens. The existing value is displayed in the screen
keyboard and is selected.
2. Enter the value.
The keys with for example the letters G to Z are available to enter a hexadecimal value;
however, the characters are not entered. Depending on the settings, the HMI device
outputs an audible signal.
You have the following options to enter a value:
The selected value is deleted when you enter the first character. Completely reenter
the value.
Use the and keys to move the cursor within the current value. You can
now edit the characters of the current value or add characters.
Use the key to delete the character to the left of the cursor. If the value is
selected, use this key to delete the selected part of the value.
The key deletes the character positioned to the right of the cursor. If the value is
Use the key to display the infotext of the I/O field.
This key is only enabled if infotext has been configured for the input object or the
current screen.
3. Use the key to confirm your entry or cancel it with . Either action closes
the screen keyboard.
Result
You have changed the numerical value or entered a new one.
ITEM 2500
Operating a project
8.4.3 Entering and editing alphanumerical values
Alphanumerical screen keyboard
When you touch an operating element for alphanumerical input on the HMI-device touch
screen, the alphanumerical screen keyboard appears. This is the case, for example, for a
text box. The screen keyboard is automatically hidden again when input is complete.

Note
Opened screen keyboard
PLC job 51 "Select screen" has no effect while the screen keyboard is open.
Language change
Language change in the project has no influence on the alphanumerical screen keyboard.
This means you cannot enter Cyrillic or Asian characters.

Keyboard levels
The alphanumerical screen keyboard has various levels.
Normal level
Shift level
If you change the levels with key , the key assignments change.
ITEM 2500
Operating a project
Procedure
Alphanumerical values can be entered character-by-character via the buttons on the
alphanumerical screen keyboard.
Proceed as follows:
1. Touch the desired operator control on the screen.
The alphanumerical screen keyboard opens. The existing value is displayed in the screen
keyboard and is selected.
2. Enter the value.
The selected value is deleted when you enter the first character. Completely reenter
the value.
Use the and keys to move the cursor within the current value. You can
now edit the characters of the current value or add characters.
Use the key to delete the character to the left of the cursor. If the value is
The key deletes the character positioned to the right of the cursor. If the value is
Using key it is possible to switch between the keyboard levels of the screen
keyboard. On switchover, the key assignments of the screen keyboard change.
Use the key to display the infotext of the I/O field.
This key is only enabled if infotext has been configured for the input object or the
current screen.
3. Use the key to confirm your entry or cancel it with . Either action closes the
screen keyboard.
Result
You have changed the alphanumeric value or entered a new one.
ITEM 2500
Operating a project
8.4.4 Entering the date and time
Entering the date and time
Enter the date and time in the same way you enter alphanumerical values.

Note
When entering the date and time, please note that the format is determined by the
configured project language.

8.4.5 Entering symbolic values
Drop down list
Operating elements for entering symbolic values offer you a list from which you can select
the input values. When you touch a symbolic I/O field on the HMI device touch screen, the
following drop down list opens.

Procedure
Proceed as follows:
1. Touch the required operating element.
The drop down list of the operating element opens. Select and to scroll in the drop
down list.
2. Touch the required entry in the drop down list.
The selected entry is accepted as an entry.
Result
You have changed the symbolic value or entered a new one.
ITEM 2500
Operating a project
8.4.6 Displaying infotext
Purpose
The configuration engineer uses infotext to provide additional information and operating
instructions. The configuration engineer can configure infotext on screens and operating
elements.
The infotext of an I/O field may contain, for example, information on the value to be entered.

Opening infotext for operating elements
1. Touch the required operating element.
The screen keyboard opens. You can see from the appearance of the key whether
infotext has been configured for the operating element or the current screen.
2. Touch the key on the screen keyboard.
The infotext for the operating element is displayed. If there is no infotext for the selected
screen object, the infotext for the current screen is displayed, if it has been configured.
You can scroll through the contents of long infotext with and .

Note
Switching between displayed infotext
The configuration engineer can configure infotext for an I/O field and the associated
screen. You can switch between two infotexts by touching the infotext window.

3. Close the displayed infotext by pressing .
Alternative procedure
Depending on your configuration, infotext can also be called via a configured
operating element.
ITEM 2500
Operating a project
8.5 Entries using the keys
8.5.1 Control keys
Introduction
The following tables show the control keys with which you operate the project. You will also
find detailed descriptions under the individual operating elements.
Select operating elements

TAB

SHIFT
+
TAB

Tabulator Selects the next/previous operating element in the
tab sequence.

Cursor keys Selects the next operating element to the left, right,
above or below the current screen object.
Navigates in the operating element.
Using operating elements

SHIFT
+

SHIFT
+

SHIFT
+

SHIFT
+
Position the cursor Positions the cursor within an operating element,
for example in the I/O field.
HOME

Scroll back Scrolls back a page in a list.
F
N
+
HOME

Scroll to the beginning Scrolls to the beginning of a list.
END

Scroll forward Scrolls one page forward in a list.
F
N
+
END

Scroll to the end Scrolls to the end of a list.
ITEM 2500
Operating a project
ENTER

Enter key Operates buttons.
Accepts and ends an entry.
Opens a drop down list box.
Toggles within a text box between character
mode and normal mode.
In character mode, a single character is
selected. In this mode, you can advance in the
character set using the cursor keys.
ESC

Cancel Deletes the characters of a value entry and
restores the original value.
Closes the active dialog.
INS
DEL

Delete characters Deletes the character to the right of the current
cursor position.

Delete characters Deletes the character to the left of the current
cursor position.
ALT
+
Open drop down list box Opens a drop down list box.
CTRL
+
ENTER

Accept value Accepts the selected value in the drop down list
box without closing the list.
Enter key combinations

Key Functions Purpose
A-Z

Toggle key assignment Switches over key assignment of keys with
multiple assignment.
No LED is lit:
The number assignment is enabled. Pressing
the button once toggles to letter assignment.
An LED is lit:
The left or right letter assignment is enabled.
Each time the key is pressed, the system toggles
between the left letter assignment, the right letter
assignment and the number assignment.
SHIFT

Toggle between upper-case
and lower-case
Used in key combinations, for example for entering
upper-case letters.
F
N

Switch to additional
key assignment
Some of the keys contain a blue imprinted key
assignment , for example the "%" character.
Used in key combinations for the blue
key assignment.
CTRL

ALT

ITEM 2500
Operating a project
Acknowledge alarms

ACK

Acknowledge Acknowledges the currently displayed fault
alarm or all the alarms of an alarm group as
group acknowledgment.
The LED lights up as long as unacknowledged fault
alarms are active.
Displaying infotext

HELP

Displaying infotext Opens a window with the configured infotext at the
selected object, for example alarm or I/O field. If an
infotext exists for the selected object, the LED
lights up.
Multi-key operation
Unwanted actions may be triggered, if the operator unintentionally actuates a
key combination.

CAUTION
Unintentional actions
In "Online" mode, simultaneous operation of more than two keys may cause unintentional
actions in the plant.
Never press more than two keys simultaneously.

ITEM 2500
Operating a project
8.5.2 Example: enter characters using the alphanumeric keyboard
Using the same keys of the alphanumeric keyboard you can enter up to six different
characters. The entry result depends on the combination of the keys pressed.
The values "5", "M", "m", "N", "n" and "%" are entered using the same key
5
M N
% of
the keyboard. You can use the keys
A-Z
,
SHIFT
and
F
N
to switch between the
different assignments.
The following table shows the entry options using the key
5
M N
% .

Key
A-Z
Key
SHIFT
Key
F
N
Result
No LED is lit Not relevant Not pressed 5
Left LED is illuminated. Not pressed Not pressed m
Left LED is illuminated. Pressed Not pressed M
Right LED is illuminated. Not pressed Not pressed n
Right LED is illuminated. Pressed Not pressed N
Not relevant Not relevant Pressed %
8.5.3 Function keys
Function keys
Function key assignment is defined during configuration. The configuration engineer can
assign function keys globally and locally.
Function keys with global function assignment
A globally assigned function key always triggers the same action on the HMI device or in
the PLC irrespective of the screen displayed. Such an action could be, for example,
the activation of a screen or the closure of an alarm window.
Function keys with local function assignment
A function key with local function assignment is screen-specific and is therefore only
effective within the active screen.
The function assigned locally to a function key can vary from screen to screen.
The function key of a screen can be assigned one function only, either a global or local one.
The local assignment function takes priority over the global setting.
The configuration engineer can assign function keys in such a way that you can operate
operating elements with function keys, for example, the alarm view, trend view, recipe view
or Status Force.
ITEM 2500
Operating a project
8.5.4 General procedures
Introduction
The control keys and function keys of the HMI device are available for key control
General procedure
The operating elements of a screen are operated using the control keys of the HMI device.
Proceed as follows:
1. Continue to press the key
TAB
or the cursor keys until the required operating element is
selected on the screen.
2. Depending on the operating element, perform further actions. Detailed descriptions can
be found under the respective operating element.
Examples:
I/O field: Enter numerical, alphanumeric or symbolic values in the I/O field
Slider control: Move the slider control
3. Confirm the operation with the key
ENTER
or abort the operation with the key
ESC
.
8.5.5 Entering and editing numerical values
Formats for numerical values
You can enter values in numerical text boxes based on the following formats:
Decimal
Hexadecimal
Binary
Limit value test of numerical values
Tags can be assigned limit values. If you enter a value that lies outside of this limit, it will not
be accepted, for example, 80 with a limit value of 78. In this case the HMI device will deliver
a system alarm, if an alarm window is configured. The original value is displayed again.
ITEM 2500
Operating a project
Procedure
Numerical and alphanumerical values can be entered in character mode using
the system keys.
Proceed as follows:
1. Select the desired text box within the screen with
TAB
.
The existing value is selected in the text box.
2. Enter the value using the numerical keypad.
The existing value is deleted when you enter the first character. Completely reenter
the value.
Press
SHIFT
and a cursor key simultaneously. The selection of the field content is
canceled. Move the cursor in the existing value. You can now edit the characters of
the current value or add characters.
The
INS
DEL
key deletes the character positioned to the right of the cursor. Use the
key to delete the character to the left of the cursor.
To enter the hexadecimal characters "A" to "F", switch the numerical keypad to letter
assignment using the key
A-Z
.
If the LED of the
HELP
key is lit, infotext is available for the selected object or the
current screen.
Use the key
HELP
to display the infotext for the operating element or current screen.
3. Select
ENTER
to confirm your entry.
Result
You have changed the numerical value or entered a new one.
ITEM 2500
Operating a project
8.5.6 Entering and editing alphanumerical values
Procedure
Alphanumerical values can be entered in character mode using the system keys.
Proceed as follows:
1. Select the desired text box within the screen with
TAB
.
The existing value is selected in the text box.
2. Enter the value using the system keys.
The existing value is deleted when you enter the first character. Completely reenter
the value.
Press
SHIFT
and a cursor key simultaneously. The selection of the field content is
canceled. Move the cursor in the existing value. You can now edit the characters of
the current value or add characters.
The
INS
DEL
key deletes the character positioned to the right of the cursor. Use the
key to delete the character to the left of the cursor.
To enter letters, switch the numerical keypad to letter assignment using the key
A-Z
.
If the LED of the
HELP
key is lit, infotext is available for the selected object or the
current screen.
Use the key
HELP
to display the infotext for the operating element or current screen.
3. Select
ENTER
Result
You have changed the alphanumeric value or entered a new one.
ITEM 2500
Operating a project
8.5.7 Entering the date and time
Entering the date and time
Enter the date and time in the same way you enter alphanumerical values.

Note
When entering the date and time, please note that the format is determined by the
configured project language.

8.5.8 Entering symbolic values
Drop down list
When you select a symbolic I/O field, a drop down list opens.

Procedure
Symbolic values are selected from the entries of a drop down list.
Proceed as follows:
1. Select the desired symbolic text box within the screen with
TAB
.
2. Open the drop down list using the key
ENTER
. The drop down list opens.
3. Select the required entry using the cursor keys , or .
4. Select
ENTER
Result
You have changed the symbolic value or entered a new one.
ITEM 2500
Operating a project
8.5.9 Displaying infotext
Purpose
The configuration engineer uses infotext to provide additional information and
operating instructions. The configuration engineer can configure infotext on screens
and operating elements.
The infotext of an I/O field may contain, for example, information on the value to be entered.

If the LED of the key
HELP
lights up, an infotext has been configured for the selected display
object or for the current screen.
Procedure
1. Press
HELP
.
The infotext for the selected screen object is displayed. If there is no infotext for
the selected screen object, the infotext for the current screen is displayed, if it
has been configured.
You can scroll through the contents of long infotexts using the cursor keys and .

Note
Switching between displayed infotext
The configuration engineer can configure infotext for an I/O field and the associated
screen. You can switch between two infotexts by pressing the key
ENTER
.

2. Close the infotext by pressing key
ESC
.
Depending on your configuration, infotext can also be called via a function key or via an
existing operating element.
ITEM 2500
Operating a project
8.6 Bar and gauge
8.6 Bar and gauge
Bar
The bar is a dynamic display object. The bar displays a value from the PLC as a
rectangular area. The bar allows you to recognize the following at a glance:
The distance of the current value from the configured limit values
Whether a set point value has been reached
The bar can display values such as fill levels or batch counts.

Layout
The layout of the bar depends on the configuration:
The bar may feature a scale of values
The configured limit values can be indicated by lines
Color changes can signal when a limit value has been exceeded or has not been reached
Gauge
The gauge is a dynamic display object. The gauge displays numeric values in analog form
by means of a pointer. This enables an operator at the HMI device to see at a glance if the
boiler pressure is in the normal range, for example.

Layout
The layout of the gauge depends on the configuration:
A trailing pointer can display the maximum value reached so far on the scale. The trailing
pointer is reset when the screen is reloaded
The label on the scale can show the measured variable, for example boiler pressure and
the physical unit, for example bar
Operation
The bar and the gauge are for display only. Both objects cannot be controlled
by the operator.
ITEM 2500
Operating a project
8.7 Operating the switch
8.7 Operating the switch
Introduction
The switch is an operating element and display object with two predefined switching states,
for example "On" and "Off". Switches can signalize the state of a plant section, for example if
a motor is running or not. At the same time, you can use the switch to change the state of
the corresponding plant section via the HMI device, for example from "On" to "Off".
Layout
The layout of the switch depends on the configuration:
Switch with slider
The two states are displayed by the position of the slider
1

Slider
Switch with text or graphic
The two states are displayed by the label on the slider
Depending on the switching state, the switch is labeled with one of two texts or
one of two graphics.
Examples:
"Backward" or "Forward"
or
Procedure using the touch screen
Switch with slider
Proceed as follows:
Move the slider to the other position or double-click the slider area
Switch with text or graphic
Proceed as follows:
Touch the switch
Procedure using the keys
Proceed as follows:
1. Select the desired switch within the screen with
TAB
.
2. Press
ENTER
.
Result
The switch changes its appearance. The associated value is switched.
ITEM 2500
Operating a project
8.8 Operating the trend view
Trends
Trends continuously display the current process data or process data from a log.
Trend view
Trends are displayed in the trend view. A trend view can display several
trends simultaneously.
Value Tag assignment Trend Date/time
Pressure pattern Pressure 31.01.2006 13:06:34 25
2
3
1

Ruler
Buttons for trend operation
Trend value in the value table
Layout and operation
The layout and operation of the trend view depends on the configuration. The configuration
engineer determines, for example, the following:
Appearance of the trend view, the axes, value ranges and labels
Operating options of the trend view
Limit values for the trend values
The change of color of the trend in the event of limit violation
ITEM 2500
Operating a project
Value table
The trend values can be read from the value table if this is configured:
When the ruler is displayed, the trend values are shown at a position of the ruler in the
value table
When the ruler is hidden, the latest trend values are displayed in the value table
Ruler
When configured, a ruler is available to provide an exact reading of the trend values in the
value table.
You can move the ruler to the desired position of the trend view.
Operation
The trend view can be operated as follows:
Enlarge or reduce the time interval displayed
Scroll forward or back by one display width
Stop and resume trend recording
Move the ruler
Hide and display the ruler
The following table shows the trend view buttons:

Buttons Key combination Function

Stops or continues trend recording.

CTRL
+
+
Z Y

Enlarges the displayed time section.

CTRL
+
Reduces the displayed time section.

SHIFT
+
Scrolls one display width backwards (to the left)

SHIFT
+
Scrolls one display width forwards (to the right)
CTRL
+
ENTER

Scrolls back to the beginning of the trend recording. The start
values of the trend recording are displayed there.

CTRL
+
ALT
+
Moves the ruler backwards (to the left)

CTRL
+
ALT
+
Moves the ruler forwards (to the right)

Shows or hides the ruler.
In addition, the configuration engineer can configure function keys or operating elements
with which you can control trend views.
ITEM 2500
Operating a project
8.9 Operating the slider control
Touch operation
Touch the required button in the trend view.
The position of the ruler can also be changed by means of touching and dragging the ruler
on the touch screen.
Proceed as follows:
1. Using the key
TAB
select the desired button within the trend view.
2. Confirm your entry by pressing the key
ENTER
.
Introduction
The slider control can be used to monitor and change process values within a defined range.
The slider control can also be configured without a slider. In this case, you cannot enter a
value. The slider control is then only used for displaying values.
1
2

Slider control for entering values
Value display with current value
Layout
The layout of the slider control depends on the configuration:
The slider control can contain a label and a setting range
The current value can be displayed below the area of the slider control
ITEM 2500
Operating a project
Proceed as follows:
1. Touch the slider of the desired slider control.
2. Move the slider to the required value.
If a value display has been configured, you can check the exact value that has been set.
3. Release the slider.
Key control
The following table shows the control keys used to set the slide to a desired value:

Key combination Description
SHIFT
+ or
SHIFT
+
Increase value by 1
SHIFT
+ or
SHIFT
+
Reduce value by 1
HOME

Increase value in 5% increments.
END

Decrease value in 5% increments.
F
N
+
HOME

Set maximum value
F
N
+
END

Set minimum value
Proceed as follows:
1. Using the key
TAB
mark the desired switch within the screen.
2. Move the slider to the required value.
If a value display has been configured, you can check the exact value that has been set.
Result
The set value is applied.
ITEM 2500
Operating a project
8.10 Operating the Status Force
8.10.1 Overview
Application
You read or write access values of the connected PLC directly with Status Force. Status
Force allows you to monitor or change addresses of the PLC program, etc. You don't need
to connect an additional programming device or additional PC to the PLC.

Note
Status Force can only be used in combination with SIMATIC S5 or SIMATIC S7.

Layout
The layout of Status Force depends on the configuration.
The figure shows the general layout of Status Force. A value can be monitored or controlled
on every line.
The following figure shows an example of Status Force.

The configuration engineer specifies which columns appear in Status Force.
The table shows the significance of all configurable columns.

Column Functions
"Connection" The PLC whose address ranges must be displayed.
"Type", "DB Number", "Offset", "Bit" The address range of the value
"Data Type", "Format" The data type of the value
"Status Value" The value read from the specified address.
"Control Value" The value to be written to the specified address.
ITEM 2500
Operating a project
Operating elements
Depending on your configuration, you can operate the Status Force using
the following buttons:

Buttons Functions

"Read" button
Updates the display in the "Status Value" column.
This button engages when it is pressed. You cannot operate any text boxes until
the button is actuated again and the refresh is stopped.

"Write" button
Applies the new value in the "Control Value" column. The control value is written
to the PLC.
8.10.2 Touch operation
Status Force can be operated as follows:
Change the column sequence
Read the status values of the connected PLC
Enter values and transfer them to the PLC
Change column sequence
Depending on the configuration, you can change the column sequence of Status Force.
Proceed as follows:
1. Touch the column header which you wish to exchange with a different column header
2. Keeping the touch screen pressed, move the column heading to the column heading you
wish to exchange it with
Result
The columns are displayed in the modified sequence.
ITEM 2500
Operating a project
Procedure for reading the status value
Proceed as follows:
1. Enter the address and the desired format of a value for each line. Touch the respective
columns to display the screen keyboard.
2. Once you have entered all of the desired values, touch the button.
Result
All values are read cyclically by the PLC and entered in the "Status Value" column until
the button is touched again.
Requirements for forcing
The following requirements must be fulfilled in order to force values:
The "Control Value" column must be available
The "Write" button must be available
Procedure for forcing a value
Proceed as follows:
1. Enter the address of a value for each line. Enter the desired value in the "Control Value"
column. Touch the respective columns to display the screen keyboard.
2. Once you have entered all of the desired values, touch the button.
Result
The values from the "Control Value" column are transferred once to the PLC.
8.10.3 Key control
Status Force can be operated as follows:
Change the column width.
Read the status values of the connected PLC
Enter values and transfer them to the PLC
ITEM 2500
Operating a project
Key control
The following table lists the key combinations for operating the Status Force:

Keys Functions
CTRL
+
} {

Operates the "Read" button.
CTRL
+
ENTER

Operates the "Write" button.
CTRL
+
CTRL
+
Selects the first/last field in the current line.
CTRL
+
CTRL
+
Selects the first/last field in the current column.
CTRL
+
INS
DEL

Deletes the current line.
Otherwise:
Do not select a PLC in the "Connection" column.
ENTER

Opens selection box.
CTRL
+
ALT
+
Increases the width of the current column.
CTRL
+
ALT
+
Decreases the width of the current column.
CTRL
+
+
Z Y

Optimizes column width.
Procedure for reading the status value
Proceed as follows:
1. Enter the address and format of the status value for each status value you wish to read in
one line. Select the respective fields and enter the values using the keyboard.
2. Press
CTRL
+
} {
.
Result
All status values are read cyclically from the PLC and entered in the "Status Value" column
until the
CTRL
+
} {
keys are pressed again.
ITEM 2500
Operating a project
8.11 Operating the Sm@rtClient view
Requirements for forcing
The following requirements must be fulfilled in order to force values:
The "Control Value" column must be available
The "Write" button must be available
Procedure for forcing a value
Proceed as follows:
1. Enter the address of a value for each line. Enter the desired control value in the "Control
Value" column. Select the respective fields and enter the values using the keyboard.
2. Once you have entered all of the desired control values, press the
CTRL
+
ENTER
key.
Result
The values from the "Control Value" column are transferred once to the PLC.
Alternatively, you can also select the buttons and using the key
TAB

and operate it using key
ENTER
.
8.11.1 Overview
Application
The Sm@rtClient view enables you to monitor and remotely operate the current project of a
remote HMI device. With the correct configuration, several equal priority HMI devices can
access a remote HMI device.

Note
If another HMI device accesses your HMI device via the Sm@rtClient view, this leads to an
additional load on your HMI device.

Layout
In the Sm@rtClient view, the remote HMI is displayed with the complete layout.
Depending on the configuration, you can monitor and also operate this screen.
You can also operate the function keys like buttons on an HMI device with a touch screen.
ITEM 2500
Operating a project
Monitoring mode
On a Sm@rtClient view which is configured for monitoring mode, you can only monitor the
remote HMI device. You cannot control its operation.
Operation
Note
It is not possible to operate the direct keys of the remote HMI device from the
local HMI device.

The available operating elements depend on the HMI devices used:
Same type of HMI devices
You can operate the project of the remote HMI device with the operating elements of
your HMI device
Operate keys from a local touch screen
All the keys of the remote HMI device are displayed as buttons on the touch screen.
You can also touch them to operate them
Touch operation from a local HMI device using keys
You operate the buttons in the usual manner.
8.11.2 Touch operation
The Sm@rtClient view can be operated as follows:
Starting remote control
Forcing permission
Ending remote operation
ITEM 2500
Operating a project
Procedure for starting remote operation
Proceed as follows:
1. On the HMI device change to the screen with the Sm@rtClient view.
The following options are available for establishing the connection to the remote
HMI device:
The connection is established automatically.
The connection must be established by touching the appropriate button.
Depending on the configuration, you may be required to enter the address of the
remote HMI device and a password.
2. The current screen of the project running on the remote device is displayed on the screen
of your HMI device.
3. You can now monitor and control this screen depending on your configuration.
Scroll bars are displayed if the screen of the remote HMI device is larger than that of the
current HMI device.
Procedure for forcing permissions
If several HMI devices have access to a HMI device, only one HMI device has operating
permission at any one time.
Two cases must be distinguished for this case:
If another HMI device is already controlling the remote HMI device, if configured
accordingly, you can force operating permission for the remote HMI device
You are trying to operate the remote HMI device
A dialog appears in which you are prompted to enter the appropriate password for
forcing remote control
You are now authorized to operate the remote HMI device
If another HMI device is accessing your HMI device via the Sm@rtClient view, you can
force local operating permission for your HMI device
Touch the screen of your HMI device five times consecutively
You are given permission to operate your local HMI device
Procedure for ending remote control
You can end monitoring and control of a remote HMI device with one of the following
methods depending on the configuration:
Touch a button configured for this action
Exit the screen containing the Sm@rtClient view
If configured, a menu is displayed after you have touched an empty space over a
longer period. Select the "Close" menu item.
ITEM 2500
Operating a project
8.11.3 Key control
The Sm@rtClient view can be operated as follows:
Starting remote control
Forcing permission
Ending remote control
Procedure for starting remote operation
Proceed as follows:
1. On the HMI device change to the screen with the Sm@rtClient view.
The following options are available for establishing the connection to the remote
HMI device:
The connection is established automatically.
Continue to press the key
TAB
until the Sm@rtClient view is selected.
Depending on the configuration, you may be required to enter the address of the
remote HMI device and a password.
The connection is established. The current screen of the project running on the remote
device is displayed on the screen of your HMI device.
2. You can now monitor and control this screen depending on your configuration.
3. Scroll bars are displayed if the screen of the remote HMI device is larger than that of the
current HMI device. Move the scroll bars in the direction required using keys
CTRL
+
or
CTRL
+ .
Procedure for forcing permissions
If several HMI devices access an HMI device, only one HMI device has permission
to operate.
Two cases must be distinguished for this case:
If another HMI device is already controlling the remote HMI device, if configured
accordingly, you can force operating permission for the remote HMI device
You are trying to operate the remote HMI device
A dialog appears in which you are prompted to enter the appropriate password for
forcing remote control
You are now authorized to operate the remote HMI device
If another HMI device is accessing your HMI device via the Sm@rtClient view, you can
force local operating permission for your HMI device
Press
SHIFT
five times consecutively.
You are given permission to operate your local HMI device
ITEM 2500
Operating a project
8.12 Project security
Procedure for ending remote control
You can end monitoring or control of a remote HMI device with one of the following methods
depending on the configuration:
Press the key configured for this
Exit the screen containing the Sm@rtClient view
If configured, display a menu with
SHIFT
+
CTRL
. Select the desired menu command
with
ALT
and the respective identification letter.
8.12.1 Overview
Design of the security system
The configuration engineer can protect the operation of a project by implementing
a security system.
The security system is based on authorizations, user groups and users.
If operating elements protected by a password are operated, the HMI device first requests
that you log on. A logon screen is displayed in which you enter your user name and
password. After logging on, you can operate the operating elements for which you have
the necessary authorizations.
The logon dialog can be set up by the configuration engineer via an individual
operating element.
In the same way, the configuration engineer can set up an operating element to log off. After
logging off, objects assigned password protection can no longer be operated; to do so,
log on again.
User groups and authorizations
Project-specific user groups are created by the configuration engineer. The "Administrators"
and "PLC User" groups are included in all projects by default. User groups are assigned
authorizations. Authorization required for an operation is specifically defined for each
individual object and function in the project.
ITEM 2500
Operating a project
Users and passwords
Each user is assigned to exactly one user group.
The following people are allowed to create users and assign them passwords:
The configuration engineer during configuration
The administrator on the HMI device
A user with user management authorization on the HMI device
Irrespective of the user group, each user is allowed to change his own password.
Logoff times
A logoff time is specified in the system for each user. If the time between any two user
actions, such as entering a value or changing screens, exceeds this logoff time, the user is
automatically logged off. The user must then log on again to continue to operate objects
assigned password protection.
Backup and restore
The user data is encrypted and saved on the HMI device to protect it from loss due to
power failure.
The users, passwords, group assignments and logoff times set up on the HMI device can be
backed up and restored. This prevents you having to enter all of the data again on another
HMI device.

NOTICE
The currently valid user data is overwritten in the following cases:
Depending on the transfer settings, when the project is transferred again
Upon restore of a backed-up project
Upon import of the user administration via an operating element. Further information on
this may be available in your plant documentation
The retransferred or restored user data and passwords are valid with immediate effect.

Limits for user, password and user View

Number of characters
Length of user name, maximum 40
Length of password, minimum 3
Length of password, maximum 24
Entries in user view, maximum 50
ITEM 2500
Operating a project
8.12.2 User view
Application
The user view is used to display the users on the HMI device:
All users on the HMI device are displayed in the user view to the administrator or
to a user with administrator authorizations
If you are a user without user management authorization, you can only see your
personal user entry
The authorizations of a user after logging on depends on the user group to which
the user is assigned.
Layout
The configuration engineer can implement a simple or enhanced user view.
The two user views offer the same functions. They differ only in the display of information.
Simple user view
If you are not logged on to the HMI device, the only entry contained in the simple user
view is "<ENTER>".
If you are logged on to the HMI device, the simple user view only displays the user name
and user group.

Enhanced user view
The enhanced user view displays information about the users.

The enhanced user view contains the following columns:
Users
Password
Group
Logoff time
The passwords are encrypted by appear as asterisks.
ITEM 2500
Operating a project
8.12.3 User logon
Logon dialog
Use the logon dialog to log on to the security system of the HMI device. Enter your user
name and password in the logon dialog.

The logon dialog opens in the following cases:
You are operating an operating element with password protection
You are operating an operating element that was configured for displaying the logon
dialog
You activate the "<ENTER>" entry in the simple user view
You activate a blank entry in the extended user view
The logon dialog will be automatically displayed when the project is started, depending on
the configuration
Requirements
The logon dialog is open.
Proceed as follows:
1. Enter the user name and password.
Touch the corresponding text box. The alphanumerical screen keyboard is displayed.
2. Select "OK" to confirm logon.
ITEM 2500
Operating a project
Proceed as follows:
1. Using the key
TAB
select the "User" text box within the logon dialog.
2. Enter the user name using the system keys.
To enter letters, switch the numerical keypad to letter assignment using the key
A-Z
.
3. Using the key
TAB
select the "Password" text box.
4. Enter the password using the system keys.
5. Touch the "OK" button to confirm your entries.

Note
The user name is not case-sensitive.
The password is case-sensitive.

Result
After successful logon to the security system, you can execute password-protected functions
on the HMI device for which you have authorizations.
If you enter a wrong password, an error message is displayed when an alarm window has
been configured.
8.12.4 User logoff
Requirements
You have logged into the security system of the HMI device.
Procedure
You have the following options for logging off:
You operate an operating element that was configured for logoff
You will be logged off automatically if you are not operating the project and if the logoff
time has been exceeded
You will also be automatically logged off if you enter an incorrect password.
Result
You are no longer logged into the project. In order to operate an operating element with
password protection, you must first log on again.
ITEM 2500
Operating a project
8.12.5 Creating users
8.12.5.1 Creating users with touch operation
Requirements
You have opened a screen containing the user view.
You have user management authorization or you are the administrator.

NOTICE
Blank

Procedure for creating a user in the simple user view
Proceed as follows:
1. Touch the "<New User>" entry in the user view.

2. Enter the desired user name and password.
Touch the corresponding text box. The alphanumerical screen keyboard is displayed.
3. Touch the "OK" button.

4. Assign the user to a group.
In order to do so, open the "Group" drop down list box by means of the button. Select
and to scroll in the drop down list box.
5. Touch the required entry in the drop down list box.
The selected entry is then accepted as input.
ITEM 2500
Operating a project
6. Touch the text box "Logoff time". The screen keyboard is displayed.
7. Enter a value between 0 and 60 for the logoff time in minutes. The value 0 stands for "no
automatic logoff."
Procedure for creating a user in the enhanced user view
Proceed as follows:
1. Touch the desired field in the blank line of the user view.
The appropriate screen keyboard is displayed.
2. Switch into input mode by means of the key.
3. Enter the respective user data in the field:
Assign the user to one of the groups from the drop down list box.
Enter a value between 0 and 60 for the logoff time in minutes. The value 0 stands for
"no automatic logoff."
Result
The new user is created.
8.12.5.2 Creating users with key operation
Requirements
You have user management authorization or you are the administrator.

NOTICE
Blank

ITEM 2500
Operating a project
Procedure for creating a user in the simple user view
Proceed as follows:
1. Select the user view using the key
TAB
or using the cursor keys.
2. Select the entry "<New user>" in the user view with the cursor keys and confirm with
ENTER
.

3. Enter the desired user name using the system keys.
4. Select the next text box with the
TAB
key and enter a password using the system keys.

6. Select the "Group" selection box with
TAB
.
7. Assign the user to a group.
Select
ENTER
to open the drop down list box. The drop down list box opens.
Select the required entry using or .
Confirm your entry by pressing the key
ENTER
.
8. Select the text box "Logoff time" with
TAB
.
9. Enter the desired logoff time using the system keys.
ITEM 2500
Operating a project
Procedure for creating a user in the enhanced user view
Proceed as follows:
1. Select the user view with the
TAB
key via the configured tab order.
2. Select a blank line with the or keys.
3. Select the desired field in the blank line of the user view with the or keys.
ENTER
.
5. Enter the desired user data:
Enter the data using the system keyboard. To enter letters, switch the numerical
keypad to letter assignment using the key
A-Z
.
Assign the user to one of the groups from the drop down list box. Open the drop down
list box with the
ENTER
key and select the desired entry with the or keys.
ENTER
.
Result
The new user is created.
ITEM 2500
Operating a project
8.12.6 Changing user data
8.12.6.1 Changing user data with touch operation
Requirements
Which data you are allowed to change depends on your authorization:
You are an administrator or a user with user management authorization. In these cases
you are allowed to change the data for all the users on the HMI device in the user view:
User name
Group assignment
Password
Logoff time
You are a user without user management authorization. In this case you are only allowed
to change your personal user data:
Password
Logoff time, if configured

Note
You can only change the logoff time and password for the "Admin" user.
You can only change the logoff time for the "PLC_User". This user is used for logging
on via the PLC.

Procedure for changing user data in the simple user view
Proceed as follows:
1. In the user view, touch the user whose user data you want to change
2. When entering the data, use exactly the same procedure as for creating a user
Procedure for changing user data in the enhanced user view
Proceed as follows:
1. In the user view, touch the user whose user data you want to change
Result
The user data for the user is changed.
ITEM 2500
Operating a project
8.12.6.2 Changing user data with key operation
Requirements
Which data you are allowed to change depends on your authorization:
You are an administrator or a user with user management authorization. In these cases
you are allowed to change the data for all the users on the HMI device in the user view:
User name
Group assignment
Password
Logoff time
You are a user without user management authorization. In this case you are only allowed
to change your personal user data:
Password
Logoff time, if configured

Note
You can only change the logoff time and password for the "Admin" user.
You can only change the logoff time for the "PLC_User". This user is used for logging
on via the PLC.

Procedure for changing user data in the simple user view
Proceed as follows:
TAB
.
2. In the user view, use the cursor keys to select the user whose user data you want to
change. Confirm your entry by pressing the key
ENTER
.
3. When entering the data, use exactly the same procedure as for creating a user.
Procedure for changing user data in the enhanced user view
Proceed as follows:
TAB
.
2. Use the cursor keys to select the field in which you want to change data. Confirm your
entry by pressing the key
ENTER
.
Result
The user data for the user is changed.
ITEM 2500
Operating a project
8.12.7 Deleting users
Requirements
To delete a user, you must be an administrator or have user management authorization.

Note
The "Admin" and "PLC_User" users exist by default. These users cannot be deleted.

Procedure
To delete a user, delete the user name entered.
Result
The user has been deleted and may no longer log onto the project.
ITEM 2500
Operating a project
8.13 Closing the project
8.13 Closing the project
Procedure
Proceed as follows:
1. Use the corresponding operating element object to close the project.
Wait for the Loader to open after you closed the project.
2. Switch off power to the HMI device.
ITEM 2500

Operating alarms
9
9.1 Overview
Alarms
Alarms indicate events and states on the HMI device which have occurred in the system,
in the process or on the HMI device itself. A status is reported when it is received.
An alarm could trigger one of the following alarm events:
Incoming
Outgoing
Acknowledge
The configuration engineer defines which alarms must be acknowledged by the user.
An alarm may contain the following information:
Date
Time
Alarm text
Location of fault
State
Alarm class
Alarm number
Alarm group
Diagnostics capability
ITEM 2500
Operating alarms
9.1 Overview
Alarm classes
Alarms are assigned to various alarm classes:
Error
Alarms in this class must always be acknowledged. Error alarms normally indicate critical
errors within the plant such as "Motor temperature too high"
Operation
Warning alarms usually indicate states of a plant such as "Motor switched on"
System
System alarms indicate states or events which occur on the HMI device
SIMATIC diagnostic alarms
SIMATIC diagnostic alarms show states and events of the SIMATIC S7
or SIMOTION PLCs
User-specific alarm classes
The properties of this alarm class must be defined in the configuration
Alarm groups
The configuration engineer can group alarms into alarm groups. When you acknowledge an
individual alarm of an alarm group, you acknowledge all alarms which belong to the same
alarm group.
Alarm buffer
The alarm events are stored in an internal buffer. The size of this alarm buffer depends on
the HMI device type.
Alarm report
The configuration engineer can activate alarm reporting on the project. In this case, alarm
events are output directly on the connected printer.
The configuration engineer can define whether each individual alarm is logged. An alarm of
this type is printed when the alarm events "Incoming" and "Outgoing" occur.
If you want to print alarms of the "System" alarm class, you have to print the contents of the
associated alarm buffer. For this case the configuration engineer has to configure an
operating element for printing the alarm buffer.
Alarm log
Alarm events are stored in an alarm log, provided this log file is configured. The capacity of
the log file is limited by the storage medium and system limits.
ITEM 2500
Operating alarms
9.2 Detecting queued alarms
9.2 Detecting queued alarms
Introduction
You can recognize the presence of alarms which must be acknowledged by the following:
For an HMI device with keys: The LED in the key
ACK
lights up.
Depending on the configuration: An alarm indicator is displayed on screen.
The configuration determines whether an alarm has to be acknowledged or not. This is also
defined by the alarm class which an alarm belongs to.
LED in the "ACK" key
On an HMI device with keys, an LED is integrated in the key
ACK
. The LED is lit if there are
alarms requiring acknowledgment which must still be acknowledged.
The LED goes out when you acknowledge all alarms requiring acknowledgment.
Alarm indicator
The alarm indicator is a graphic symbol indicating pending alarms or alarms requiring
acknowledgment, depending on the configuration.

The alarm indicator flashes as long as alarms are pending for acknowledgment. The number
displayed indicates the number of pending alarms. The configuration engineer can assign
functions to be executed when the alarm indicator is operated.
Usually, the alarm indicator is only used for error alarms. Further information may be
available in your plant documentation.
ITEM 2500
Operating alarms
9.3 Message display
9.3 Message display
Displaying alarms
Alarms are displayed in the alarm view or in the alarm window on the HMI device.
Alarm view
Depending on the configuration, the alarm view is displayed as follows:
As a single line. Alarm numbers and alarm texts are displayed as single lines
As simple alarm view
As enhanced alarm view
In the simple or enhanced alarm views the configuration engineer specifies the alarm
information to be displayed.
Depending on the configuration, alarms from alarm logs are also displayed in the alarm view.
Simple alarm view
19.04.2005 11:41:37 ! 1
Motor 23 too hot

The buttons have the following functions:

Buttons Functions

Displaying infotext for an alarm.

Process alarm.

Acknowledge alarm.

Select the next or previous alarm in the list.

Scroll one page up or down.
Enhanced alarm view
1 !
Motor 23 too hot
K 19.04.2005 12:04:59
Date Time No. Status

ITEM 2500
Operating alarms
9.3 Message display
The buttons have the following functions:

Buttons Functions

Displaying infotext for an alarm.

Process alarm.

Acknowledging alarms.
Changing the column sequence and sorting in the enhanced alarm view
Depending on the configuration, you can change the column sequence and sorting order on
HMI devices with touch operation.
Change column sequence
Touch the column header which you wish to exchange with a different column header
Keeping the touch screen pressed, move the column heading to the column heading
you wish to exchange it with
Change sorting order
To change the sorting order of the alarms, touch the respective column header on the
touch screen
Alarm class layout
The various alarm classes are identified in order to distinguish between them in
the alarm view.

Icon Alarm class
! Error
Without a symbol Operation
Symbol depending on the configuration User-defined alarm classes
S7 SIMATIC or SIMOTION diagnostic alarms
$ System
The configuration engineer can change the symbols for the alarm classes. Further
information on this may be available in your plant documentation.
Alarm window
The alarm window is independent of the process screen. Depending on the configuration,
the alarm window opens automatically as soon as a new alarm is pending for
acknowledgment. The alarm window can be configured so that it only closes after all the
alarms have been acknowledged.
The layout and the operation of the alarm window are the same as for the alarm view.
ITEM 2500
Operating alarms
9.4 Displaying infotexts
9.4 Displaying infotexts
Displaying infotext
The configuration engineer can also provide infotext for alarms.
Proceed as follows:
1. Touch the desired alarm in the alarm view or the alarm window.
The alarm is selected.
2. Touch the button in the simple alarm view or in the enhanced alarm view.
If configured, the infotext assigned to this alarm is displayed.
3. Close the screen for displaying the Infotext by means of the button.
Proceed as follows:
1. Select the desired alarm in the alarm view.
2. Press
HELP
.
If configured, the infotext assigned to this alarm is displayed.
3. Close the infotext by pressing key
HELP
.
ITEM 2500
Operating alarms
9.5 Acknowledge alarm
9.5 Acknowledge alarm
Requirements
The alarm to be acknowledged is displayed in the alarm window or the alarm view.
Proceed as follows:
1. Touch the desired alarm in the alarm view or the alarm window.
The alarm is selected.
The alarm view and the alarm window have a tab sequence with which you can select
operating elements and the last selected alarm using the keyboard.
1. Select the desired alarm view or alarm window with
TAB
.
2. Select the desired alarm. Use the
HOME
,
END
, or keys.
3. Press
ACK
.
Alternative operation
Depending on the configuration, you can also acknowledge an alarm with a function key.
Result
The alarm is acknowledged. If the alarm belongs to an alarm group, all the alarms of the
associated group are acknowledged.
More information on acknowledgment and on available alarm groups may be found in your
plant documentation.
ITEM 2500
Operating alarms
9.6 Editing alarms
9.6 Editing alarms
Introduction
The configuration engineer can assign additional functions to each alarm. These functions
are executed when the alarm is processed.

Note
When you edit an unacknowledged alarm, it is acknowledged automatically.

Requirements
The alarm to be edited is displayed in the alarm window or the alarm view.
Proceed as follows:
1. Touch the desired alarm in the alarm view or the alarm window. The alarm is selected.
Proceed as follows:
1. Select the desired alarm view or alarm window with
TAB
.
2. Select the desired alarm. Use the
HOME
,
END
, or keys.
3. Continue to press the key
TAB
until the button is selected in the simple alarm view or
in the extended alarm view.
ENTER
.
Result
The system executes the additional functions of the alarm. Further information on this may
be available in your plant documentation.
ITEM 2500

Operating recipes
10
10.1 Overview
Introduction
Recipes are used when different variants of a product are manufactured with the same
process. In this case, the product variants differ in terms of their type and quantity of the
components, but not in terms of the manufacturing process sequence. The configuration
engineer can store the combination of each individual product variant in a recipe.
Field of application
Recipes can be used everywhere the same product components are used in variable
combinations to create different product variants.
Examples:
Beverage industry
Food processing industry
Pharmaceutical industry
Paint industry
Building materials industry
Steel industry
ITEM 2500
Operating recipes
10.2 Structure of a recipe
Recipes
The recipe collection for the production of a product family can be compared to a file cabinet.
A recipe which is used to manufacture a product corresponds to a drawer in a file cabinet.
Example:
In a plant for producing fruit juice, recipes are required for different flavors. There is a recipe,
for example, for the flavors orange, grape, apple and cherry.
1
2
3
4
5

File cabinet Recipe collection Recipes for a fruit juice plant
Drawer Recipe Orange flavored drinks
Drawer Recipe Grape flavored drinks
Drawer Recipe Apple flavored drinks
Drawer Recipe Cherry flavored drinks
ITEM 2500
Operating recipes
Recipe data records
The drawers of the file cabinet are filled with suspension folders. The suspension folders in
the drawers represent records required for manufacturing various product variants.
Example:
Product variants of the flavor apple might be a soft drink, a juice or nectar, for example.
1 2 3 4

Drawer Recipe Product variants of apple flavored drinks
Suspension folder Recipe data record Apple drink
Suspension folder Recipe data record Apple nectar
Suspension folder Recipe data record Apple juice
Elements
In the figure showing the file cabinet, each suspension folder contains the same number of
sheets. Each sheet in the suspension folder corresponds to an element of the recipe data
record. All the records of a recipe contain the same elements. The records differ, however,
in the value of the individual elements.
Example:
All drinks contain the same components: water, concentrate, sugar and flavoring. The
records for soft drink, fruit juice or nectar differ, however, in the quantity of sugar
used in production.
ITEM 2500
Operating recipes
10.3 Recipes in the project
Overview
If recipes are used in a project, the following components interact:
Recipe view / recipe screen
On the HMI device, recipes are displayed and edited in the recipe view or in
a recipe screen.
The recipe data records from the internal memory of the HMI device are displayed and
edited in the recipe view.
The values of the recipe tags are displayed and edited in the recipe screen
Depending on the configuration, the values displayed in the recipe view are synchronized
with the values of recipe tags.
HMI device recipe memory
Recipes are saved in the form of data records in the HMI device recipe memory.
The recipe data can also be saved in recipe tags.
Recipe tags
The recipe tags contain recipe data. When you edit recipes in a recipe screen, the recipe
values are stored in recipe tags. Depending on the configuration, the values of the recipe
tags are exchanged with the PLC.
The recipe tags can be synchronized with the recipe data records so that the same
values are saved in both.
Memory card
The memory card is an external storage medium for recipe data records. The recipe
data records are exported from the HMI device recipe memory and are saved on the
memory card in a *.csv file. The records can be reimported from the memory card to
the recipe memory.
ITEM 2500
Operating recipes
Data flow
The following figure shows the data flow in a project with recipes.
Recipe 1
Recipe 2
Recipe 3
Recipe n
Recipe memory HMl device
PLC
Recipe view
Recipe
screen
Recipe tag
Memory card
3

1
2
5
6
4
7

Editing, saving or deleting a recipe data record
Display recipe data record
Synchronize or do not synchronize recipe tags
Display and edit recipe tags in the recipe screen
Write records from the recipe view to the PLC or read records from the PLC and
display them in the recipe view
Recipe tags are to the PLC online or offline
Export or import recipe data record to memory card
ITEM 2500
Operating recipes
10.4 Recipe displays
Displaying recipes
You can display and edit recipes on the HMI device with a recipe view or recipe screen.
Recipe view
A recipe view is a screen object used to manage recipe data records. The recipe view shows
recipe data records in tabular form.
Depending on the configuration, the recipe view is displayed as follows:
As enhanced recipe view
As simple recipe view
The configuration engineer also defines which operating elements are displayed in
the recipe view.
Enhanced recipe view
The following figure shows an example of the enhanced recipe view.
4
4
5
7
2
1
3
6

Selection box for the recipe
Selection box for the recipe data record
Element name
The element name designates a specific element in the recipe data record
Display field
This show the number of the selected recipe or the selected recipe data record
Value of the element
Buttons for editing a recipe data record
Status bar for display of the status messages
ITEM 2500
Operating recipes
Simple recipe view
The simple recipe view consists of three areas:
Recipe list
Record list
Element list
In the simple recipe view, each area is shown separately on the HMI device. Depending on
the configuration, the simple recipe view starts with the recipe list or data record list.
The following figure shows an example of the record list.
Beverage
Juice
Nectar
1
2
3
2 3 1

Number of the recipe data record
Recipe data records
Buttons for changing the displayed list and calling the menu
Display of values
NOTICE
Changing the recipe data record in the background
Applies to the processing of a recipe data record:
If values of the corresponding recipe data record are changed by a PLC job, the recipe view
is not updated automatically.
To update the recipe view, reselect the respective recipe data record.

ITEM 2500
Operating recipes
Recipe screen
A recipe screen allows the correlation between the plant and the recipe data to be displayed
in graphic form. The configuration engineer combines I/O fields and screen objects to form a
custom input screen. The configuration engineer can distribute the I/O fields of a recipe over
several recipe screens, thus allowing recipe elements to be arranged by subject. The recipe
screen can be operated using buttons configured accordingly.
The following figure shows an example of the recipe screen.
Water
Concentrate
Sugar
Aroma
Recipe name
Data record name
No.:
No.:
Save
Load
Data from the PLC
Data to PLC
Orange
Nectar
1
2
40
70
30
30
l
l
kg
l
2 3 4 1

Element name and associated values
The element name designates a specific element in the recipe data record
Buttons for editing a recipe data record
Modified recipe view
Buttons for transferring recipe data
The values displayed or entered in the recipe screen are saved in recipe tags. The recipe
values are exchanged with the PLC immediately or later via these tags.
A configured recipe view can itself be a component of a recipe screen. You must
synchronize the tags in order to synchronize data between the tags of the recipe screen
and the recipe data records displayed in the recipe view. Synchronization of tags is only
possible in the enhanced recipe view.
ITEM 2500
Operating recipes
10.5 Recipe values in the HMI device and the PLC
10.5 Recipe values in the HMI device and the PLC
Introduction
You can change the values of a recipe on the HMI device and therefore influence the
manufacturing process or a machine.
Depending on the configuration, the recipe values are displayed, edited and saved in
different ways:
If you are editing recipes with a recipe view in your project, the values are saved
in recipe data records
If you are editing recipes in a recipe screen in your project, the values are saved
in recipe tags
Differences may occur between the display values in the recipe view and the values saved in
the associated tags in an ongoing project when you edit recipes with a recipe view and in a
recipe screen. To prevent this, the recipe data record values must be synchronized with the
values of the recipe tags.
You have however the option to perform synchronization operations at any time.
Synchronization only takes place if the configuration engineer has activated the respective
settings for a recipe.

Note
Recipe tags can only be synchronized in the enhanced recipe view.

Synchronizing recipe tags
Synchronization of the recipe tags depends on the configuration:
Automatic synchronization:
The values of the recipe view are synchronized with the associated recipe tags. In this
case, changes to values in the recipe view have an immediate effect on the values of the
associated recipe tags. The values are only synchronized, when an operating element
that is outside the recipe view is operated.
Synchronization by the user:
The values of the recipe view and the associated recipe tags are not synchronized
automatically. The configuration engineer has assigned the same function to the
button or a different operating element in the recipe view. The recipe tags and the recipe
view are only synchronized when you operate the buttons or the appropriate operating
element.
ITEM 2500
Operating recipes
10.6 Operating the recipe view
Recipe tags online / offline
The configuration engineer can configure a recipe so that changes to the values of the recipe
tags do not have an immediate effect on the current process.
Synchronization of the recipe values between the HMI device and the PLC depends on
whether the configuration engineer has selected the settings "Tags online" or the setting
"Tags offline" for a recipe.
"Tags online":
This setting has the following effect:
When you change recipe values in the recipe screen, these changes are applied
immediately by the PLC and immediately influence the process
If recipe values are changed in the PLC, the changed values are displayed
immediately in the recipe screen
"Tags offline":
With this setting, changed recipe values are not synchronized immediately between the
HMI device and the PLC
In this case, the configuration engineer must configure operating elements for transferring
the values to the PLC or reading them from the PLC in a recipe screen. The recipe values
are only synchronized between HMI device and PLC when you operate the appropriate
operating element
10.6.1 Overview
Operation
The recipe view can be operated as follows:
Enter values for the recipe elements
Create recipe data records
Save recipe data records or save them under a new name
Delete recipe data records
Synchronize values of the recipe view with the associated recipe tags
Transfer recipe data records from the PLC and to the PLC
ITEM 2500
Operating recipes
Operating elements of the recipe view
The following table shows the operating elements of the recipe view.

Buttons Key combination Functions

CTRL
+
} {

Creates a new recipe data record.
If a start value is configured, it is shown in the text box.

CTRL
+
ENTER

Saves the displayed values of the recipe data record.
The storage location is predefined by the project.

CTRL
+
*

The recipe data record is saved under a different name irrespective
of the recipe view. A dialog box opens in which the name is entered.

CTRL
+
INS
DEL

The displayed recipe data record is deleted.

CTRL
+
=

The values of the recipe view are synchronized with the associated
recipe tags. The values changed during editing are written to the
associated recipe tags. Subsequently all the values of the tags are
read out and updated in the table.

CTRL
+
The recipe values from the PLC are displayed in the recipe view.

CTRL
+
The values of the set recipe data record displayed in the recipe view
are transferred to the PLC.
Operating the recipe screen
You operate the recipes in a recipe screen with the operating elements provided by the
configuration engineer.
10.6.2 Creating a recipe data record
Introduction
You create a new recipe data record by modifying an existing record. You then save the
modified data record under a new name.
Requirements
A screen with a recipe view is displayed.
ITEM 2500
Operating recipes
Proceed as follows:
1. If the recipe view contains several recipes: Select the recipe for which you want to create
a new recipe data record.
2. Touch .
A new recipe data record with the next available number is created.
If you change the new data record number to an existing data record number, the existing
data record is overwritten.
3. Enter values for the elements of the data record.
The elements of the recipe data record can be assigned default values depending on the
configuration.
4. Touch .
5. Enter a name for the data record.
The data record is saved under the new name.
If the recipe data record already exists, a dialog is opened. In this dialog, specify whether
the existing data record is to be overwritten.
Proceed as follows:
1. If the recipe view contains several recipes: Select the recipe for which you want to create
a new recipe data record.
2. Press
CTRL
+
} {
.
A new recipe data record with the next available number is created.
The elements of the recipe data record can be assigned default values depending on the
configuration.
4. Press
CTRL
+ * .
5. Enter a name for the data record.
6. Confirm your entry.
The data record is saved under the new name.
If the recipe data record already exists, a dialog is opened. In this dialog, specify whether
the existing data record is to be overwritten.
Result
The new recipe data record is saved to the selected recipe.
ITEM 2500
Operating recipes
10.6.3 Editing a recipe data record
Introduction
Edit the values of the recipe data records and save them in a recipe view.
Synchronization with the PLC
If you want to display the current recipe values from the PLC in the recipe view,
you first have to read the current values from the PLC with .
The values changed in the recipe view only become effective when the amended
data record is transferred to the PLC by means of the button.
Requirements
Proceed as follows:
1. If the recipe view contains several recipes: Select the recipe which contains the desired
recipe data record.
2. Select the recipe data record you want to change.
3. Change the data record as required.
4. Save your changes by means of the button.
If you want to save the recipe data record under a different name, touch the key.
5. The recipe data record is saved.
Proceed as follows:
recipe data record.
3. Change the data record as required.
4. Save your changes with
CTRL
+
ENTER
.
If you want to save the recipe data record under a different name, press
CTRL
+ * .
The recipe data record is saved.
Result
The edited recipe data record has now been saved in the selected recipe.
ITEM 2500
Operating recipes
10.6.4 Deleting a recipe data record
Introduction
You can delete all the data records of a recipe which are not required.
Requirements
Proceed as follows:
recipe data record.
2. Select the recipe data record you want to delete.
3. Touch .
Proceed as follows:
recipe data record.
2. Select the recipe data record you want to delete.
3. Press
CTRL
+
INS
DEL
.
Result
The recipe data record is deleted.
ITEM 2500
Operating recipes
10.6.5 Synchronizing tags
Introduction
The values of the recipe elements can be saved to recipe tags, depending on the
configuration.
Differences may occur between the display values in the recipe view and the actual values of
tags in an ongoing project. Synchronize the tags to equalize such differences.
Synchronization always includes all the variables which belong to a recipe data record.

NOTICE
Changed tag name
Tags and the value of the recipe data record cannot be assigned to each other if the tag
name of the tag to be synchronized has been changed. The tags in question are not
synchronized.

Note
Recipe tags can only be synchronized in the enhanced recipe view.

Requirements
Proceed as follows:
recipe data record.
2. Select the recipe data record you want to synchronize.
3. Touch .
Proceed as follows:
recipe data record.
2. Select the recipe data record you want to synchronize.
3. Press
CTRL
+
=
.

Result
The elements of the recipe data record are synchronized with the recipe tags.
If the values of the recipe view and the tag do not match, the more current value is accepted.
ITEM 2500
Operating recipes
10.6.6 Reading a recipe data record from the PLC
Introduction
In the current project, the values which are also stored in the recipes in the HMI device can
be changed directly in the plant. This is the case, for example, if a valve was opened further
directly at the plant than is stored in the recipe. The values of the recipe data records saved
in the HMI device possibly no longer match the values in the PLC.
To synchronize the recipe values, read the values from the PLC and display them in the
recipe view.
Requirements
Proceed as follows:
recipe data record.
2. Select the recipe data record to which you want to apply the values from the PLC.
3. Touch .
The values are read from the PLC.
4. If you want to store the displayed values in the HMI device, touch the button.
Proceed as follows:
recipe data record.
2. Select the recipe data record to which you want to apply the values from the PLC.
3. Press
CTRL
+ .
4. If you want to store the displayed values in the HMI device, press the keys
CTRL
+
ENTER
.
Result
The values were read from the PLC, displayed on the HMI device and saved to the selected
recipe data record.
ITEM 2500
Operating recipes
10.6.7 Transferring a recipe data record to the PLC
Introduction
In order for an edited recipe data record to take effect in the process, you must transfer the
values to the PLC.
The display values in the recipe view are always transferred to the PLC.
Requirements
Proceed as follows:
1. If the recipe view contains several recipes: Select the recipe which contains
the desired recipe data record.
2. Select the recipe data record whose values you want to transfer to the PLC.
3. Touch .
Proceed as follows:
1. If the recipe view contains several recipes: Select the recipe which contains
2. Select the recipe data record whose values you want to transfer to the PLC.
3. Press
CTRL
+ .
Result
The display values in the recipe view were transferred to the PLC and take effect
in the process.
ITEM 2500
Operating recipes
10.7 Operating the simple recipe view
10.7.1 Overview
Introduction
The simple recipe view consists of three areas:
Recipe list
Record list
Element list
You can use the context menu to operate each of these display areas.
Operation
The simple recipe view can be operated as follows:
Enter values for the recipe elements
Create recipe data records
Save recipe data records or save them under a new name
Delete recipe data records
Transfer recipe data records from the PLC and to the PLC
Operating elements of the simple recipe view
Toggle between the display areas and the context menus to operate the simple recipe views.
The following table shows the operation of the display area.

Touch operation Key control Functions
Touching an entry
ENTER

The next lower display area opens.

ESC

The next higher display area opens.

The context menu of the display area opens.

The following table shows the operation of the context menu.

Touch operation Key control Functions

ESC

The menu is closed.
The display area opens.
Touch the menu
command
Input of the number
of the menu
command
The menu command is executed.
ITEM 2500
Operating recipes
Context menus of the simple recipe view
A number is assigned to each menu command which you can use to call the menu
command with key control.
With touch operation, touch the menu command to execute it.
Some menu functions can also be called directly in the lists of the simple recipe view using
the keys.
Recipe list

No. Menu
command
Key combination Functions
0 New A new recipe data record is created for the selected
recipe.
1 Displaying
infotext
HELP

The infotext configured for the simple recipe view is
displayed.
2 Open
ENTER

The record list of the selected recipe opens.

Record list

No. Menu
command
0 New A new recipe data record is created for the selected
recipe.
1 Delete
INS
DEL

The selected record is deleted.
2 Save as The selected record is saved under a different name
irrespective of the simple recipe view. A dialog box
opens in which the name is entered.
3 Rename The selected record is renamed. A dialog box opens in
which the name is entered.
Element list

No. Menu
command
0 Save The selected record is renamed.
1 To PLC The display values of the selected record are
transferred from the HMI device to the PLC.
2 From PLC The recipe values from the PLC are displayed on the
HMI device in the recipe view.
3 Save as The selected record is renamed. A dialog box opens in
which the name is entered.
Touch operation of the menu
Touch the desired menu command. The command is executed.
ITEM 2500
Operating recipes
Key control of the menu
Select the required entry using or . Press
ENTER
.
Alternatively, press the numerical key with the number of the desired menu command.
The command is executed.
Operating the recipe screen
You operate the recipes in a recipe screen with the operating elements provided by the
configuration engineer.
10.7.2 Creating a recipe data record
Introduction
Create a new recipe data record in the recipe list or in the record list. Then enter the values
for the new record in the element list and save the record.
Requirements
A screen with a simple recipe view is displayed.
Procedure
Proceed as follows:
1. If the recipe list contains several recipes: Select the recipe for which you want to create a
new recipe data record.
2. Open the recipe list menu.
3. Select the menu command "0 New".
A new record is created.
The element list of the new record opens.
The tags of the record can be assigned default values depending on the configuration.
5. Open the element list menu and select the menu command "0 Save".
6. Enter a name for the new record.
Result
The new recipe data record is saved to the selected recipe.
ITEM 2500
Operating recipes
10.7.3 Editing a recipe data record
Introduction
Edit the values of the recipe data records in a simple recipe view.
Synchronization with the PLC
If you want to display the current recipe values from the PLC in the simple recipe view,
you first have to read the current values from the PLC with the menu command
"2 from PLC" in the element list.
The values changed in the recipe view only take effect in the PLC when you transfer
the edited data record to the PLC with the menu command "1 to PLC".
Requirements
Procedure
Proceed as follows:
1. If the recipe list contains several recipes: Select the recipe which contains
2. Open the data record list.
4. Open the element list.
5. Change the values of the records as required.
6. Save your changes with the menu command "0 Save".
The recipe data record is saved.
Result
The edited recipe data record has now been saved in the selected recipe.
ITEM 2500
Operating recipes
10.7.4 Deleting a recipe data record
Introduction
You can delete all the data records which are not required.
Requirements
Proceed as follows:
3. Select the data record you want to delete.
4. Open the menu.
5. Select the menu command "1 Delete".
Proceed as follows:
3. Select the data record you want to delete.
4. Press
INS
DEL
.
Result
The data record is deleted.
ITEM 2500
Operating recipes
10.7.5 Reading a recipe data record from the PLC
Introduction
The values of recipe elements are exchanged with the PLC via tags.
In the current project, the values which are also stored in the recipes in the HMI device can
be changed directly in the plant. This is the case, for example, if a valve was opened further
directly at the plant than is stored in the recipe. The values of the tags on the HMI device
possibly no longer match the values in the PLC.
To synchronize the recipe values, read the values from the PLC and display them in the
recipe view.
Requirements
Procedure
Proceed as follows:
2. Select the element list of the recipe data record to which you want to apply
the values from the PLC.
3. Open the menu.
4. Select the menu command "2 from PLC".
5. If you want to save the display values in the HMI device, select the menu
command "0 Save".
Result
The values were read from the PLC, displayed on the HMI device and saved to
the selected recipe data record.
ITEM 2500
Operating recipes
10.7.6 Transferring a recipe data record to the PLC
Introduction
In order for an edited recipe data record to take effect in the process, you must transfer the
values to the PLC.
The display values in the recipe view are always transferred to the PLC.
Requirements
Procedure
Proceed as follows:
2. Select the element list of the recipe data record whose values you want
to transfer to the PLC.
3. Open the menu.
4. Select the menu command "1 To PLC".
Result
The values of the recipe data record were transferred to the PLC and take effect
in the process.
ITEM 2500
Operating recipes
10.8 Importing a recipe data record
10.8 Importing a recipe data record
Introduction
You can import values from a CSV file to a recipe data record,
depending on the configuration.
Requirements
An operating element with the function "Import data record" has been configured,
for example a button
Procedure
Proceed as follows:
1. If the recipe view contains several recipes: Select the recipe which contains the recipe
data record to be imported.
2. Operate the operating element with the function "Import data record".
The record is imported from an external data medium as a CSV file and then displayed
in the recipe view after import.
Result
The imported recipe data record is saved on the HMI device.
Deviating structure
If the structure of the CSV file differs from the structure of the recipe, deviations are
handled as follows:
Any additional values in the CSV file will be rejected
The system applies the configured default value to the recipe data record if the CSV file
contains an insufficient number of values
If the CSV file contains values of the wrong data type, the configured default value is set
in the recipe data record
Example:
The imported CSV file contains values that were entered as floating point numbers.
However, the corresponding tag expects an integer value. In this case, the system
discards the imported value and uses the configured default.
ITEM 2500
Operating recipes
10.9 Exporting a recipe data record
10.9 Exporting a recipe data record
Introduction
You can export one or more recipe data records to a CSV file, depending on the
configuration. After export, the values in the recipe data record can be further processed in a
spreadsheet program such as MS Excel. The degree to which you can influence the export
depends on the configuration.
Requirements
An operating element with the function "Export record" has been configured.
The following tags are configured equally in the recipe view and for the
"Export record" operating element:
Recipe number
Data record number
Procedure
Proceed as follows:
recipe data record.
2. Select the recipe data record you want to export.
3. Operate the operating element which was configured for export, for example the
"Export data record" button.
The data record is exported as a CSV file to an external data medium.
Result
The recipe data record is exported.
ITEM 2500
Operating recipes
10.10 Examples
10.10 Examples
10.10.1 Entering a recipe data record
Introduction
You would like to enter production data on the HMI device without interrupting
the process in the machine or plant. For this reason, the production data should
not be transferred to the PLC.
Procedure
Proceed as follows:
1. Call the recipe view or a recipe screen.
2. Select the desired recipe data record.
3. Enter the values of the elements.
4. Save the recipe data record.
The recipe data record is saved in the internal memory of the HMI device.
The following figure shows the data flow schematically.
Recipe 1
Recipe 2
Recipe 3
Recipe n
PLC
Recipe view
Recipe
screen
Recipe tag
3
1
2
5
4

Display recipe data record
Save recipe data record
Tags are synchronized
Tags are offline
ITEM 2500
Operating recipes
10.10 Examples
10.10.2 Manual production sequence
Introduction
You request the production data of different workpieces from the PLC and display this data
on the screen of the HMI device for inspection. You want to correct the transferred
production data in the recipe view or the recipe screen if necessary.
Procedure
A scanner connected to the PLC reads the barcode of a workpiece. The barcode names
correspond to the names in the recipe data record. Based on the barcode name, the PLC
can read the required recipe data record. The recipe data record is displayed for inspection
on the HMI device. You can now edit and save the recipe data record. Then transfer the
edited recipe data record to the PLC again.
The following figure shows the data flow schematically.
Recipe 1
Recipe 2
Recipe 3
Recipe n
PLC
Recipe view
Recipe
screen
Recipe tag
3
1
4
1
2

The recipe data record is read from the PLC and written to the PLC again following
changes
Tags are synchronized
Recipe data records are saved in the recipe memory of the HMI device
ITEM 2500

11
11.1 Maintaining and caring for the touch screen and keyboard overlay
Introduction
The HMI device is designed for maintenance-free operation. The touch screen and
keyboard overlay should nevertheless be cleaned regularly.
Requirement
Damp cleaning cloth
Washing up liquid or foaming screen cleaning agent
Procedure
NOTICE
Unintentional response
If you clean the touch screen or an HMI device with a keyboard overlay when it is switched
on, you may cause maloperations.
Switch off the HMI device, or if the HMI device is running, clean the touch screen only in
a blocked state! Note that the touch screen block automatically ends after 15 seconds.
Damage caused by unauthorized cleaning products
Using compressed air or steam cleaners, or aggressive solutions or scouring agents will
damage the HMI device.
Do not clean the HMI device with compressed air or steam jet blowers. Do not use
aggressive solvents or scouring powder.

Proceed as follows:
1. Switch off the HMI device or block the touch screen.
2. Spray the cleaning solution onto a cleaning cloth.
Do not spray directly onto the HMI device.
3. Clean the HMI device.
When cleaning the display wipe from the screen edge inwards.
ITEM 2500
11.2 Clean screen on MP 377 Touch
11.2 Clean screen on MP 377 Touch
Introduction
The HMI touch screen can be cleaned when it is switched on and a project is running. An
operating element must be available in the project that can be used to call the "clean"
screen. Once the clean screen is activated, touch screen operation is locked for a configured
period of time. The time the touch screen is locked can be set between 5 and 30 seconds.
The time remaining for the lockout is indicated by a progress bar.

NOTICE
Unintentional responses
When cleaning the touch screen, an unintentional response in the controller can be
triggered by touching keys.
Always open the clean screen or switch off the HMI device before you clean the touch
screen while the system is running!
Once the period for the clean screen has passed, operations are again possible. Avoid data
inadvertent operations.
Cannot be operated when the clean screen is active
When the clean screen is active, operations on the HMI device are not possible.
Wait for the period for the clean screen to lapse. Then you can operate the plant again with
the HMI device.

11.3 Spare parts and repairs
Repairs
In case of repair, the HMI device must be shipped to the Return Center in Frth. Repairs
may only be carried out at the Return Center in Frth.
Depending on the work necessary to repair the device, the Center may decide to give you a
credit note. A credit note is only granted when the sender orders a new HMI device.
The address is:
Siemens AG
Industry Sector
Returns Center
Siemensstr. 2
90766 Frth
Germany
Spare parts
You can find spare parts and accessories for the HMI devices in
the section Accessories (Page 26).
ITEM 2500

12
12.1 Dimension drawings
12.1.1 Dimension drawings of the MP 377 12" Touch
All dimensions in mm.
Tolerance 1 mm
335
309
72
30 6
2
7
5
2
4
7
5
3
1
7

ITEM 2500
12.2 Specifications
12.2 Specifications
HMI device

MP 377
12" Touch
MP 377
12" Key
MP 377
15" Touch
MP 377 PRO
15" Touch
MP 377
19" Touch
Weight without packaging 3.75 kg 5.41 kg 4.69 kg Approx. 7.3 kg,
with basic
adapter approx.
7.7 kg
7.65 kg
Display

MP 377
12" Touch
MP 377
12" Key
MP 377
15" Touch
MP 377 PRO
15" Touch
MP 377
19" Touch
Type LCD TFT
Display area, active 246 mm x 184.5 mm (12.1") 304.1 mm x 228.1 mm (15") 376.3 mm x
301.1 mm
(19")
Resolution 800 x 600 pixels 1 024 x 768 pixels 1 280 x 1 024
pixels
Colors, displayable 64 K
Brightness control Yes
Backlighting
Half brightness life time, typical
CCFL
50 000 h
Pixel error class according to
DIN EN ISO 13406-2
II
Input device

MP 377
12" Touch
MP 377
12" Key
MP 377
15" Touch
MP 377 PRO
15" Touch
MP 377
19" Touch
Type Touch screen,
analog, resistive
Keyboard Touch screen, analog, resistive
Memory

MP 377
12" Touch
MP 377
12" Key
MP 377
15" Touch
MP 377 PRO
15" Touch
MP 377
19" Touch
Application memory 12 MB
ITEM 2500
12.2 Specifications
Interfaces

MP 377
12" Touch
MP 377
12" Key
MP 377
15" Touch
MP 377 PRO
15" Touch
MP 377
19" Touch
1 x RS 422/RS 485 Max. 12 Mbps, applies to DP operations
2 x USB 2.0 USB host
Conforms to USB standard 2 (supporting low-speed and full-speed USB devices),
maximum load 500 mA
2 x Ethernet RJ45 10/100 Mbps
Audio Line out
Supply voltage

MP 377
12" Touch
MP 377
12" Key
MP 377
15" Touch
MP 377 PRO
15" Touch
MP 377
19" Touch
Rated voltage
Voltage range, permissible
+24 V DC
19.2 to 28.8 V (20%, +20%)
Transients, maximum
permissible
35 V (500 ms)
Time between two transients,
minimum
50 s
Current consumption
Typical
Constant current,
maximum
Power on current surge I
2
t

Approx. 1 300 mA
Approx. 1 800 mA
Approx. 4 A
2
s

Approx. 1 700 mA
Approx. 2 500 mA
Approx. 4 A
2
s

Approx. 2 200
mA
Approx. 3 100
mA
Approx. 4 A
2
s
Fuse, internal Electronic
Miscellaneous

MP 377
12" Touch
MP 377
12" Key
MP 377
15" Touch
MP 377 PRO
15" Touch
MP 377
19" Touch
Realtime clock, buffered
1)
Yes
Loudspeaker Onboard
Magnetic field intensity 50/60 Hz;100 A/m RMS

1)
Bridging time of the buffering - approx. 6 weeks.
ITEM 2500
12.3 Bit assignment of the direct keys
12.3 Bit assignment of the direct keys
The following figures show the assignment of the keys and LEDs to the bytes in the
PLC process image.
Further information may be available in your plant documentation.

Note
Do not use the LED bits "ACK", "A-Z", and "HELP" when a project is running on
the HMI device.

Bit assignment of the direct keys for the MP 377 12" Key
0 7 1 4 6 5 3 2 0 7 1 4 6 5 3 2
Button bits LED bits
Byte
"n"
n+ 1
n+ 2
n+ 3
n+ 4
S8 S7 S6 S5 S4 S3 S2 S1
S14 S13 S12 S11 S10 S9 S15 S16
F6 F5 F2 F3 F4 F1 F7 F8
ACK ALT CTRL SHlFT
F12 F13 F14 F15 F16 F11 F10 F9
F20 F19 F18 F17
S8 S7 S6 S5 S4 S3 S2 S1
S14 S13 S12 S11 S10 S9 S15 S16
F6 F5 F2 F3 F4 F1 F7 F8
ACK A-Z A-Z lNFO
F12 F13 F14 F15 F16 F11 F10 F9
F20 F19 F18 F17
1) 2)

1)
Left LED
2)
Right LED
Bit assignment of the direct keys for the MP 377 12" Touch, MP 377 15" Touch and
MP 377 19" Touch
0 7 1 4 6 5 3 2
Touch assignment
Byte
n
n + 1
n + 2
n + 3
n + 4
7 6 5 4 3 2 1 0
13 12 11 10 9 8 14 15
21 20 17 18 19 16 22 23
39 38 37 36
27 28 29 30 31 26 25 24
35 34 33 32

ITEM 2500
12.4 Description of the ports
12.4.1 Power supply
Plug connector, 2-pin
1 2

Pin Assignment
1 +24 VDC (L+)
2 GND 24 V (M)
12.4.2 X10/IF 1B (RS 422/RS 485)
Sub-D socket, 9-pin, with screw lock
5 1
6 9

Pin Assignment for the RS 422 Assignment for the RS 485
1 n. c. n. c.
2 GND 24 V GND 24 V
3 TxD+ Data channel B (+)
4 RD+ RTS
1)

5 GND 5 V, floating GND 5 V, floating
6 +5 VDC, floating +5 VDC, floating
7 +24 VDC, out (max. 100 mA) +24 VDC, out (max. 100 mA)
8 TxD Data channel A ()
9 RxD RTS
1)

1)
On pin 4 or pin 9, can be set with DIP switch on the rear of the device
ITEM 2500
12.4.3 X1 (PROFINET)
RJ45 plug connector
1 8

Pin Assignment
1 Tx+
2 Tx
3 Rx+
4 n. c.
5 n. c.
6 Rx
7 n. c.
8 n. c.
12.4.4 X20, X21 (USB)
USB socket
1 4

Pin Assignment
1 +5 VDC, out (max. 500 mA)
2 USB-DN
3 USB-DP
4 GND
ITEM 2500
12.4.5 X40 (line out)
Line out connector
1
2
3

Pin Assignment
1 Left audio channel
2 Right audio channel
3 GND

ITEM 2500
ITEM 2500

Appendix
A
A.1 ESD guideline
Definition of ESD
All electronic modules are equipped with large-scale integrated ICs or components. Due to
their design, these electronic elements are highly sensitive to overvoltage, and thus to
any electrostatic discharge. These electronic components are therefore specially
identified as ESDs.
Abbreviations
The following abbreviation is commonly used for electrostatic sensitive devices:
EGB Elektrostatisch Gefhrdete Bauteile/Baugruppen (Germany)
ESD Electrostatic Sensitive Device (internationally recognized term)
Labeling
ESDs are labeled with the following symbol:

Electrostatic charging
CAUTION
Electrostatic charging
ESDs may be destroyed by voltages far below the level perceived by human beings.
Voltages of this kind develop when a component or an assembly is touched by a person
who is not grounded against static electricity. Usually, it is unlikely that damage to an ESD
as a result of overvoltage is detected immediately but may become apparent only after a
longer period of operation.
Prevent electrostatic charging of your body before you touch the ESD!

ITEM 2500
Appendix
A.1 ESD guideline
Anyone who is not connected to the electrical potential of their surroundings is subjected to
electrostatic charging.
The following figure indicates the maximum electrostatic charge anyone is subjected to when
coming into contact with the materials shown. These values correspond with specifications
to IEC 801-2.
2
3
1
5
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
10 20 30 40 50 60 70 80 90 100
16
[kV]
[%]
V
o
l
t
a
g
e
Relative humidity

Synthetic materials
Wool
Antistatic materials such as wood or concrete
Protective measures against electrostatic discharge
CAUTION
Observe grounding measures
When working with electrostatic sensitive devices, make sure that the person,
the workplace and the packaging are properly grounded. This helps to avoid
electrostatic charging.

As a rule, only touch the ESD if this is unavoidable, for example for maintenance. When you
touch modules, make sure that you do not touch the pins on the modules or the PCB tracks.
In this way, the discharged energy can not affect the sensitive devices.
Discharge electrostatic electricity from your body if you are performing measurements on an
ESD. Do so by touching grounded metallic parts.
Always use grounded measuring instruments.
ITEM 2500
Appendix
A.2 System alarms
A.2 System alarms
Introduction
System alarms on the HMI device provide information about internal states of the HMI device
and PLC.
The following overview shows the causes of system alarms and how to eliminate the cause
of error.
Some of the system alarms described in this section are relevant to individual HMI devices
based on their range of features.

Note
System alarms are only indicated if an alarm window was configured. System alarms are
output in the language currently set on your HMI device.

System alarm parameters
System alarms may contain encrypted parameters which are relevant to troubleshooting
because they provide a reference to the source code of the runtime software. These
parameters are output after the text "Error code:"
ITEM 2500
Appendix
A.2 System alarms
Meaning of the system alarms
All the system alarms that can be displayed are listed below. The system alarms are divided
into different ranges:
10000 - Printer alarms
Number Effect/cause Remedy
10000 The print job could not be started or was canceled
due to an unknown error. Faulty printer setup. Or:
No authorization is available for accessing the
network printer.
Power supply failure during data transfer.
Check the printer settings, cable connections and the
power supply.
Set up the printer once again. Obtain a network printer
authorization.
If the error persists, contact the Hotline!
10001 No printer is installed or a default printer has not
been set up.
Install a printer and/or select it as the default printer.
10002 Overflow of the graphics buffer for printing. Up to
two images are buffered.
Allow sufficient intervals between successive print jobs.
10003 Images can now be buffered again. --
10004 Overflow of the buffer for printing lines in text mode
(e.g. alarms). Up to 1000 lines are buffered.
Allow sufficient intervals between successive print jobs.
10005 Text lines can now be buffered again. --
10006 The Windows printing system reports an error.
Refer to the output text and the error ID to
determine the possible causes. Nothing is printed
or the print is faulty.
Repeat the action if necessary.

20000 - Global script alarms
Number Effect/causes Remedy
20010 An error has occurred in the specified script line.
Execution of the script was therefore aborted. Note
the system alarm that may have occurred prior to
this.
Select the specified script line in the configuration.
Ensure that the tags used are of the allowed types.
Check system functions for the correct number and
types of parameters.
20011 An error has occurred in a script that was called by
the specified script.
Execution of the script was therefore aborted in the
called script.
Note the system alarm that may have occurred
prior to this.
In the configuration, select the script that has been
called directly or indirectly by the specified script.
Ensure that the tags used are of the allowed types.
Check system functions for the correct number and
types of parameters.
20012 The configuration data is inconsistent. The script
could therefore not be generated.
Recompile the configuration.
20013 The scripting component of WinCC flexible
Runtime is not correctly installed. Therefore, no
scripts can be executed.
Reinstall WinCC flexible Runtime on your PC.
Rebuild your project with "Project > Generator >
Generate" and transfer the project to the HMI device.
20014 The system function returns a value that is not
written in any return tag.
Select the specified script in the configuration.
Check whether the script name has been assigned a
value.
20015 Too many successive scripts have been triggered
in short intervals. When more than 20 scripts are
queued for processing, any subsequent scripts are
rejected. In this case, the script indicated in the
alarm is not executed.
Find what is triggering the scripts. Extend the times,
e.g. the polling time of the tags which trigger the
scripts.

ITEM 2500
Appendix
A.2 System alarms
30000 - Alarms for IFwSetValue: SetValue()
30010 The tag could not accept the function result, e.g.
when it has exceeded the value range.
Check the tag type of the system function parameter.
30011 A system function could not be executed because
the function was assigned an invalid value or type
in the parameter.
Check the parameter value and tag type of the invalid
parameter. If a tag is used as a parameter, check its
value.
30012 A system function could not be executed because
the function was assigned an invalid value or type
in the parameter.
Check the parameter value and tag type of the invalid
parameter. If a tag is used as a parameter, check its
value.

40000 - Linear scaling alarms
40010 The system function could not be executed since
the parameters could not be converted to a
common tag type.
Check the parameter types in the configuration.
40011 The system function could not be executed since
the parameters could not be converted to a
common tag type.
Check the parameter types in the configuration.

50000 - Data server alarms
50000 The HMI device is receiving data faster than it is
capable of processing. Therefore, no further data is
accepted until all current data have been
processed. Data exchange then resumes.
--
50001 Data exchange has been resumed. --

60000 - Win32 function alarms
60000 This alarm is generated by the
DisplaySystemAlarms function. The text to be
displayed is transferred to the function as a
parameter.
--
60010 The file could not be copied in the direction defined
because one of the two files is currently open or the
source/target path is not available.
It is possible that the Windows user has no access
rights to one of the two files.
Restart the system function or check the paths of the
source/target files. Using Windows NT/2000/XP: The
user executing WinCC flexible Runtime must be
granted access rights for the files.
60011 An attempt was made to copy a file to itself.
It is possible that the Windows user has no access
rights to one of the two files.
Check the path of the source/target file.
Using Windows NT/2000/XP with NTFS: The user
executing WinCC flexible Runtime must be granted
access rights for the files.

ITEM 2500
Appendix
A.2 System alarms
70000 - Win32 function alarms
70010 The application could not be started because it
could not be found in the path specified or there is
insufficient memory space.
Check whether the application exists in the specified
path or close other applications.
70011 The system time could not be modified.
The error alarm only appears in connection with
area pointer "Date/time PLC". Possible causes:
An invalid time was transferred in the job
mailbox.
The Windows user has no right to modify the
system time.
If the first parameter in the system alarm is
displayed with the value 13, the second parameter
indicates the byte containing the incorrect value.
Check the time which is to be set.
Using Windows NT/2000/XP: The user executing
WinCC flexible Runtime must be granted the right to
change the system time of the operating system.
70012 An error occurred when executing the function
"StopRuntime" with the option "Runtime and
operating system".
Windows and WinCC flexible Runtime are not
closed.
One possible cause is that other programs cannot
be closed.
Close all programs currently running.
Then close Windows.
70013 The system time could not be modified because an
invalid value was entered. Incorrect separators may
have been used.
70014 The system time could not be modified. Possible
causes:
An invalid time was transferred.
The Windows user has no right to modify the
system time.
Windows rejects the setting request.
Using Windows NT/2000/XP: The user executing
WinCC flexible Runtime must be granted the right to
change the system time of the operating system.
70015 The system time could not be read because
Windows rejects the reading function.
--
70016 An attempt was made to select a screen by means
of a system function or job. This is not possible
because the screen number specified does not
exist.
Or: A screen could not be generated due to
insufficient system memory.
Or: The screen is blocked.
Or: Screen call has not been executed correctly.
Check the screen number in the function or job with the
screen numbers configured.
Assign the number to a screen if necessary.
Check the details for the screen call and whether the
screen is blocked for specific users.
70017 Date/time is not read from the area pointer because
the address set in the PLC is either not available or
has not been set up.
Change the address or set up the address in the PLC.
70018 Acknowledgment that the password list has been
successfully imported.
--
70019 Acknowledgment that the password list has been
successfully exported.
--
70020 Acknowledgment for activation of alarm reporting. --
70021 Acknowledgment for deactivation of alarm
reporting.
--
ITEM 2500
Appendix
A.2 System alarms
70022 Acknowledgment to starting the Import Password
List action.
--
70023 Acknowledgment to starting the Export Password
List action.
--
70024 The value range of the tag has been exceeded in
the system function.
The calculation of the system function is not
performed.
Check the desired calculation and correct it
if necessary.
70025 The value range of the tag has been exceeded in
the system function.
The calculation of the system function is not
performed.
if necessary.
70026 No other screens are stored in the internal screen
memory.
No other screens can be selected.
--
70027 The backup of the RAM file system has been
started.
--
70028 The files from the RAM have been copied in the
Flash memory.
The files from the RAM have been copied in the
Flash memory. Following a restart, these saved
files are copied back to the RAM file system.
--
70029 Backup of the RAM file system has failed.
No backup copy of the RAM file system has been
made.
Check the settings in the "Control Panel > OP" dialog
and save the RAM file system using the "Save Files"
button in the "Persistent Storage" tab.
70030 The parameters configured for the system function
are faulty.
The connection to the new PLC was not
established.
Compare the parameters configured for the system
function with the parameters configured for the PLCs
and correct them as necessary.
70031 The PLC configured in the system function is not
an S7 PLC.
The connection to the new PLC was not
established.
Compare the S7 PLC name parameter configured for
the system function with the parameters configured for
the PLC and correct them as necessary.
70032 The object configured with this number in the tab
order is not available in the selected screen.
The screen changes but the focus is set to the first
object.
Check the number of the tab order and correct it if
necessary.
70033 An e-mail cannot be sent because a TCP/IP
connection to the SMTP server no longer exists.
This system alarm is generated only at the first
attempt. All subsequent unsuccessful attempts to
send an e-mail will no longer generate a system
alarm. The event is regenerated when an e-mail
has been successfully sent in the meantime.
The central e-mail component in WinCC flexible
Runtime attempts, in regular intervals (1 minute), to
establish the connection to the SMTP server and to
send the remaining e-mails.
Check the network connection to the SMTP server and
re-establish it if necessary.
70034 Following a disruption, the TCP/IP connection to
the SMTP server could be re-established.
The queued e-mails are then sent.
--
ITEM 2500
Appendix
A.2 System alarms
70036 No SMTP server for sending e-mails is configured.
An attempt to connect to an SMTP server has
failed and it is not possible to send e-mails.
WinCC flexible Runtime generates the system
alarm after the first attempt to send an e-mail.
Configure an SMTP server:
In WinCC flexible Engineering System
using "Device settings > Device settings"
In the Windows CE operating system
using "Control Panel > Internet Settings > E-mail >
SMTP Server"
70037 An e-mail cannot be sent for unknown reasons.
The contents of the e-mail are lost.
Check the e-mail parameters (recipient etc.).
70038 The SMTP server has rejected sending or
forwarding an e-mail because the domain of the
recipient is unknown to the server or because the
SMTP server requires authentication.
The contents of the e-mail are lost.
Check the domain of the recipient address or
deactivate the authentication on the SMTP server if
possible. SMTP authentication is currently not used in
WinCC flexible Runtime.
70039 The syntax of the e-mail address is incorrect or
contains illegal characters.
The contents of the e-mail are discarded.
Check the e-mail address of the recipient.
70040 The syntax of the e-mail address is incorrect or
contains illegal characters.
--
70041 The import of the user management was aborted
due to an error.
Nothing was imported.
Check your user management or transfer it again to
the panel.
70042 The value range for the tags has been exceeded
while executing the system function.
The system function calculation has not been
carried out.
if necessary.
70043 The value range for the tags has been exceeded
while executing the system function.
The system function calculation has not been
carried out.
if necessary.

80000 - Archive alarms
80001 The log specified is filled to the size defined (in
percent) and must be stored elsewhere.
Store the file or table by executing a move or copy
function.
80002 A line is missing in the specified log. --
80003 The copying process for logging was not
successful.
In this case, it is advisable to check any
subsequent system alarms, too.
--
80006 Since logging is not possible, this causes a
permanent loss of the functionality.
In the case of databases, check whether the
corresponding data source exists and start up the
system again.
80009 A copying action has been completed successfully. --
80010 Since the storage location was incorrectly entered
in WinCC flexible, this causes a permanent loss of
the functionality.
Configure the storage location for the respective log
again and restart the system when the full functionality
is required.
ITEM 2500
Appendix
A.2 System alarms
80012 Log entries are stored in a buffer. If the values are
read to the buffer faster than they can be physically
written (using a hard disk, for example),
overloading may occur and recording is then
stopped.
Archive fewer values.
Or:
Increase the logging cycle.
80013 The overload status no longer applies. Archiving
resumes the recording of all values.
--
80014 The same action was triggered twice in quick
succession. Since the process is already in
operation, the action is only carried out once.
--
80015 This system alarm is used to report DOS or
database errors to the user.
--
80016 The logs are separated by the system function
"CloseAllLogs" and the incoming entries exceed
the defined buffer size.
All entries in the buffer are deleted.
Reconnect the logs.
80017 The number of incoming events cause a buffer
overflow. his can be caused, for example, by
several copying actions being activated at the
same time.
All copy jobs are deleted.
Stop the copy action.
80019 The connection between WinCC flexible and all
logs were closed, for example, after executing the
system function "CloseAllLogs".
Entries are written to the buffer and are then written
to the logs when a connection is re-established.
There is no connection to the storage location and
the storage medium may be replaced, for example.
--
80020 The maximum number of simultaneously copy
operations has been exceeded. Copying is not
executed.
Wait until the current copying actions have been
completed, then restart the last copy action.
80021 An attempt was made to delete a log which is still
busy with a copy action. Deletion has not been
executed.
Wait until the current copying actions have been
completed, then restart the last action
80022 An attempt was made to use the system function
"StartSequenceLog" to start a sequence log for a
log which is not configured as a sequence log. No
sequence log file is created.
In the project, check
If the "StartSequenceLog" system function was
properly configured
if the tag parameters are properly provided with
data on the HMI device
80023 An attempt was made to copy a log to itself.
The log is not copied.
In the project, check
if the "CopyLog" system function was properly
configured
if the tag parameters are properly provided with
data on the HMI device
80024 The "CopyLog" system function does not allow
copying when the target log already contains data
("Mode" parameter). The log is not copied.
Edit the "CopyLog" system function in the project if
necessary. Before you initiate the system function,
delete the destination log file.
ITEM 2500
Appendix
A.2 System alarms
80025 You have canceled the copy operation.
Data written up to this point are retained. The
destination log file (if configured) is not deleted.
The cancellation is reported by an error entry
$RT_ERR$ at the end of the destination log.
--
80026 This alarm is output after all logs are initialized.
Values are written to the logs from then on. Prior to
this, no entries are written to the logs, irrespective
whether WinCC flexible Runtime is active or not.
--
80027 The internal Flash memory has been specified as
the storage location for a log. This is not
permissible.
No values are written to this log and the log file is
not created.
Configure "Storage Card" or a network path as the
storage location.
80028 The alarm returns a status report indicating that the
logs are currently being initialized. No values are
logged until the alarm 80026 is output.
--
80029 The number of logs specified in the alarm could not
be initialized. The logs are initialized.
The faulty log files are not available for logging
jobs.
Evaluate the additional system alarms related to this
alarm. Check the configuration, the ODBC (Open
Database Connectivity) and the specified drive.
80030 The structure of the existing log file does not match
the expected structure.
Logging is stopped for this log.
Delete the existing log data manually, in advance.
80031 The log in CSV format is corrupted.
The log cannot be used.
Delete the faulty file.
80032 Logs can be assigned events. These are triggered
as soon as the log is full. If WinCC flexible Runtime
is started and the log is already full, the event is not
triggered.
The log specified no longer logs data because it is
full.
Close WinCC flexible Runtime, delete the log, then
restart WinCC flexible Runtime.
Or:
Configure a button which contains the same actions as
the event and press it.
80033 "System Defined" is set in the data log file as the
data source name. This causes an error. No data is
written to the database logs, whereas the logging to
the CSV logs works.
Install MSDE again.
80034 An error has occurred in the initialization of the
logs. An attempt has been made to create the
tables as a backup. This action was successful. A
backup has been made of the tables of the
corrupted log file and the cleared log was restarted.
No action is necessary. However, it is recommended to
save the backup files or delete them in order to make
the space available again.
80035 An error has occurred in the initialization of the
logs. An attempt has been made to create backups
of the tables and this has failed. No logging or
backup has been performed.
It is recommended to save the backups or to delete
them in order to release memory.
80044 The export of a log was interrupted because
Runtime was closed or due to a power failure. It
was detected that the export needed to be resume
when Runtime restarted.
The export resumes automatically.
ITEM 2500
Appendix
A.2 System alarms
80045 The export of a log was interrupted due to an error
in the connection to the server or at the server
itself.
The export is repeated automatically. Check:
The connection to the server
If the server is running
If there is enough free space on the server
80046 The destination file could not be written while
exporting the log.
Check whether there is enough space on the server
and it you have permission to create the log file.
80047 The log could not be read while exporting it. Check whether the storage medium is correctly
inserted.
80049 The log could not be renamed while preparing to
export it.
The job can not be completed."
Check whether the storage medium is correctly
inserted and if there is sufficient space on the medium.
80050 The log which shall be exported is not closed.
The job can not be completed.
Make sure the "CloseAll Logs" system function is
called before using the "ExportLog" system function.
Change the configuration as required.

90000 - FDA alarms
90024 No operator actions can be logged due to lack of
space on the storage medium for log. The operator
action will therefore not be executed.
Make more space available by inserting an empty
storage medium or swapping out the log files on the
server using "ExportLog".
90025 No user actions can be logged because of error
state of the archive. Therefore the user action will
not be executed.
Check whether the storage medium is correctly
inserted.
90026 No operator actions can be logged because the log
is closed. The operator action will therefore not be
executed.
Before further operator actions are carried out, the log
must be opened again using the system function
"OpenAllLogs". Change the configuration as required.
90028 The password you entered is incorrect. Enter the correct password.
90029 Runtime was closed during ongoing operation
(perhaps due to a power failure) or a storage
medium in use is incompatible with Audit Trail. An
Audit Trail is not suitable if it belongs to another
project or has already be archived.
Ensure that you are using the correct storage medium.
(perhaps due to a power failure).
--
(perhaps due to a power failure).
--
90032 Running out of space on the storage medium
for log.
90033 No more space on the storage medium for log. As
of now, no more operator actions requiring logging
will be executed.
90039 You do not have the necessary authorization to
perform this action.
Adapt or upgrade your authorizations.
90040 Audit Trail is switched off because of a forced user
action.
Activate the "Audit Trail" again using the system
function "StartLog".
ITEM 2500
Appendix
A.2 System alarms
90041 A user action which has to be logged has been
executed without a logged on user.
A user action requiring logging should only be possible
with permission. Change the configuration by setting a
required permission for the input object.
90044 A user action which has to be confirmed was
blocked, because there is another user action
pending.
Repeat the user action if necessary.

110000 - Offline function alarms
110000 The operating mode was changed. "Offline" mode
is now set.
--
110001 The operating mode was changed. "Online" mode
is now set.
--
110002 The operating mode was not changed. Check the connection to the PLCs.
Check whether the address area for the area pointer 88
Coordination" in the PLC is available.
110003 The operating mode of the specified PLC was
changed by the system function
"SetConnectionMode".
The operating mode is now "offline".
--
110004 The operating mode of the specified PLC has been
changed by the system function
"SetConnectionMode".
The operating mode is now "online".
--
110005 An attempt was made to use the system function
SetConnectionMode to switch the specified PLC to
"online" mode, although the entire system is in
"offline" mode. This changeover is not allowed.
The PLC remains in "offline" mode.
Switch the complete system to "online" mode, then
execute the system function again.
110006 The content of the "project version" area pointer
does not match the user version configured in
WinCC flexible. WinCC flexible Runtime is
therefore closed.
Check:
The project ID entered on the PLC.
The project ID entered in WinCC flexible.

120000 - Trend alarms
120000 The trend is not displayed because you configured
an incorrect axis to the trend or an incorrect trend.
Change the configuration.
120001 The trend is not displayed because you configured
an incorrect axis to the trend or an incorrect trend.
120002 The trend is not displayed because the tag
assigned attempts to access an invalid PLC
address.
Check whether the data area for the tag exists in the
PLC, the configured address is correct and the value
range for the tag is correct.

ITEM 2500
Appendix
A.2 System alarms
130000 - System information alarms
130000 The action was not executed. Close all other programs.
Delete files no longer required from the hard disk.
130001 The action was not executed. Delete files no longer required from the hard disk.
130002 The action was not executed. Close all other programs.
Delete files no longer required from the hard disk.
130003 No data medium found. The operation is canceled. Check, for example, if
The correct data medium is being accessed
The data medium is inserted
130004 The data medium is write-protected. The operation
is canceled.
Check whether access has been made to the correct
data carrier. Remove the write protection.
130005 The file is read only. The operation is canceled. Check whether access has been made to the correct
file. Edit the file attributes if necessary.
130006 Access to file failed. The operation is canceled. Check, for example, if
The correct file is being accessed
The file exists
Another action is preventing simultaneous access to
the file
130007 The network connection is interrupted.
Records cannot be saved or read over the network
connection.
Check the network connection and eliminate the cause
of error.
130008 The storage card is not available.
Records cannot be saved to / read from the
storage card.
Insert the storage card.
130009 The specified folder does not exist on the storage
card.
Any files saved to this directory are not backed up
when you switch off the HMI device.
Insert the storage card.
130010 The maximum nesting depth can be exhausted
when, for example, a value change in a script
results in the call of another script and the second
script in turn has a value change that results in the
call of yet a further script etc.
The configured functionality is not supported.
Check the configuration.

140000 - Connection alarms chns7: Connection + device
140000 An online connection to the PLC is established. --
140001 The online connection to the PLC was shut down. --
140003 No tag updating or writing is executed. Check the connection and if the PLC is switched on.
Check the parameter definitions in the Control Panel
using "Set PG/PC interface".
Restart the system.
ITEM 2500
Appendix
A.2 System alarms
140004 No tag update or write operations are executed
because the access point or the module
configuration is faulty.
Verify the connection and check whether the PLC is
switched on.
Check the access point or the module configuration
(MPI, PPI, PROFIBUS) in the Control Panel with "Set
PG/PC interface".
Restart the system.
140005 No tag updating or writing is executed because the
HMI device address is incorrect (possibly too high).
Use a different HMI device address.
Verify the connection and check whether the PLC is
switched on.
Restart the system.
140006 No tag updating or writing is executed because the
baud rate is incorrect.
Select a different baud rate in WinCC flexible
(according to module, profile, communication peer,
etc.).
140007 Tags are not updated or written because the bus
profile is incorrect (see %1).
The following parameters could not be written to
the registry:
1: Tslot
2: Tqui
3: Tset
4: MinTsdr
5: MaxTsdr
6: Trdy
7: Tid1
8: Tid2
9: Gap Factor
10: Retry Limit
Check the user-defined bus profile.
Check the connection and if the PLC is switched on.
Restart the system.
140008 No tag updating or writing is executed because
baud rate is incorrect. The following parameters
could not be written to the registry:
0: General error
1: Wrong version
2: Profile cannot be written to the registry.
3: The subnet type cannot be written to the
registry.
4: The Target Rotation Time cannot be written to
the registry.
5: Faulty Highest Address (HSA).
Check the connection and if the PLC is switched on.
Restart the system.
140009 Tags are not updated or written because the
module for S7 communication was not found.
Reinstall the module in the Control Panel using "Set
PG/PC interface".
140010 No S7 communication partner found because the
PLC is shut down.
DP/T:
The option PG/PC is the only master is not set in
the Control Panel under Set PG/PC interface.
Switch the PLC on.
DP/T:
If only one master is connected to the network, disable
"PG/PC is the only master" in "Set PG/PC interface".
If several masters are connected to the network, enable
these. Do not change any settings, for this will cause
bus errors.
140011 No tag updating or writing is executed because
communication is down.
Check the connection and that the communication
partner is switched on.
ITEM 2500
Appendix
A.2 System alarms
140012 There is an initialization problem (e.g. when
WinCC flexible Runtime was closed in Task
Manager).
Or:
Another application (e.g.STEP7) with different bus
parameters is active and the driver cannot be
started with the new bus parameters (transmission
rate, for example).
Restart the HMI device.
Or:
Run WinCC flexible Runtime, then start your other
applications.
140013 The MPI cable is disconnected and, thus, there is
no power supply.
Check the connections.
140014 The configured bus address is in already in use by
another application.
Edit the HMI device address in the PLC configuration.
140015 Wrong transmission rate
Or:
Faulty bus parameters (e.g. HSA)
Or:
OP address > HSA or: Wrong interrupt vector
(interrupt does not arrive at the driver)
Correct the relevant parameters.
140016 The hardware does not support the configured
interrupt.
Change the interrupt number.
140017 The set interrupt is in use by another driver. Change the interrupt number.
140018 The consistency check was disabled by
SIMOTION Scout. Only a corresponding note
appears.
Enable the consistency check with SIMOTION Scout
and once again download the project to the PLC.
140019 SIMOTION Scout is downloading a new project to
the PLC. Connection to the PLC is canceled.
Wait until the end of the reconfiguration.
140020 The version in the PLC and that of the project
(FWX file) do not match.
Connection to the PLC is canceled
The following remedies are available:
Download the current version to the PLC using
SIMOTION Scout.
Regenerate the project using WinCC flexible ES, close
WinCC flexible Runtime and restart with a new
configuration.

150000 - Connection alarms chnAS511: Connection
150000 No more data is read or written. Possible causes:
The cable is defective
The PLC does not respond, is defective, etc.
The wrong port is used for the connection
System overload
Ensure that the cable is plugged in, the PLC is
operational, the correct port is being used.
Restart the system if the system alarm persists.
150001 Connection is up because the cause of the
interruption has been eliminated.
--

ITEM 2500
Appendix
A.2 System alarms
160000 - Connection alarms IVar (WinLC) / OPC: Connection
System overload
--
160010 No connection to the server because the server
identification (CLS-ID) cannot be determined.
Values cannot be read or written.
Check access rights.
Check, for example, if
The server name is correct
The computer name is correct
The server is registered
Check, for example, if
The server name is correct
The computer name is correct
The server is registered
Note for advanced users:
Interpret the value from HRESULT.
160013 The specified server was started as InProc server.
This has not been released and may possibly lead
to incorrect behavior because the server is running
in the same process area as the WinCC flexible
Runtime software.
Configure the server as OutProc Server or Local
Server.
160014 Only one OPC server project can be started on a
PC/MP. An alarm is output when an attempt is
made to start a second project.
The second project has no OPC server
functionality and cannot be located as an OPC
server by external sources.
Do not start a second project with OPC server
functionality on the computer.

170000 - S7 dialog alarms
170000 S7 diagnostics events are not indicated because it
is not possible to log on to the S7 diagnostics
functions at this device. The service is not
supported.
--
170001 The S7 diagnostics buffer cannot be viewed
because communication with the PLC is shut
down.
Set the PLC to online mode.
170002 The S7 diagnostics buffer cannot be viewed
because reading of the diagnostics buffer (SSL)
was canceled with error.
--
170003 An S7 diagnostics event cannot be visualized. The
system returns internal error %2.
--
ITEM 2500
Appendix
A.2 System alarms
170004 An S7 diagnostics event cannot be visualized. The
system returns an internal error of error class %2,
error number %3.
--
170007 It is not possible to read the S7 diagnostics buffer
(SSL) because this operation was canceled with an
internal error of class %2 and error code %3.
--

180000 - Misc/common alarms
180000 A component/OCX received configuration data with
a version ID which is not supported.
Install a newer component.
180001 System overload because too many actions
running in parallel. Not all the actions can be
executed, some are rejected.
Several remedies are available:
Generate the alarms at a slower rate (polling)
Initiate scripts and functions at greater intervals
If the alarm appears more frequently:
Restart the HMI device.
180002 The screen keyboard could not be activated.
Possible causes:
"TouchInputPC.exe" was not registered due to a
faulty Setup.
Reinstall WinCC flexible Runtime.

190000 - Tag alarms
190000 It is possible that the tag is not updated. --
190001 The tag is updated after the cause of the last error
state has been eliminated (return to normal
operation).
--
190002 The tag is not updated because communication
with the PLC is down.
Select the system function "SetOnline" to go online.
190004 The tag is not updated because the configured tag
address does not exist.
190005 The tag is not updated because the configured
PLC type does not exist for this tag.
190006 The tag is not updated because it is not possible to
map the PLC type in the data type of the tag.
190007 The tag value is not modified because the
connection to the PLC is interrupted or the tag is
offline.
Set online mode or reconnect to the PLC.
190008 The threshold values configured for the tag have
been violated, for example, by
A value entered
A system function
A script
Observe the configured or current threshold values of
the tag.
ITEM 2500
Appendix
A.2 System alarms
190009 An attempt has been made to assign the tag a
value which is outside the permitted range of
values for this data type.
For example, a value of 260 was entered for a byte
tag or a value of -3 for an unsigned word tag.
Observe the range of values for the data type of the
tags.
190010 Too many values are written to the tag (for
example, in a loop triggered by a script).
Values are lost because only up to 100 actions are
saved to the buffer.
Increase the time interval between multiple write
actions.
Do not use an array tag longer than 6 words when
you configure an acknowledgment on the HMI
device using "Acknowledgment HMI".
190011 Possible cause 1:
The value entered could not be written to the
configured PLC tag because the high or low limit
was exceeded.
The system discards the entry and restores the
original value.
Possible cause 2:
The connection to the PLC was interrupted.

Make sure that the value entered lies within the range
of values of the control tags.

Check the connection to the PLC.
190012 It is not possible to convert a value from a source
format to a target format, for example:
An attempt is being made to assign a value to a
counter that is outside the valid, PLC-specific value
range.
A tag of the type Integer should be assigned a
value of the type String.
Check the range of values or the data type of the tags.
190013 The user has entered a string that is longer than
the tag. The string is automatically shortened to the
permitted length.
Only enter strings that do not exceed the permitted tag
length.

ITEM 2500
Appendix
A.2 System alarms
190100 - Area pointer alarms
190100 The area pointer is not updated because the
address configured for this pointer does not exist.
Type
1 Warnings
2 Errors
3 PLC acknowledgment
4 HMI device acknowledgment
5 LED mapping
6 Trend request
7 Trend transfer 1
8 Trend transfer 2
No.:
Consecutive number displayed in WinCC flexible
ES.
190101 The area pointer is not updated because it is not
possible to map the PLC type to the area pointer
type.
Parameter type and no.:
see alarm 190100
--
190102 The area pointer is updated after the cause of the
last error state has been eliminated (return to
normal operation). Parameter type and no.: See
alarm 190100.
--

200000 - PLC coordination alarms
200000 Coordination is not executed because the address
configured in the PLC does not exist/is not set.
Change the address or set up the address in the PLC.
200001 Coordination is canceled because the write access
to the address configured in the PLC is not
possible.
Change the address or set the address in the PLC at an
area which allows write access.
200002 Coordination is not carried out at the moment
because the address format of the area pointer
does not match the internal storage format.
Internal error
200003 Coordination can be executed again because the
last error state is eliminated (return to normal
operation).
--
200004 The coordination may not be executed. --
System overload
Ensure that the cable is plugged in and the PLC is
operational.

ITEM 2500
Appendix
A.2 System alarms
200100 - PLC user version alarms
200100 Coordination is not executed because the address
configured in the PLC does not exist/is not set.
Change the address or set up the address in the
PLC.
200101 Coordination is canceled because the write access to
the address configured in the PLC is not possible.
Change the address or set the address in the PLC at
an area which allows write access.
200102 Coordination is not carried out at the moment
because the address format of the area pointer does
not match the internal storage format.
Internal error
200103 Coordination can be executed again because the last
error state is eliminated (return to normal operation).
--
200104 The coordination may not be executed. --
System overload
Ensure that the cable is plugged in and the PLC is
operational.

210000 - PLC job alarms
210000 Jobs are not processed because the address
configured in the PLC does not exist/has not been set
up.
PLC.
210001 Jobs are not processed because read/write access to
the address configured in the PLC is not possible.
PLC in an area which allows read/write access.
210002 Jobs are not executed because the address format of
the area pointer does not match the internal storage
format.
Internal error
210003 The job buffer is processed again because the last
error status has been eliminated (return to normal
operation).
--
210004 It is possible that the job buffer will not be processed. --
210005 A control request with an illegal number was initiated. Check the PLC program.
210006 An error occurred while attempting to execute the
control request. As a result, the control request is not
executed. Observe the next/previous system alarms.
Check the parameters of the control request.
Recompile the configuration.

220000 - WinCC channel adapter alarms
220001 The tag is not downloaded because the associated
communication driver / HMI device does not support
the download of Boolean/discrete data types.
220002 The tag is not downloaded because the associated
communication driver / HMI device does not support
write access to the data type BYTE.
220003 The communication driver cannot be loaded. The
driver may not be installed.
Install the driver by reinstalling WinCC flexible
Runtime.
ITEM 2500
Appendix
A.2 System alarms
220004 Communication is down and no update data is
transferred because the cable is not connected or
defective etc.
Check the connection.
220005 Communication is up. --
220006 The connection between the specified PLC and the
specified port is active.
--
220007 The connection to the specified PLC is interrupted at
the specified port.
Check whether
The cable is plugged in
The PLC is OK
The correct port is used
Your configuration is OK (port parameters,
protocol settings, PLC address)
220008 The communication driver cannot access or open the
specified port. The port may be in use by another
application or the port used is not available on the
destination device.
There is no communication with the PLC.
Close all the applications which access this port and
restart the computer.
Use another port of the system.

230000 - View alarms
230000 The value entered could not be accepted. The system
discards the entry and restores the previous value.
Either
The value range has been exceeded
Illegal characters have been entered
The maximum permitted number of users has
been exceeded
Enter a practical value or delete any unneeded
users.
230002 The currently logged in user has not the required
authorization. The system therefore discards the input
and restored the previous value.
Log on as a user with appropriate authorization.
230003 Changeover to the specified screen failed because
the screen is not available/configured. The current
screen remains selected.
Configure the screen and check the screen selection
function.
230005 The value range of the tag has been exceeded in the
I/O field.
The original value of the tag is retained.
Observe the range of values for the tag when
entering a value.
230100 During navigation in the web browser, the system
returned a message which may be of interest to the
user.
The web browser continues to run but may not (fully)
show the new page.
Navigate to another page.
230200 The connection to the HTTP channel was interrupted
due to an error. This error is explained in detail by
another system alarm.
Data is no longer exchanged.
Check the network connection.
Check the server configuration.
230201 The connection to HTTP channel was established.
Data is exchanged.
--
ITEM 2500
Appendix
A.2 System alarms
230202 WININET.DLL has detected an error. This error
usually occurs when an attempt to connect to the
server fails or the server refuses to connect because
the client lacks the proper authorization.
An unknown server certificate may also be the cause
if the connection is encrypted by means of SSL.
The alarm text provides details.
This text is always in the language of the Windows
installation because it is returned by the Windows OS.
Process values are no longer exchanged.
Depending on the cause:
When an attempt to connect fails or a timeout error
occurs:
Check the network connection and the network
Check the server address
Check whether the WebServer is actually running
on the destination station.
Faulty authorization:
The configured user name and/or password do
not match those on the server. Establish
consistency
When the server certificate is rejected:
Certificate signed by an unknown CA ( ):
Either ignore this item in your project, or
Install a certificate that has been signed with a
root certificate known to the client computer
The date of the certificate is invalid:
Install a certificate with a valid date on the server
Invalid CN (Common Name or Computer Name):
Install a certificate with a name that corresponds
to that of the server address
230203 Although a connection can be made to the server, the
HTTP server refuses to connect because
WinCC flexible Runtime is not running on the
server, or
The HTTP channel is not supported (503 Service
unavailable)
Other errors can only occur if the Webserver does not
support the HTTP channel. The language of the alarm
text depends on the Webserver.
Data is not exchanged.
Error 503 Service unavailable:
Check that WinCC flexible Runtime is running on the
server and the HTTP channel is supported.
230301 An internal error has occurred. An English text
explains the error in more detail. This may be caused
by insufficient memory.
OCX does not work.
--
230302 The name of the remote server cannot be resolved.
The attempt to connect failed.
Check the configured server address.
Check whether the DNS service is available on the
network.
230303 The remote server is not running on the addressed
computer.
Wrong server address.
The attempt to connect failed
Check the configured server address.
Check whether the remote server is running on the
target computer.
230304 The remote server on the addressed computer is
incompatible with VNCOCX.
Use a compatible remote server.
230305 The authentication has failed because the password
is incorrect.
Configure the correct password.
ITEM 2500
Appendix
A.2 System alarms
230306 Error in the connection to the remote server. This may
occur as a result of network problems.
Check whether
The bus cable is plugged in
There are network problems
230307 The connection to the remote server was shut down
because
The remote server was shut down, or
The user instructed the server to close all
connections
The connection is closed.
--
230308 This alarm provides information on the connection
status.
An attempt is made to connect.
--

240000 - Authorization alarms
240000 WinCC flexible Runtime is operating in demo mode.
You have no authorization or your authorization is
corrupted.
Install the authorization.
240001 WinCC flexible Runtime is operating in demo mode.
Too many tags are configured for the installed
version.
Load an adequate authorization / powerpack.
240002 WinCC flexible Runtime is operating with a time-
limited emergency authorization.
Restore the full authorization.
240004 Error while reading the emergency authorization.
WinCC flexible Runtime is operating in demo mode.
Restart WinCC flexible Runtime, install the
authorization or repair the authorization (see
Commissioning Instructions Software Protection).
240005 The Automation License Manager has detected an
internal system fault.
Possible causes:
A corrupt file
A defective installation
No free space for the Automation License
Manager etc.
Reboot the HMI device or PC. If this does not solve
the problem, remove the Automation License
Manager and install it again.

250000 - S7 Force alarms
250000 The tag in the specified line in "Status Force" is not
updated because the address configured for this tag
is not available.
Check the set address and then verify that the
address is set up in the PLC.
updated because the PLC type configured for this tag
does not exist.
Check the set address.
ITEM 2500
Appendix
A.2 System alarms
updated because it is not possible to map the PLC
type in the tag type.
Check the set address.
250003 An attempt to connect to the PLC failed. The tags are
not updated.
Check the connection to the PLC. Check that the
PLC is switched on and is online.

260000 - Password system alarms
260000 An unknown user or an unknown password has been
entered in the system.
The current user is logged off from the system.
Log on to the system as a user with a valid
password.
260001 The logged in user does not have sufficient
authorization to execute the protected functions on
the system.
Log on to the system as a user with sufficient
authorization.
260002 This alarm is triggered by the system function
"TrackUserChange".
--
260003 The user has logged off from the system. --
260004 The user name entered into the user view already
exists in the user management.
Select another user name because user names have
to be unique in the user management.
260005 The entry is discarded. Enter a shorter user name.
260006 The entry is discarded. Use a shorter or longer password.
260007 The logon timeout value entered is outside the valid
range of 0 to 60 minutes.
The new value is discarded and the original value is
retained.
Enter a logon timeout value between 0 and 60
minutes.
260008 An attempt was made to read a PTProRun.pwl file
created with ProTool V 6.0 in WinCC flexible.
Reading the file was canceled due to incompatibility of
the format.
--
260009 You have attempted to delete the user "Admin" or
"PLC User". These users are fixed components of the
user management and cannot be deleted.
If you need to delete a user, because perhaps you
have exceeded the maximum number permitted,
delete another user.
260012 The passwords entered in the "Change Password"
dialog and the confirmation field are not identical.
The password has not been changed. User will be
logged off.
You have to log on to the system again. Then enter
the identical password twice to be able to change the
password.
260013 The password entered in the "Change Password"
dialog is invalid because it is already in use.
The password has not been changed. User will be
logged off.
You have to log on to the system again. Then enter
a new password that has not been used before.
260014 You have tried unsuccessfully to log on 3 times in
succession.
You will be locked out and assigned to group no. 0.
You can log on to the system with your correct
password. Only an administrator can change the
assignment to a group.
260023 The password you entered does not meet the
necessary security guidelines.
Enter a password that contains at least one number.
Enter a password that contains at least one
character.
ITEM 2500
Appendix
A.2 System alarms
Enter a password that contains at least one special
character.
260028 Upon system start-up, an attempt to log on, or when
trying to change the password of a SIMATIC log-on
user, the system attempts to access the SIMATIC
Logon Server.
If attempting to log on, the new user is not logged in. If
a different user was logged on before, then this user
is logged off.
Check the connection to the SIMATIC Logon Server
and its configuration; for example:
1. Port number
2. IP address
3. Server name
4. Functional transfer cable
Or use a local user.
260029 The SIMATIC Logon user is not associated to any or
several groups.
The new user is not logged in. If a different user was
logged on before, then this user is logged off.
Check the user data on the SIMATIC Logon Server
and the configuration in your WinCC flexible project.
A user may only be assigned to one group.
260030 The SIMATIC Logon user could not change his
password on the SIMATIC Logon Server. The new
password may not comply with the password
regulations on the server or the user does not have
the right to change his password.
The old password remains and the user is logged off.
Log in again and choose a different password.
Check the password rules on the SIMATIC Logon
Server.
260031 It was not possible to log the user on to the SIMATIC
Logon Server. The user name or the password could
be incorrect or the user does not have sufficient rights
to log on.
Try again. If necessary, check the password data on
the SIMATIC Logon Server.
260032 It was not possible to log the user on to the SIMATIC
Logon Server as his account is blocked.
Check the user data on the SIMATIC Logon Server.
260033 The action change password or log on user could not
be carried out.
Check the configuration of the SIMATIC Logon
Server.
260034 The last logon operation has not yet ended. A user
action or a logon dialog can therefore not be called.
The logon dialog is not opened. The user action is not
executed.
Wait until the logon operation is complete.
260035 The last attempt to change the password was not
completed. A user action or a logon dialog can
therefore not be called.
The logon dialog is not opened. The user action is not
executed.
Wait until the procedure is complete.
260036 There are insufficient licenses on the SIMATIC Logon
Sever. The logon is not authorized.
Check the licensing on the SIMATIC Logon Server.
260037 There is no license on the SIMATIC Logon Sever. A
logon is not possible.
It is not possible to log on via the SIMATIC Logon
Server, only via a local user.
Check the licensing on the SIMATIC Logon Server.

ITEM 2500
Appendix
A.2 System alarms
270000 - System alarms
270000 A tag is not indicated in the alarm because it attempts
to access an invalid address in the PLC.
Check whether the data area for the tag exists in the
PLC, the configured address is correct and the value
range for the tag is correct.
270001 There is a device-specific limit as to how many alarms
may be queued for output (see the operating
instructions). This limit has been exceeded.
The view no longer contains all the alarms.
However, all alarms are written to the alarm buffer.
--
270002 The view shows alarms of a log for which there is no
data in the current project.
Wildcards are output for the alarms.
Delete older log data if necessary.
270003 The service cannot be set up because too many
devices want to use this service.
A maximum of four devices may execute this action.
Reduce the number of HMI devices which want to
use the service.
270004 Access to persistent buffer is not possible. Alarms
cannot be restored or saved.
If the problems persist at the next startup, contact
Customer Support (delete Flash).
270005 Persistent buffer damaged: Alarms cannot be
restored.
If the problems persist at the next startup, contact
Customer Support (delete Flash).
270006 Project modified: Alarms cannot be restored from the
persistent buffer.
The project was generated and transferred new to
the HMI device; The error should no longer occur
when the device starts again.
270007 A configuration problem is preventing the restore (a
DLL is missing, a directory is unknown, etc.).
Update the operating system and then transfer your
project again to the HMI device.

280000 - DPHMI alarms Connection
--
System overload
Check whether
The PLC is OK
280002 The connection used requires a function block in the
PLC.
The function block has responded. Communication is
now enabled.
--
ITEM 2500
Appendix
A.2 System alarms
280003 The connection used requires a function block in the
PLC.
The function block has not responded.
Check whether
The PLC is OK
Remedy depends on the error code:
1: The function block must set the COM bit in the
response container.
2: The function block must not set the ERROR bit in
the response container.
3: The function block must respond within the
specified time (timeout).
4: Go online to the PLC.
280004 The connection to the PLC is interrupted. There is no
data exchange at present.
Check the connection parameters in WinCC flexible.

290000 - Recipe system alarms
290000 The recipe tag could not be read or written. It is
assigned the start value.
The alarm can be entered in the alarm buffer for up to
four more failed tags if necessary. After that, alarm
290003 is output.
Check in the configuration that the address has been
set up in the PLC.
290001 An attempt has been made to assign a value to a
recipe tag which is outside the value range permitted
for this type.
four more failed tags if necessary. After that, alarm
290004 is output.
Observe the value range for the tag type.
290002 It is not possible to convert a value from a source
format to a target format.
four more failed recipe tags if necessary. After that,
alarm 290005 is output.
Check the value range or type of the tag.
290003 This alarm is output when alarm number 290000 is
triggered more than five times.
In this case, no further separate alarms are
generated.
Check in the configuration that the tag addresses
have been set up in the PLC.
generated.
Observe the value range for the tag type.
generated.
Check the value range or type of the tag.
290006 The threshold values configured for the tag have been
violated by values entered.
Observe the configured or current threshold values
of the tag.
ITEM 2500
Appendix
A.2 System alarms
290007 There is a difference between the source and target
structure of the recipe currently being processed. The
target structure contains an additional data recipe tag
which is not available in the source structure.
The data recipe tag specified is assigned its start
value.
Insert the specified data recipe tag in the source
structure.
290008 There is a difference between the source and target
structure of the recipe currently being processed. The
source structure contains an additional data recipe tag
which is not available in the target structure and
therefore cannot be assigned.
The value is rejected.
Remove the specified data recipe tag in the specified
recipe from the project.
290010 The storage location configured for the recipe is not
permitted.
Possible causes:
Illegal characters, write protection, data carrier out of
space or does not exist.
Check the configured storage location.
290011 The record with the specified number does not exist. Check the source for the number (constant or tag
value)
290012 The recipe with the specified number does not exist. Check the source for the number (constant or tag
value)
290013 An attempt was made to save a record under a record
number which already exists.
The action is not executed.
Check the source for the number (constant or tag
value)
First, delete the record
Change the "Overwrite" function parameter
290014 The file specified to be imported could not be found. Check:
The file name
Ensure that the file is in the specified directory
290020 Alarm reporting that the download of records from the
HMI device to the PLC has started.
--
HMI device to the PLC was completed.
--
HMI device to the PLC was canceled due to an error.
Check in the configuration whether:
The tag addresses are configured in the PLC
The recipe number exists
The record number exist
The "Overwrite" function parameter is set
PLC to the HMI device has started.
--
PLC to the HMI device was completed.
---
PLC to the HMI device was canceled due to an error.
Check in the configuration whether:
The tag addresses are configured in the PLC
The recipe number exists
The record number exist
The "Overwrite" function parameter is set
ITEM 2500
Appendix
A.2 System alarms
290026 An attempt has been made to read/write a record
although the record is not free at present.
This error may occur in the case of recipes for which
downloading with synchronization has been
configured.
Set the record status to zero.
290027 Unable to connect to the PLC at present. As a result,
the record can neither be read nor written.
Possible causes:
No physical connection to the PLC (no cable plugged
in, cable is defect) or the PLC is switched off.
Check the connection to the PLC.
290030 This alarm is output after you selected screen which
contains a recipe view in which a record is already
selected.
Reload the record from the storage location or retain
the current values.
290031 While saving, it was detected that a record with the
specified number already exists.
Overwrite the record or cancel the action.
290032 While exporting records it was detected that a file with
the specified name already exists.
Overwrite the file or cancel the process.
290033 Confirmation request before deleting records. --
290040 A record error with error code %1 that cannot be
described in more detail occurred.
The action is canceled.
It is possible that the record was not installed correctly
on the PLC.
Check the storage location, the record, the "Data
record" area pointer and if necessary, the connection
to the PLC.
Restart the action after a short time.
If the error persists, contact Customer Support.
Forward the relevant error code to Customer
Support.
290041 A record or file cannot be saved because the storage
location is full.
Delete files no longer required.
290042 An attempt was made to execute several recipe
actions simultaneously. The last action was not
executed.
Trigger the action again after waiting a short period.
290043 Confirmation request before storing records. --
290044 The data store for the recipe has been destroyed and
is deleted.
--
290050 Alarm reporting that the export of records has started. --
290051 Alarm reporting that the export of records was
completed.
--
290052 Alarm reporting that the export of records was
canceled due to an error.
Ensure that the structure of the records at the
storage location and the current recipe structure on
the HMI device are identical.
290053 Alarm reporting that the import of records has started. --
290054 Alarm reporting that the import of records was
completed.
--
290055 Alarm reporting that the import of records was
Ensure that the structure of the records at the
storage location and the current recipe structure on
the HMI device are identical.
290056 Error when reading/writing the value in the specified
line/column.
The action was canceled.
Check the specified line/column.
ITEM 2500
Appendix
A.2 System alarms
290057 The tags of the recipe specified were toggled from
"offline" to "online" mode.
Each change of a tag in this recipe is now
immediately downloaded to the PLC.
--
290058 The tags of the specified recipe were toggled from
"offline" to "online" mode.
Modifications to tags in this recipe are no longer
immediately transferred to the PLC but must be
transferred there explicitly by downloading a record.
--
290059 Alarm reporting that the specified record was saved. --
290060 Alarm reporting that the specified record memory was
cleared.
--
290061 Alarm reporting that clearing of record memory was
--
290062 The record number is above the maximum of 65536.
This record cannot be created.
Select another number.
290063 This occurs with the system function
"ExportDataRecords" when the parameter "Overwrite"
is set to No.
An attempt has been made to save a recipe under a
file name which already exists.
The export is canceled.
Check the "ExportDataRecords" system function.
290064 Alarm reporting that the deletion of records has
started.
--
290065 Alarm reporting that the deletion of records has
successfully completed.
--
290066 Confirmation request before deleting records. --
290068 Security request to confirm if all records in the recipe
should be deleted.
--
290069 Security request to confirm if all records in the recipe
should be deleted.
--
290070 The record specified is not in the import file. Check the source of the record number or record
name (constant or tag value).
290071 During the editing of record values, a value was
entered which exceeded the low limit of the recipe
tag.
The entry is discarded.
Enter a value within the limits of the recipe tag.
290072 When editing record values, a value was entered
which exceeds the high limit of the recipe tag.
The entry is discarded.
Enter a value within the limits of the recipe tag.
290073 An action (e.g. saving a record) failed due to an
unknown error.
The error corresponds to the status alarm
IDS_OUT_CMD_EXE_ERR in the large recipe view.
--
290074 While saving, it was detected that a record with the
specified number already exists but under another
name.
Overwrite the record, change the record number or
cancel the action.
290075 A record with this name already exists.
The record is not saved.
Please select a different record name.
ITEM 2500
Appendix
A.2 System alarms
290110 The default values could not be set due to an error. --
290111 The Recipes subsystem cannot be used. Recipe
views have no content and recipe-specific functions
will not be performed.
Possible causes:
An error occurred while transferring the recipes.
The recipe structure was changed in ES. When
the project was downloaded again, the recipes
were not transferred with it. This means that the
new configuration data is not being transferred to
the old recipes on the device.
Transfer the project to the device again, together
with the recipes (the corresponding check box in the
Transfer dialog must be checked).

300000 - Alarm_S alarms
300000 Faulty configuration of process monitoring (e.g. using
PDiag or S7-Graph): More alarms are queued than
specified in the specifications of the CPU. No further
ALARM_S alarms can be managed by the PLC and
reported to the HMI devices.
Change the PLC configuration.
300001 ALARM_S is not registered on this PLC. Select a controller that supports the ALARM_S
service.

310000 - Report system alarms
310000 An attempt is being made to print too many reports in
parallel.
Only one log file can be output to the printer at a given
time; the print job is therefore rejected.
Wait until the previous active log was printed.
Repeat the print job if necessary.
310001 An error occurred on triggering the printer. The report
is either not printed or printed with errors.
Evaluate the additional system alarms related to this
alarm.
Repeat the print job if necessary.

320000 - Alarms
320000 The movements have already been indicated by
another device.
The movements can no longer be controlled.
Deselect the movements on the other display units
and select the motion control screen on the required
display unit.
320001 The network is too complex.
The faulty addresses cannot be indicated.
View the network in STL.
320002 No diagnosable alarm message (error) selected.
The unit associated with the alarm message could not
be selected.
Select a diagnostics alarm from the ZP_ALARM
alarm screen.
320003 No alarm message (error) exists for the selected unit.
The detail view cannot visualize any networks.
Select the defective unit from the overview screen.
320004 The required signal states could not be read by the
PLC. The faulty addresses cannot be found.
Check the consistency between the configuration on
the display unit and the PLC program.
ITEM 2500
Appendix
A.2 System alarms
320005 The project contains ProAgent elements which are not
installed. ProAgent diagnostic functions cannot be
performed
In order to run the project, install the optional
ProAgent package.
320006 You have attempted to execute a function which is not
supported in the current constellation.
Check the type of the selected unit.
320007 No error-triggering addresses were found on the
networks.
ProAgent cannot indicate any faulty addresses.
Switch the detail screen to STL layout mode and
check the status of the addresses and exclusion
addresses.
320008 The diagnostic data stored in the configuration are not
synchronized with those in the PLC.
ProAgent can only indicate the diagnostic units.
Transfer the project to the HMI device again.
synchronized with those in the PLC. The diagnostic
screens can be operated as usual.
ProAgent may be unable to show all diagnostic texts.
synchronized with those in STEP7.
The ProAgent diagnostics data is not up-to-date.
320011 A unit with the corresponding DB number and FB
number does not exist.
The function cannot be executed.
Check the parameters of the "SelectUnit" function
and the units selected in the project.
320012 The "Step sequence mode" dialog is no longer
supported.
Use the ZP_STEP step sequence screen from the
corresponding standard project for your project.
Instead of calling the
Overview_Step_Sequence_Mode function, call the
"FixedScreenSelection" function using ZP_STEP as
the screen name.
320014 The selected PLC cannot be evaluated for ProAgent.
The Alarm view assigned to the
"EvaluateAlarmDisplayFault" system function could
not be found.
Check the parameters of the
"EvaluateAlarmDisplayFault" system function.

330000 - GUI alarms
330022 Too many dialogs are open on the HMI device. Close all dialogs you do not require on the HMI
device.
330026 The password will expire after the number of days
shown.
Enter a new password.

ITEM 2500
Appendix
A.2 System alarms
350000 - GUI alarms
350000 PROFIsafe packages have not arrived within the
necessary period.
There is a communication problem with the F-CPU.
RT is terminated
Check the WLAN connection.
350001 PROFIsafe packages have not arrived within the
necessary period.
There is a communication problem with the F-CPU.
The PROFIsafe connection is re-established.
Check the WLAN connection.
350002 An internal error has occurred.
Runtime is terminated
Internal error
350003 Feedback concerning the connection established with
the F-CPU.
The Emergency-Off buttons are active immediately.
--
350004 PROFIsafe communication was set and the
connection was cleared.
The Runtime can be terminated.
The Emergency-Off buttons are deactivated
immediately.
--
350005 Incorrect address configured for the F-slave.
No PROFIsafe connection.
Check and modify the address of the F slave in
WinCC flexible ES.
350006 The acknowledgement buttons in the
"Acknowledgement" and "Panic" functions were not
tested before logging on.
It is not possible to log onto the effective range.
Press the two acknowledgement buttons one after
another in the "Acknowledgement" and "Panic"
positions.
350008 The wrong number of failsafe buttons was configured.
No PROFIsafe connection.
Change the number of failsafe buttons in the project.
350009 The device is in Override mode.
It may no longer be possible to detect the location
because transponder detection fails.
Exit Override mode.
350010 Internal error: The device has no failsafe buttons. Send the device back.
Worldwide contact person

ITEM 2500
Appendix
A.2 System alarms
ITEM 2500

Abbreviations
B

ANSI American National Standards Institution
CPU Central Processing Unit
CSV Comma Separated Values
CTS Clear To Send
DC Direct Current
DCD Data Carrier Detect
DHCP Dynamic Host Configuration Protocol
DIL Dual-in-Line (electronic chip housing design)
DNS Domain Name System
DP Distributed I/O
DSN Data Source Name
DSR Data Set Ready
DTR Data Terminal Ready
IO Input and Output
ESD Components and modules endangered by electrostatic discharge
EMC Electromagnetic Compatibility
EN European standard
ES Engineering System
ESD Components and modules endangered by electrostatic discharge
GND Ground
HF High Frequency
HMI Human Machine Interface
IEC International Electronic Commission
IF Interface
IP Internet Protocol
LED Light Emitting Diode
MAC Media Access Control
MOS Metal Oxide Semiconductor
MPI Multipoint Interface (SIMATIC S7)
MS Microsoft
MTBF Mean Time Between Failures
n. c. Not connected
OP Operator Panel
PC Personal Computer
PG Programming device
PPI Point-to-Point Interface (SIMATIC S7)
RAM Random Access Memory
PELV Protective Extra Low Voltage
RJ45 Registered Jack Type 45
RTS Request to send
ITEM 2500
Abbreviations

RxD Receive Data
SD Card Security Digital Card
SELV Safety Extra Low Voltage
SP Service Pack
PLC Programmable Logic Controller
STN Super Twisted Nematic
Sub-D Subminiature D (plug)
TAB Tabulator
TCP/IP Transmission Control Protocol/Internet Protocol
TFT Thin Film Transistor
TTY Teletype
TxD Transmit Data
UL Underwriters Laboratory
USB Universal Serial Bus
UPS Uninterruptible power supply
WINS Windows Internet Naming Service
ITEM 2500

Glossary
"Transfer" mode
An operating mode of the HMI device in which an executable project is transferred from the
configuring PC to an HMI device.
Acknowledge
Acknowledgment of an alarm confirms that it has been noted.
Alarm logging
Output of user-specific alarms to a printer, in parallel to their output to
the HMI device screen.
Alarm, acknowledging
Acknowledgment of an alarm confirms that it has been noted.
Alarm, activated
Moment at which an alarm is triggered by the PLC or HMI device.
Alarm, deactivated
Moment at which the initiation of an alarm is reset by the PLC.
Alarm, user-specific
A user-specific alarm designates a certain operating status of the plant connected to
the HMI device via the PLC.
Automation device
PLC of the SIMATIC S5 series, for example the AG S5-115U
Automation system
Controller of the SIMATIC S7 series, for example a SIMATIC S7-300
Bootloader
Used to start the operating system. Automatically started when the HMI device is switched
on. After the operating system has been loaded, the Loader opens.
ITEM 2500
Glossary

Configuration software
Software used to generate projects used for the purpose of process visualization.
An example of configuring software is WinCC flexible.
Configuring PC
A configuring PC is a programming device or PC on which plant projects are created using
an engineering software.
Display duration
Defines whether a system alarm is displayed on the HMI device and the duration of
the display.
EMC
Electromagnetic compatibility is the ability of electrical equipment to function properly in its
electromagnetic environment without influencing this environment.
Event
Functions are triggered by defined incoming events. Events can be configured. Events which
can be assigned to a button include "Press" and "Release", for example.
Field array
Area reserved in configured screens for the input and output of values.
Flash memory
Non-volatile memory with EEPROM chips, used as mobile storage medium or as memory
module installed permanently on the motherboard.
Function keys
Key on the HMI device which supports user-specific functions. A function is assigned to
the key in the configuration. The assignment of the keys may be specific to an active
screen or not.
Half Brightness Life Time
Time period after which the brightness reaches 50% of the original value. The specified
value is dependent on the operating temperature.
Hardcopy
Output of the screen content to a printer.
ITEM 2500
Glossary

HMI device
An HMI device is a device used for the operation and monitoring of machines and plants.
The statuses of the machine or plant are indicated by means of graphic elements or by
indicator lamps on the HMI device. The operating elements of the HMI device allow the
operator to interact with the processes of the machine or plant.
HMI device image
A file that can be transferred from the configuring PC to the HMI device. The HMI device
image contains the operating system and elements of the runtime software required to
run a project.
I/O field
An I/O field enables the input or output of values on the HMI device which are transferred
to the PLC.
Infotext
An infotext is a configured information on objects within a project. Infotext for an alarm, for
example, may contain information on the cause of the fault and troubleshooting routines.
Object
An object is a component of a project. Example: screen or alarm. Objects are used to view or
enter texts and values on the HMI device.
Operating element
Component of a project used to enter values and trigger functions. A button, for example, is
an operating element.
Plant
General term referring to machines, processing centers, systems, plants and processes
which are operated and monitored on an HMI device.
PLC
A PLC is a general term for devices and systems with which the HMI device communicates,
e.g. SIMATIC S7.
PLC job
A PLC job triggers a function for the PLC at the HMI device.
ITEM 2500
Glossary

Process visualization
Visualization of technical processes by means of text and graphic elements. Configured
plant screens allow operator intervention in active plant processes by means of the input and
output data.
Project
Result of a configuration using a configuration software. The project normally contains
several screens with embedded system-specific objects, basic settings and alarms. The
project file of a project configured in WinCC flexible is saved under the file name
extension *.hmi.
You need to distinguish between a project on the configuring PC and that on an HMI device.
A project may be available in more languages on the configuring PC than can be managed
on the HMI device. The project on the configuring PC can also be set up for different HMI
devices. Only the runtime project that has been generated for the respective HMI device can
be transferred to it.
Project file
File generated from the runtime project file for use on the HMI device. The project file is
normally not transferred and remains on the configuring PC.
The file name extension of a source file is *.hmi.
Project file, compressed
Compressed format of the project file. The compressed project file can be transferred
together with the runtime project file to the respective HMI device. For this purpose,
backtransfer must be enabled in the project on the configuring PC. The compressed project
file is normally stored on an external memory card.
The file extension of a compressed file is *.pdz.
Recipe
Combination of tags forming a fixed data structure. The data structure configured can be
assigned data on the HMI device and is then referred to as a record. The use of recipes
ensures that all the assigned data is transferred synchronously to the PLC during the
transfer of a record.
Runtime project file
File generated from the project file for a specific HMI device. The runtime project file is
transferred to the corresponding HMI device and used to operate and monitor plants.
The extension of a compressed file is *.pdz.
Runtime software
The runtime software is a process visualization software used to test a project on a
configuring PC.
ITEM 2500
Glossary

Screen
Form of the visualization of all logically related process data for a plant. The visualization of
the process data can be supported by graphic objects.
Screen object
Configured object used to display or operate the plant, e.g. rectangle, I/O field or alarm view.
STEP 7
STEP 7 is the programming software for SIMATIC S7, SIMATIC C7 and
SIMATIC WinAC PLCs.
STEP 7 Micro/WIN
STEP 7 Micro/WIN is the programming software for SIMATIC S7-200 PLCs.
Symbolic I/O field
A symbolic I/O field is a field for the input and output of the value. Contains a list of default
entries from which one can be selected.
System alarm
A system alarm is assigned to the "System" alarm class. A system alarm refers to internal
states on the HMI device and the PLC.
Tab sequence
During configuration, this defines the sequence in which objects are activated on
pressing the <TAB> key.
Tag
Defined memory location to which values can be written to and read from. This can be done
from the PLC or the HMI device. Based on whether the tag is interconnected with the PLC or
not, we distinguish between "external" tags (process tags) and "internal" tags.
Transfer
Transfer of a runtime project from the configuring PC to the HMI device.

ITEM 2500
Glossary

ITEM 2500

Index
/
/Audit, 32
A
Accessory kit, 25
ACK, 239
ACK key, 203
Acknowledge
Alarm, 203, 243
Error alarm, 243
Acknowledge key, 203
Acoustic feedback, 191
Acoustic signal, 196
For inadvertent operation, 191
with inadvertent operation, 99
Acoustics
Feedback, 122, 124
Address assignment
TCP/IP network, 145
Addressing, 142
Admin, 233, 234, 235
Alarm, 237
Acknowledge, 203, 243
Editing, 244
Functional scope, 29
LED, 240
Alarm buffer, 238
Alarm class, 238, 241
Alarm event, 237
Alarm group, 238
Alarm indicator, 239
Alarm line, 240
Alarm log, 238
Alarm report, 238
Alarm view, 240
Expanded, 240
Simple, 240
Alarm window, 241
ALARM_S, 29
Alphanumerical
Key assignment, 105, 202
Screen keyboard, 197
Alphanumerical value
Changing, 207
Editing, 198
Entering, 198, 207
ALT key, 105, 202
Ambient conditions
Climatic, 46
Mechanical, 45
Test, 46
Approvals, 39
Authorization, 224
Automatic
Transfer, 164
Automation License Manager, 186
A-Z key, 105, 202
B
Backlighting
Reducing, 119
Setting, 99
Backspace key, 104, 202
Backtransfer, 163, 166
Backup, 98, 155, 162, 168, 169, 171, 225
Registry Information, 98, 116
Temporary files, 116
to external storage device, 98, 153
With ProSave, 171
With WinCC flexible, 169
Bar, 210
Basic adapter, 27
Basic knowledge
Required, 3
Booting, 125
Bottom view, 15, 17, 19, 21, 23
Brightness
Changing, 118
Browser
Home page, 98
Setting, 98
Bus connection, 33
Bus parameters
Profile, 141
C
Cable
Data exchange, 76
Cables
Connecting, 61
ITEM 2500
Index

Calibrating
Touch screen, 98, 110
Cancel
Secure mode, 94
Cancel
Password protection, 113
Cancel key, 104, 202
Care, 273
CE approval, 39
Certificate
Delete, 98, 152
Importing, 98, 152
LED, 98
Changing
Brightness, 118
User data, 233, 234
Character repeat, 98
Clean screen, 274
Cleaning product, 273
Clearance
MP 377, 49
Climatic
Storage conditions, 44
Transport conditions, 44
Closing
Project, 236
Rear wall, 80
Column sequence
Alarm view, 241
Compatibility conflict, 168
Conductor cross-section, 65
Equipotential bonding, 63
Configuration PC
Connecting, 71
Wiring diagram, 71
Configuration phase, 159
Configure
Screen keyboard, 98, 106
Configuring
Network, 143
Operating system, 89
PC/PPI cable, 72
RS-422/RS-485 port, 70
Configuring PC, 159
Connecting
Configuration PC, 71
Mains terminal, 66
PLC, 68
Power supply, 65, 66
Printer, 75
PROFINET, 69
UPS, 67
USB device, 74
Connection, 33
Connection graphic
UPS, 67
Connection sequence, 61
Connections to PLC
Number, 33
Contact person, 5
Control cabinet
Working on, 38
Control key, 82
Keyboard unit, 104
Control panel
Control Panel, 96
MPI, 140
Open, 97
Operating, 100, 102
PROFIBUS, 140
Conventions, 4
Cookies, 98, 150
Creating
Recipe data record, 255, 264
Users, 230
C-Tick mark (Australia), 40
CTRL key, 105, 202
Currency, 98
Cursor key, 82, 104, 201
D
Data channel
Enabling, 136
Locking, 136
Parameter assignment, 99, 136
Data flow, 249
Date, 98
Entering, 199, 208
Setting, 114
Synchronizing, 115
Date format, 98, 116
Date/time properties, 98, 114
Decimal, 195
Default gateway, 146
Degree of protection, 48
Protection against ingress of solid foreign
bodies, 50, 52
Protection against water, 50, 52
Delay time
Setting, 99, 131
ITEM 2500
Index

Delete
Certificate, 98, 152
Users, 235
Delete key, 104, 202
Device name
For network operation, 144
Setting, 99
Dewing, 44
DHCP, 146
DIP switch
Setting, 70
Direct key, 192
Bit assignment, 282
Display
MP 377, 280
Display format, 205
Displaying
Info text, 200, 209
Information on the MP 377, 127
Infotext, 203
Memory information, 129
System information, 129
Disposal, 5
Disturbance
Pulse-shaped, 42
Sinusoidal, 43
DNS, 146
Server, 142
Documentation
Enclosed, 53
Double-click, 98
Setting, 108
Drop down list, 199, 208
Drop down list box
Open, 104, 202
E
EC Declaration of Conformity, 39
Editing
Alarm, 244
Elbow adapter, 26
Electrical isolation
Safe, 66
Electrical potential difference, 63
Electrostatic charging, 287
Electrostatic, 287
Precautions, 288
Element list, 251, 262
E-Mail
Setting, 99, 148
EMC directive, 39
Emission, 41, 43
Encryption, 150
END key, 104, 201
Enhanced alarm view, 240
Enhanced recipe view, 250
Enhanced user view, 226
Enter key, 202
ENTER key, 104, 202
Entering
Alphanumerical value, 198, 207
Date, 199, 208
Key combination, 105, 202
Numerical value, 196, 206
Recipe data record, 271
Symbolic value, 199
Text box, 194
Time, 199, 208
Entry on the HMI device
By means of function key, 204
Using operating elements, 189
Equipotential bonding
Cable, 64
Connecting, 63
Requirements, 63
Wiring diagram, 64
Equipotential bonding rail, 64
Error alarm
Acknowledge, 243
ESC key, 104, 202
ESD
Abbreviations, 287
Labeling, 287
Ethernet settings
IP address, 146
Excel Viewer, 32
Explorer
Operating, 91
Exporting
External
Keyboard, 100
Mouse, 100
F
Factory setting
With ProSave, 180
ITEM 2500
Index

Factory settings, 73
Feedback
Acoustic, 122, 124, 191
Optical, 191
FM Approval, 40
FN key, 105, 202
Front view, 15, 17, 19, 21, 23
Function
Additional, 31
Function key
Labeling, 86
Function keys, 82
Global assignment, 204
Local assignment, 204
Function test, 78
Functional scope
Alarm buffer, 29
ALARM_S, 29
Alarms, 29
Graphics list, 29
Info text, 31
Limit value monitoring, 29
Log, 30
Recipe, 30
Safety, 31
Scaling, 29
Screen, 30
Tags, 29
Text list, 29
G
Gauge, 210
Graphics list
Group acknowledgement, 203
H
High frequency radiation, 37
HMI device
EMC-compatible installation, 42
Information, 98
Mounting, 57, 59
Ports, 62
Restart, 125
Restarting, 98
Shutting down, 78
Switching on, 77
Technical specifications, 280
Testing, 77
HMI Input Panel
Options, 106
HOME key, 104, 201
Home page
Internet, 149
Host cable
Safety instruction, 73
I
Identification, 147
Importing
Certificate, 98, 152
Inadvertent operation
Acoustic signal, 99, 191
Info text
Displaying, 200, 209
Information
For the HMI device, 127
Infotext
Displaying, 203
Key, 203
LED, 242
Initial startup, 159
Input device
MP 377, 280
Input Panel, 98
Installing
Option, 162, 182, 183, 185
Instructions
General, 41
Insulation test
Test voltage, 50, 52
Interface
Rated load, 74
Interfaces
MP 377, 281
Internal clock, 115
Internet
Browser, 92
Explorer, 92
Home page, 149
Options, 98
Search engine, 149
Security settings, 98
Service, 5
Settings, 99, 148
Support, 5
Internet options
Privacy, 151
IP address
ITEM 2500
Index

Ethernet, 146
Setting, 98
K
Key
ACK, 203
ALT, 105, 202
A-Z, 105, 202
Backspace, 202
Cancel, 104
CTRL, 105, 202
Cursor, 104, 201
Delete, 104, 202
END, 104, 201
ENTER, 104, 202
ESC, 104, 202
FN, 105, 202
HOME, 104, 201
Infotext, 203
Scroll back, 104, 201
Scroll forward, 104, 201
SHIFT, 105, 202
TAB, 104, 201
Tabulator, 104
Key combination
Entering, 105, 202
Key control, 201, 205
Trend view, 214
Keyboard
External, 100
Keyboard properties, 98
L
Labeling
Approvals, 40
EC Declaration of Conformity, 39
Function key, 86
Labeling strips
Attaching, 87
Dimensions, 86
Printing, 86
LAN connection, 98
Language change
Layout
Slider control, 214
Sm@rtClient view, 220
Trend view, 212
LED
Alarm, 240
Certificate, 98
HMI device information, 98
Infotext, 242
LED ACK, 239
License key, 186
Transferring, 162, 187
Transferring back, 162, 188
Limit value
For password, 225
For user, 225
For user view, 225
Limit value check, 195
Limit value monitoring
Limit value test, 205
List of abbreviations, 321
Loader, 89
Opening, 90
Operating, 90
Log
Logoff
Users, 228
Logoff time, 225
Logon
Users, 227
Logon data, 147
M
MAC address, 134
Main dimensions
MP 377 PRO 15" Touch, 279
Mains terminal
Connecting, 66
Maintenance, 273, 274
Manual
Production sequence, 272
Transfer, 163
Mechanical
Media Player, 93
Memory
MP 377, 280
Memory card, 27
Backup, 84
First use, 153
Inserting, 83
ITEM 2500
Index

Restoring file system, 116
Unplug, 85
Displaying, 129
LED, 128
Memory management, 98, 158
Menu command
Simple recipe view, 263
Microsoft Excel Viewer, 32
Microsoft PDF Viewer, 32
Microsoft Word Viewer, 32
Monitoring mode
Sm@rtClient view, 221
Mounting, 48
EMC-compatible, 42
HMI device, 57, 59
Mounting clamp, 56
Mounting clamp
Mounting, 55, 56
Mounting cutout
Dimensions, 49
Preparing, 49
Mounting location, 48, 51
Mounting position, 47
Thin Client 15, 51
Mouse
External, 100
Mouse properties, 98
MP 377
Clearance, 49
Display, 280
Displaying information, 127
Input device, 280
Interfaces, 281
Memory, 280
Operating element, 81
Ports, 62
Weight, 280
MP 377 12" Key
Bottom view, 17
Front view, 17
Overall dimensions, 276
Rear view, 18
Side view, 17
MP 377 12" Touch
Bottom view, 15
Front view, 15
Rear view, 16
Side view, 15
MP 377 15 PRO
Bottom view, 23
Front view, 23
Rear view, 24
Side view, 23
MP 377 15" Touch
Bottom view, 19
Front view, 19
Rear view, 20
Side view, 19
MP 377 19" Touch
Bottom view, 21
Front view, 21
Rear view, 22
Side view, 21
Main dimensions, 279
MPI
Setting, 99, 140
Multi-key operation, 190, 203
Multimedia card, 83
N
Name server, 146
Network
Configuring, 143
Logon data, 98
Set up, 142
Setting, 145
Network & dial-up connections, 98
Network ID, 98
Network operation
Device name, 144
Options, 99
Non-isolated plant configuration, 66
Notice of protected rights, 3
Number format, 98, 116
Numerical
Key assignment, 105, 202
Numerical value
Changing, 206
Decimal places, 195
Display format, 205
Editing, 196
Entering, 196, 206
Limit value check, 195
Limit value test, 205
O
Office location, 5
ITEM 2500
Index

Offline
Operating mode, 160
Recipe tag, 254
Test, 167
Online
Operating mode, 160
Recipe tag, 254
Test, 167
OP properties, 98
Device, 127
Memory monitoring, 158
Persistent storage, 117
Touch, 110
OPC server, 32
Open
Control Panel, 97
Drop down list box, 104, 202
Opening
Loader, 90
Operating
Control Panel, 100, 102
Explorer, 91
Feedback, 190
Key, 201, 205
Loader, 90
Operating element, 104, 201
Project, 189
Recipe screen, 255, 264
Slider control, 215
Switches, 211
Trend view, 213
Windows CE interface, 91
With external keyboard, 190
With external mouse, 190
Operating element
Operating, 104, 201
Recipe view, 255
Selecting, 104
Operating instructions
Purpose of, 3
Scope, 3
Operating mode, 160
Changing, 160
Offline, 160
Online, 160
Transfer, 77, 160
Operating system
Configuring, 89
Update, 173
Update via ProSave, 176
Updating using WinCC flexible, 175
Operation feedback, 190
Setting, 99
Operator control options, 99
Optical feedback, 191
Option
Installing, 162, 182
Installing with ProSave, 185
Installing with WinCC flexible, 183
Removing, 162, 182
Removing with ProSave, 186
Removing with WinCC flexible, 184
Options, 32
Network operation, 99
Overall dimensions
MP 377 12" Key, 276
MP 377 12" Touch, 275
MP 377 15" Touch, 277
MP 377 19" Touch, 278
P
Parameter assignment
Data channel, 99, 136
Password, 225
Backup, 225
Restoring, 225
Specifying, 112
Password list, 225
Password properties, 98, 112, 113
Password protection, 92, 98
Cancel, 113
Set up, 112
Windows CE taskbar, 92
PC/PPI
Configuring the cable, 72
Setting the adapter, 72
PDF Viewer, 32
PELV, 66
Permissions in remote control, 222, 223
Plant configuration
Non-isolated, 66
PLC
Configuring the interface, 70
Connecting, 68
Number of connectable, 33
Protocol, 34
Reading recipe data record, 260, 267
Transferring recipe data record, 261, 268
Wiring diagram, 68
PLC_User, 233, 234, 235
Power failure, 168
Power supply
Connecting, 65, 66
ITEM 2500
Index

Setting, 99
State, 99
Wiring diagram, 65
Precautions
Electrostatic discharge, 288
Printer
Connecting, 75
Setting properties, 98
Wiring diagram, 75
Printer connection
Setting, 120
Printer properties, 98, 121
Printing
Labeling strips, 86
Via network printer, 143
ProAgent, 32
Process control phase, 159
Production sequence
Manual, 272
PROFIBUS DP
Setting, 99, 140
PROFINET, 142
Addressing, 142
Connecting, 69
PROFINET IO
Communication, 69
Communication fault, 33
Disabling direct keys, 134
Enabling direct keys, 134
Setting, 98
Project
Closing, 236
in ProTool, 161
In WinCC flexible, 161
Offline testing, 167
Operating, 189
Reuse, 161
Testing online, 167
Transferring, 159, 162
Proper use, 37
Protected trademark, 3
Protection class, 50, 52
Protective foil, 26
Protocol
PLC, 34
Proxy
Server, 98, 148, 150
Setting, 98
R
Radiation
High frequency, 37
Radio interference, 41
Emission, 43
Rated load
Interface, 74
Rated voltage, 50, 52
Reading out
Real-time clock
Internal, 115
Rear view, 16, 18, 20, 22, 24
Rear wall
Closing, 80
Recipe, 246
Control, 247
Data flow, 249
Data record, 247
Field of application, 245
Recipe screen, 250
Recipe view, 250
Synchronizing tags, 259
Recipe data record
Creating, 255, 264
Delete, 258, 266
Editing, 257, 265
Entering, 271
Exporting, 270
Importing, 269
Reading from PLC, 260, 267
Synchronize with PLC, 257
Transferring to PLC, 261, 268
Recipe list, 251, 262
Recipe screen, 252
Operating, 255, 264
Overview, 252
Recipe tag
Offline, 254
Online, 254
Synchronizing, 253, 259
Recipe view, 250
Expanded, 250
Simple, 251
Recommissioning, 159
Record list, 251, 262
Recycling, 5
Regional and language settings, 98, 116
Regional settings, 116
Registered trademark, 3
Registry Information
Backup, 98, 116
Regulations for the prevention of accidents, 38
ITEM 2500
Index

Remote control
Forcing permission, 222, 223
Start, 222, 223
Removing
Option, 162, 182, 184, 186
Repairs, 274
Reset to factory setting, 162
Restore, 98, 153, 168
Restoring, 162, 170, 172, 225
from external storage device, 98, 155
From memory card, 116
With ProSave, 172
Restoring factory settings, 73
Returns Center, 274
Reverse polarity protection, 66
RS 422 to RS 232 converter, 26
RS-422/RS-485 port
Configuring, 70
Ruler
Trend view, 213
S
S7 transfer settings, 99
Safe electrical isolation, 66
Safety
Standards, 39
Safety instruction
Backlighting, 119
Changed tag name, 259
Compatibility conflict, 168
Compressed project file, 163
Damage to the HMI device, 61
Data channel, 174
Data loss, 153, 173
Device name, 134
Direct key, 192
Electrostatic charging, 287
Equipotential bonding cable, 64
Functional problem, 74
High frequency radiation, 37
Keyboard, 82
License key, 174, 182
Loss of data possible, 155
Memory card, 85
Memory distribution, 129
Multi-key operation, 190
Observe grounding measures, 288
Path, 130, 131
Power failure, 168
Preventing inadvertent operation, 273, 274
Project file, 130, 131
Recipe data record in background, 251
Remote control for channel 1, 137
Restart, 125
Storage, 44
Switching infotext, 200, 209
Time-dependent reactions, 115
Touch screen, 81
Transfer mode, 139
Transfer mode channel 2, 137
Transport, 44
Unintentional action, 81, 82, 203
Unintentional response, 273, 274
Unintentional transfer mode, 136
USB connection sequence, 73
USB host-to-host cable, 73
USB port, 74
Working on the control cabinet, 38
Safety regulations, 38
Scaling
Screen
Screen keyboard, 98, 193
Alphanumerical, 197
Change layout, 102
Character repeat, 107
Configure, 106
For Control Panel, 101
Keyboard level, 197
Language change, 197
Numerical, 195
Representation types, 101
Screen saver, 99, 120
Setting, 119
Screen settings
Changing, 98
Scroll back key, 104, 201
Scroll forward key, 104, 201
Search engine
Internet, 149
Secure mode, 94
Cancel, 94
Security settings, 98
Security system, 224
Selecting
Service
In the Internet, 5
Service pack, 274
Set up
Network, 142
ITEM 2500
Index

Secure mode, 94
Setting
Backlighting, 99
Browser, 98
Date, 114
Date format, 116
Date/Time, 98
Delay time, 99, 131
Device name, 99
DIP switch, 70
Double-click, 108
E-Mail, 99
E-mail connection, 148
IP address, 98
Language, 193
MPI, 99, 140
Name server, 98
Network, 145
Number format, 116
Operation feedback, 99
PC/PPI adapter, 72
Power supply, 99
Printer connection, 120
Printer properties, 98
PROFIBUS, 140
PROFIBUS DP, 99
PROFINET IO, 98
Proxy, 98
Regional data, 116
Screen saver, 119
Sound, 124
Storage location, 130
Time, 114
Time format, 116
UPS, 132
Setting language, 193
Settings
Internet, 99
Language, 98
Regional, 98
S7-Transfer, 99
Shift key, 105
SHIFT key, 105, 202
Shutting down
HMI device, 78
Side view, 15, 17, 19, 21, 23
Siemens HMI input panel options, 98
Simple alarm view, 240
Menu command, 263
Simple user view, 226
Slider control, 214
Sm@rtAccess, 32
Sm@rtClient view, 220, 221
Monitoring mode, 221
Usage, 220
Sm@rtService, 32
SMTP server, 148
Software options, 32
Sort order
Alarm view, 241
Sound
Setting, 99, 124
Setting event, 124
Start
HMI device, 98, 125
Status Force, 216
Key control, 219
Touch operation, 217
storage device
Restoring from external, 155
Storage device
Saving to external, 153
Storage location
Setting, 130
Strain relief, 79
Subnet mask, 146
Supply voltage
MP 377, 281
Support
In the Internet, 5
Support arm system
Adapter set CP-L, 27
Adapter set PLUS, 27
Adapter set VESA 100, 27
Adapter set VESA 75, 27
Basic adapter, 27
Switches, 211
Switching on
MP 377, 77
Symbolic value
Editing, 199
Entering, 199
Synchronizing
Date and time, 115
Recipe tag, 253, 259
System alarm
Meaning, 290
Parameters, 289
Displaying, 129
LED, 128
System key, 82
ITEM 2500
Index

System properties, 99
Device name, 144
General, 128
Memory, 129
T
TAB key, 104, 201
Tabulator key, 104, 201
Tags
Task planner
Taskbar, 89
TCP/IP address, 145
Display, 280
Input device, 280
Interfaces, 281
Memory, 280
MP 377, 280
Supply voltage, 281
Technical support, 5
Temporary files
Backup, 116
Test
For ambient conditions, 46
Test voltage, 52
Testing
MP 377, 77
Text box, 194
Character mode, 202
Normal mode, 202
Text list
Time, 98
Entering, 199, 208
Setting, 114
Synchronizing, 115
Time format, 98, 116
Time zone
Setting, 114
Time-dependent reactions, 115
Touch operation
Trend view, 214
Touch screen
Calibrating, 98, 110
Trademark, 3
Training center, 5
Transfer, 159, 160, 163
Automatic, 164
Cancel, 77
Manual, 163
Transfer mode
Unintentional, 136
Via MPI, 139
Via PROFIBUS DP, 139
Transfer settings, 99, 136
Channel, 136
Directories, 130, 131
Transferring
Project, 159, 162
Transferring back
Transport damage, 53
Trend view, 212
Key control, 214
Touch operation, 214
Trends
Limit violation, 212
U
UL approval, 40
Unintentional action, 81, 82, 190
Unintentional transfer mode, 136
Update
Updating
About ProSave, 176
using WinCC flexible, 175
Updating the operating system, 162
UPS
Connecting, 67
Connection graphic, 67
Setting, 132
UPS properties
Configuration, 132
Current status, 133
USB
Connection sequence, 73
USB connection sequence
USB device
Connecting, 74
USB flash drive, 27
USB memory stick, 27
Use
Conditions, 45
ITEM 2500
Index

In residential areas, 41
Industrial, 41
With additional measures, 45
User data
Backup, 225
Changing, 233, 234
Restoring, 225
User group, 224
User name, 147
User view, 226
Expanded, 226
Simple, 226
Users, 225
Admin, 233, 234, 235
Changing, 229
Creating, key control, 230
Delete, 235
Logoff, 228
Logon, 227
PLC_User, 233, 234, 235
V
Value table
Trend view, 213
VBScript
Volume, 122
Setting, 99
Volume & Sounds Properties, 99
W
Weight
MP 377, 280
WinCC flexible internet settings
E-mail, 148
E-Mail, 99
Windows CE interface
Operating, 91
Windows CE taskbar, 89
WINS, 146
Server, 142
Wiring diagram
Configuration PC, 71
PLC, 68
Power supply, 65
Printer, 75
Word Viewer, 32
Working on the control cabinet, 38

ITEM 2500
SIMATIC S7-300 CPU 31xC and CPU 31x: Installation
______________
______________
______________
______________
______________
______________
______________
______________
______________
______________
______________
______________
Preface
Guide to the S7-300
documentation

1
Installation Sequence

2
S7-300 components

3
Configuring

4
Installing

5
Wiring

6
Addressing

7
Commissioning

8
Maintenance

9
Debugging functions,
diagnostics and
troubleshooting

10

General technical data

11
Appendix

A

SIMATIC
S7-300
CPU 31xC and CPU 31x:
Installation
02/2009
A5E00105492-09
This manual is part of the documentation package
with order number:

6ES7398-8FA10-8BA0
ITEM 3000

Legal information
Legal information
Warning notice system
DANGER

WARNING

CAUTION

CAUTION

NOTICE
account.
property damage.
Qualified Personnel
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be adhered to. The information in the relevant documentation must be observed.
Trademarks
owner.
editions.

Siemens AG
Industry Sector
Postfach 48 48
90026 NRNBERG
GERMANY
A5E00105492-09
03/2009
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CPU 31xC and CPU 31x: Installation
Preface
Preface
Purpose of this manual
This manual contains essential information about the following:
Installation
Communication
Memory concept
Cycle and response times
Technical specifications of the CPUs
Switching to one of the CPUs discussed here
Basic knowledge required
In order to understand this manual, you require a general knowledge of automation
engineering.
You require knowledge of STEP 7 basic software.
Scope
Table 1 Scope of the manual
CPU Convention:
CPU designations:
Order number As of firmware
version
CPU 312C 6ES7312-5BE03-0AB0 V2.6
CPU 313C 6ES7313-5BF03-0AB0 V2.6
CPU 313C-2 PtP 6ES7313-6BF03-0AB0 V2.6
CPU 313C-2 DP 6ES7313-6CF03-0AB0 V2.6
CPU 314C-2 PtP 6ES7314-6BG03-0AB0 V2.6
CPU 314C-2 DP
CPU 31xC
6ES7314-6CG03-0AB0 V2.6
CPU 312 6ES7312-1AE14-0AB0 V3.0
CPU 314 6ES7314-1AG14-0AB0 V3.0
CPU 315-2 DP 6ES7315-2AH14-0AB0 V3.0
CPU 315-2 PN/DP 6ES7315-2EH13-0AB0 V2.6
CPU 317-2 DP 6ES7317-2AJ10-0AB0 V2.6
CPU 317-2 PN/DP 6ES7317-2EK13-0AB0 V2.6
CPU 319-3 PN/DP
CPU 31x
6ES7318-3EL00-0AB0 V2.8
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Preface


Note
The special features of the F-CPUs of the S7 spectrum can be found as product information
on the Internet at following address:
(http://support.automation.siemens.com/WW/view/en/11669702/133300).

Note
We reserve the right to include a Product Information containing the latest information on
new modules or modules of a more recent version.

Changes in comparison to the previous version
The following table contains changes from the previous versions of the following
documentation from the S7-300 documentation package:
Manual of technical specifications, version 06/2008, A5E00105474-08
Installation manual, version 06/2008, A5E00105491-08

CPU 312,
V3.0
CPU 314,
V3.0
CPU 315-2 DP,
V3.0
CPU 319,
V2.8
Data set routing - - x x *
Increased performance due to shorter instruction processing
times
x x x -
Extended system diagnostics of PROFINET interface: Overview
and detailed diagnostics of connections of "open communication
via Industrial Ethernet"
- - - x
Increase
the number of blocks that can be monitored by the status
block
(from 1 to 2)
x x x x
of the amount of status information that can be monitored
with the status block as of STEP7 V5.4 + SP5
x x x x
of the number of breakpoints from 2 to 4 x x x x
of the work memory size - x x -
of the local data stack (32 KB per execution level/2 KB per
block)
x x x x
Number of block-related messages (Alarm_S) is uniformly
limited to 300
x x x x *
of S7 timers, S7 counters x - - -
the number of bit memories x - - -
Adjustable process image x x x x *
Expansion of the block number range x x x x
Uniform size of data blocks: Max. 64 KB
(exception: CPU312 only 32 KB due to maximum size of work
memory)
x x x x *
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Preface

CPU 312,
V3.0
CPU 314,
V3.0
CPU 315-2 DP,
V3.0
CPU 319,
V2.8
Time-delay interrupts: uniform for OB21/OB22 x x x x *
Watchdog interrupts: uniform for OB32 - OB35 x x x x *
Uniform block nesting depth of 16 x x x x *
Global communication: uniformly 8 GD circles x x x * x *
Size of the diagnostic buffer: generally 500 entries
(the 100 most recent entries are retentive)
x x x x *
Number of displayed diagnostic buffer entries in CPU RUN
mode is configurable.
x x x x
New function: Reading out service data x x x x
Additional Web server functionalites for
CPU 319-3 PN/DP V2.8 or higher and STEP7 V5.4 + SP5

Extended topology views - - - x
Link between device view in topology and module state - - - x
Link to Web servers of other configured devices - - - x
Status overview of all configured devices of the
PROFINET IO system
- - - x
Updating of the "Module state" and "Topology" Web pages
during activation/deactivation of stations
- - - x
Automatic page update for all dynamic pages on the Web
server
- - - x
Number of displayed diagnostic buffer entries in CPU RUN
mode is configurable.
- - - x
Diagnostic buffer entries and messages can be downloaded
as CSV file.
- - - x
Reference view in the topology display of the CPU Web
server
- - - x
* This function is already available to the CPU since an earlier version
Standards and approvals
In the Chapter General technical specifications, you will find information about standards and
approvals
Recycling and disposal
The devices described in this manual can be recycled due to their ecologically compatible
components. For environment-friendly recycling and disposal of your old equipment, contact
a certified disposal facility for electronic scrap.
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Preface

Service & Support on the Internet
In addition to our documentation, we offer a comprehensive knowledge base online on the
Internet (http://www.siemens.com/automation/service&support).
There you will find:
Our newsletter containing up-to-date information on your products
Up-to-date documents using the Search function in Service & Support
A forum for global information exchange by users and specialists
Your local representative for automation and drives in our contact database
Information about on-site services, repairs, spare parts, and lots more.
Applications and tools for the optimized use of the SIMATIC S7. Performance
measurements for DP and PN, for example, are published here on the Internet
(http://www.siemens.com/automation/pd).

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Table of contents

Preface...................................................................................................................................................... 3
1 Guide to the S7-300 documentation ........................................................................................................ 11
1.1 Documentation classification .......................................................................................................11
1.2 Guide to the S7-300 documentation............................................................................................14
2 Installation Sequence .............................................................................................................................. 19
3 S7-300 components................................................................................................................................. 21
3.1 Example of an S7-300 configuration............................................................................................21
3.2 Overview of the most important S7-300 modules........................................................................22
4 Configuring .............................................................................................................................................. 25
4.1 Overview......................................................................................................................................25
4.2 Basic engineering principles ........................................................................................................26
4.3 Component dimensions ...............................................................................................................28
4.4 Specified clearances....................................................................................................................30
4.5 Arrangement of modules on a single rack ...................................................................................31
4.6 Distribution of modules to several racks......................................................................................32
4.7 Selection and installation of cabinets...........................................................................................35
4.8 Example: Selecting a cabinet.......................................................................................................38
4.9 Electrical assembly, protective measures and grounding ...........................................................39
4.9.1 Grounding concept and overall structure.....................................................................................39
4.9.2 Installing an S7-300 with grounded reference potential ..............................................................41
4.9.3 Installing an S7-300 with ungrounded reference potential (not CPU 31xC)................................42
4.9.4 Isolated or non-isolated modules?...............................................................................................43
4.9.5 Grounding measures ...................................................................................................................45
4.9.6 Overview display: Grounding.......................................................................................................48
4.10 Selection of the load power supply ..............................................................................................50
4.11 Planning subnets .........................................................................................................................52
4.11.1 Overview......................................................................................................................................52
4.11.2 Configuring MPI and PROFIBUS subnets...................................................................................54
4.11.2.1 Overview......................................................................................................................................54
4.11.2.2 Basic principles of MPI and PROFIBUS subnets ........................................................................54
4.11.2.3 Multi-Point Interface (MPI) ...........................................................................................................57
4.11.2.4 PROFIBUS DP interface..............................................................................................................59
4.11.2.5 Network components of MPI/DP and cable lengths ....................................................................62
4.11.2.6 Cable lengths of MPI and PROFIBUS subnets ...........................................................................67
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4.11.3 Configuring PROFINET subnets................................................................................................. 72
4.11.3.1 Overview ..................................................................................................................................... 72
4.11.3.2 PROFINET devices..................................................................................................................... 72
4.11.3.3 Integration of fieldbuses into PROFINET.................................................................................... 75
4.11.3.4 PROFINET IO and PROFINET CBA .......................................................................................... 76
4.11.3.5 PROFINET cable lengths and network expansion ..................................................................... 81
4.11.3.6 Connectors and other components for Ethernet ......................................................................... 84
4.11.3.7 Example of a PROFINET subnet ................................................................................................ 84
4.11.3.8 PROFINET IO System................................................................................................................ 86
4.11.4 Routed network transitions.......................................................................................................... 88
4.11.5 Point-to-point (PtP)...................................................................................................................... 90
4.11.6 Actuator/sensor interface (ASI) ................................................................................................... 90
5 Installing .................................................................................................................................................. 91
5.1 Installing a S7-300 ...................................................................................................................... 91
5.2 Installing the mounting rail .......................................................................................................... 93
5.3 Installing modules on the mounting rail....................................................................................... 96
5.4 Labeling modules........................................................................................................................ 98
6 Wiring .................................................................................................................................................... 101
6.1 Requirements for wiring the S7-300 ......................................................................................... 101
6.2 Bonding the Protective Conductor to the Mounting Rail ........................................................... 103
6.3 Adjusting the Power Supply Module to Local Mains Voltage.................................................... 104
6.4 Wiring the Power Supply Module and the CPU........................................................................ 105
6.5 Wiring front connectors ............................................................................................................. 107
6.6 Plugging the front connectors into modules.............................................................................. 110
6.7 Wiring I/O modules and compact CPUs with Fast Connect ..................................................... 111
6.8 Labeling the module I/Os .......................................................................................................... 116
6.9 Terminating shielded cables on the shielding contact element ................................................ 117
6.10 Wiring the MPI / PROFIBUS connectors .................................................................................. 120
6.10.1 Connecting the bus connector .................................................................................................. 120
6.10.2 Setting the terminating resistor on the bus connector .............................................................. 121
7 Addressing............................................................................................................................................. 123
7.1 Slot-specific addressing of modules ......................................................................................... 123
7.2 User-specific addressing of modules........................................................................................ 125
7.2.1 User-specific addressing of modules........................................................................................ 125
7.2.2 Addressing digital modules ....................................................................................................... 126
7.2.3 Addressing analog modules...................................................................................................... 128
7.2.4 Addressing the integrated I/Os of CPU 31xC ........................................................................... 129
7.3 Addressing on PROFIBUS DP.................................................................................................. 131
7.4 Addressing on PROFINET........................................................................................................ 132
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8 Commissioning...................................................................................................................................... 133
8.1 Overview....................................................................................................................................133
8.2 Commissioning procedure .........................................................................................................133
8.2.1 Procedure: Commissioning the hardware..................................................................................133
8.2.2 Procedure: Software commissioning .........................................................................................135
8.3 Commissioning check list...........................................................................................................136
8.4 Commissioning the Modules......................................................................................................138
8.4.1 Inserting/Replacing a Micro Memory Card ................................................................................138
8.4.2 Initial power on...........................................................................................................................140
8.4.3 CPU memory reset by means of mode selector switch.............................................................141
8.4.4 Formatting the Micro Memory Card...........................................................................................144
8.4.5 Connecting the programming device (PG) ................................................................................145
8.4.5.1 Connect PG/PC to the integrated PROFINET interface of the CPU 31x PN/DP ......................145
8.4.5.2 Connecting the PG to a node.....................................................................................................146
8.4.5.3 Connecting the PG to several nodes .........................................................................................147
8.4.5.4 Using the PG for commissioning or maintenance......................................................................148
8.4.5.5 Connecting a PG to ungrounded MPI nodes (not CPU 31xC) ..................................................150
8.4.6 Starting SIMATIC Manager........................................................................................................151
8.4.7 Monitoring and modifying I/Os ...................................................................................................152
8.5 Commissioning PROFIBUS DP.................................................................................................156
8.5.1 Commissioning PROFIBUS DP.................................................................................................156
8.5.2 Commissioning the CPU as DP master.....................................................................................157
8.5.3 Commissioning the CPU as DP Slave.......................................................................................161
8.5.4 Direct data exchange.................................................................................................................166
8.6 Commissioning PROFINET IO..................................................................................................168
8.6.1 Requirements.............................................................................................................................168
8.6.2 Configuring and commissioning the PROFINET IO system......................................................168
9 Maintenance.......................................................................................................................................... 175
9.1 Overview....................................................................................................................................175
9.2 Backing up firmware on a SIMATIC Micro Memory Card..........................................................175
9.3 Updating the firmware................................................................................................................176
9.3.1 Backing up firmware on a SIMATIC Micro Memory Card..........................................................176
9.3.2 Firmware update using a Micro Memory Card...........................................................................177
9.3.3 Updating the firmware online (via networks)..............................................................................179
9.4 Backup of project data to a Micro Memory Card .......................................................................180
9.5 Resetting to the Delivery State ..................................................................................................182
9.6 Module installation / removal .....................................................................................................183
9.7 Digital output module AC 120/230 V: Changing fuses ..............................................................187
10 Debugging functions, diagnostics and troubleshooting.......................................................................... 189
10.1 Overview....................................................................................................................................189
10.2 Reading out service data ...........................................................................................................189
10.3 Identification and maintenance data of the CPU .......................................................................190
10.4 Overview: Debugging functions .................................................................................................192
10.5 Overview: Diagnostics ...............................................................................................................194
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Table of contents

10.6 Diagnostics functions available in STEP 7................................................................................ 198
10.7 Network infrastructure diagnostics (SNMP) .............................................................................. 199
10.8 Diagnostics using status and error LEDs.................................................................................. 201
10.8.1 Introduction ............................................................................................................................... 201
10.8.2 Status and error displays of all CPUs ....................................................................................... 201
10.8.3 Evaluating the SF LED in case of software errors .................................................................... 202
10.8.4 Evaluating the SF LED in case of hardware errors................................................................... 204
10.8.5 Status and Error Indicators: CPUs with DP Interface ............................................................... 205
10.8.6 Status and error indicators: CPUs with PROFINET interface for the S7-300........................... 206
10.8.7 Status and Error Indicators: PROFINET IO Devices ................................................................ 207
10.9 Diagnostics of DP CPUs ........................................................................................................... 208
10.9.1 Diagnostics of DP CPUs operating as DP Master .................................................................... 208
10.9.2 Reading out slave diagnostic data............................................................................................ 211
10.9.3 Interrupts on the DP Master ...................................................................................................... 216
10.9.4 Structure of the slave diagnostic data when the CPU is operated as intelligent slave............. 217
10.10 Diagnostics of PROFINET CPUs.............................................................................................. 225
10.10.1 Diagnostics options of PROFINET IO....................................................................................... 225
10.10.2 Maintenance.............................................................................................................................. 226
11 General technical data........................................................................................................................... 229
11.1 Standards and approvals .......................................................................................................... 229
11.2 Electromagnetic compatibility ................................................................................................... 233
11.3 Transportation and storage conditions for modules.................................................................. 235
11.4 Mechanical and climatic environmental conditions for S7-300 operation................................. 236
11.5 Specification of dielectric tests, protection class, degree of protection, and rated voltage
of S7-300................................................................................................................................... 238
11.6 Rated voltages of S7-300.......................................................................................................... 238
A Appendix................................................................................................................................................ 239
A.1 General rules and regulations for S7-300 operation................................................................. 239
A.2 Protection against electromagnetic interference....................................................................... 241
A.2.1 Basic Points for EMC-compliant system installations............................................................... 241
A.2.2 Five basic rules for securing EMC............................................................................................ 243
A.2.2.1 1. Basic rule for ensuring EMC................................................................................................. 243
A.2.3 EMC-compliant installation of automation systems .................................................................. 245
A.2.4 Examples of an EMC-compliant installation: Cabinet configuration ......................................... 247
A.2.5 Examples of an EMC-compliant installation: Wall mounting..................................................... 248
A.2.6 Cable shielding.......................................................................................................................... 249
A.2.7 Equipotential Bonding ............................................................................................................... 251
A.2.8 Cable routing inside buildings ................................................................................................... 253
A.2.9 Outdoor routing of cables.......................................................................................................... 255
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Table of contents

A.3 Lightning and surge voltage protection......................................................................................256
A.3.1 Overview....................................................................................................................................256
A.3.2 Lightning protection zone concept .............................................................................................257
A.3.3 Rules for the interface between the lightning protection zones 0 and 1....................................259
A.3.6 Example: Surge protection circuit for networked S7-300 CPUs................................................266
A.3.7 How to protect digital output modules against overvoltages caused by inductance .................268
A.4 Functional safety of electronic control equipment......................................................................270
Glossary ................................................................................................................................................ 273
Index...................................................................................................................................................... 301
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Guide to the S7-300 documentation
1
1.1 Documentation classification
Documentation classification
The documentation listed below is part of the S7-300 documentation package.
You can also find this on the Internet (http://support.automation.siemens.com/WW/view/en/)
and the corresponding entry ID.

Name of the manual Description
Manual
CPU 31xC and CPU 31x: Technical Data
Entry ID: 12996906
Operator control and display elements
Communication
Memory concept
Cycle and response times
Technical data
Entry ID: 13008499
Configuring
Installing
Wiring
Addressing
Commissioning
Maintenance and the test functions
Diagnostics and troubleshooting
Manual
CPU 31xC: Technological functions
incl. CD
Entry ID: 12429336
Description of the specific technological functions:
Positioning
Counting
Point-to-point connection
Rules
The CD contains examples of the technological
functions.
Manual
S7-300 Automation System: Module data
Entry ID: 8859629
Functional descriptions and technical
specifications of the following modules:
Signal modules
Power supplies
Interface modules
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Operation lists
CPU 31xC, CPU 31x,
IM151-7 CPU, IM154-8 CPU, BM 147-1
CPU, BM 147-2 CPU
Entry ID: 13206730
CPU 312, CPU 314, CPU 315-2 DP,
V3.0 or higher
Entry ID: 31977679
The instruction list contains:
List of the instruction set of the CPUs and their
execution times.
List of the executable blocks
(OBs/SFCs/SFBs) and their execution times.
Getting Started
S7-300 Getting Started Collection
Entry ID: 15390497
PROFINET Getting Started Collection
Entry ID: 19290251
The collections use concrete examples to provide
step-by-step instructions on how to commission a
fully functional application.
S7-300 Getting Started Collection:
CPU 31x: Commissioning
CPU 31xC: Commissioning
CPU 314C: Positioning with analog output
CPU 314C: Positioning with digital output
CPU 31xC: Counting
CPU 31xC: Point-to-point connection
CPU 31xC: Rules

PROFINET Getting Started Collection:
CPU 315-2 PN/DP, CPU 317-2 PN/DP and
CPU 319-3 PN/DP: Configuring the
PROFINET interface
CPU 317-2 PN/DP: Configuring an ET 200S
as PROFINET IO device
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Further Information
You also require information from the following descriptions:

STEP 7
System software for S7-300/400 system and
standard functions Volume 1/2
Entry ID: 1214574
Overview of the OBs, SFCs, SFBs, IEC
functions, diagnostics data, system status list
(SSL) and events in the operating systems of
the CPUs of the S7-300 and S7-400.
This manual is part of the STEP 7 reference
information.
You can also find the description in the online
help for STEP 7.
Programming with STEP 7
Entry ID: 18652056
This manual provides a complete overview of
programming with the STEP 7 Standard
Package.
This manual is part of the STEP 7 Standard
Package basic information. A description is also
available in the online help for STEP 7.
PROFINET
PROFINET System Description
Entry ID: 19292127
Basic description of PROFINET:
Network components
Data exchange and communication
PROFINET IO
Component Based Automation
Application example of PROFINET IO and
From PROFIBUS DP to PROFINET IO
Entry ID: 19289930
Guideline for the migration from PROFIBUS DP
to PROFINET I/O.
SIMATIC NET: Twisted Pair and Fiber-Optic
Networks
Entry ID: 8763736
Description of Industrial Ethernet networks,
network configuration, components, installation
guidelines for networked automation systems in
buildings, etc.
Configure SIMATIC iMap plants
Entry ID: 22762190
Description of the SIMATIC iMap configuration
software
SIMATIC iMap STEP 7 AddOn, create PROFINET
components
Entry ID: 22762278
Descriptions and instructions for creating
PROFINET components with STEP 7 and for
using SIMATIC devices in Component Based
Automation
Isochronous mode
Entry ID: 15218045
Description of the system property "Isochronous
mode"
SIMATIC communication
Entry ID: 1254686
Basics, services, networks, communication
functions, connecting PGs/OPs, engineering
and configuring in STEP 7.
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1.2 Guide to the S7-300 documentation
Service & support on the Internet
Information on the following topics can be found on the Internet
(http://www.siemens.com/automation/service):
Contacts for SIMATIC (http://www.siemens.com/automation/partner)
Contacts for SIMATIC NET (http://www.siemens.com/simatic-net)
Training (http://www.sitrain.com)
Overview
The following tables contain a guide through the S7-300 documentation.
Ambient influence on the automation system

Information about ... is available in the manual ... In Section ...
What provisions do I have to make for automation
system installation space?
Installation
Configuring Component
dimensions
Mounting Installing the
mounting rail
How do environmental conditions influence the
automation system?
Installation
Appendix
Galvanic isolation

Which modules can I use if electrical isolation is
required between sensors/actuators?
Installation
Module data
Configuring Electrical
assembly, protective measures
and grounding
Under what conditions do I have to isolate the
modules electrically?
How do I wire that?
Installation
Configuring Electrical
assembly, protective measures
and grounding
Wiring
Under which conditions do I have to isolate stations
electrically?
How do I wire that?
Installation
Configuring Configuring
subnets
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Communication between sensors/actuators and the PLC

Which module is suitable for my sensor/actuator? CPU 31xC and CPU 31x:
Technical Data
For your signal module
Technical Data
How many sensors/actuators can I connect to the
module?
Technical Data
For your signal module
Technical Data
How do I connect my sensors/actuators to the
automation system, using the front connector?
Installation
Wiring Wiring the front
connector
When do I need expansion modules (EM) and how
do I connect them?
Installation
Configuring Distribution of
modules to several racks
How do I mount modules on racks / mounting rails? CPU 31xC and CPU 31x:
Installation
Assembly Installing modules on
the mounting rail
The use of local and distributed IOs

Which range of modules do I want to use? Module data
(for centralized IOs and
expansion devices)
of the respective peripheral
(for distributed IOs /
PROFIBUS DP)

Configuration consisting of the central controller and expansion units

Which rack / mounting rail is most suitable for my
application?
Installation
Configuring
Which interface modules (IM) do I need to connect
the expansion units to the central controller?
Installation
Configuring Distribution of
modules to several racks
What is the right power supply (PS) for my
application?
Installation
Configuring
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CPU performance

Which memory concept is best suited to my
application?
Technical Data
Memory concept
How do I insert and remove Micro Memory Cards? CPU 31xC and CPU 31x:
Installation
Commissioning Commissioning
modules Removing / inserting a
Micro Memory Card (MMC)
Which CPU meets my demands on performance? S7-300 instruction list: CPU
31xC and CPU 31x

Length of the CPU response / execution times CPU 31xC and CPU 31x:
Technical Data

Which technological functions are implemented? Technological functions
How can I use these technological functions? Technological functions
Communication

Which principles do I have to take into account? CPU 31xC and CPU 31x:
Technical Data
Communication with SIMATIC
PROFINET System Description
Communication
Options and resources of the CPU CPU 31xC and CPU 31x: Technical
Data
Technical Data
How to use communication processors (CPs) to
optimize communication
CP Manual
Which type of communication network is best
suited to my application?
Installation
subnets
How do I network the various components? CPU 31xC and CPU 31x:
Installation
subnets
SIMATIC NET, twisted-pair and
fiber-optic networks
(6GK1970-1BA10-0AA0)
Network configuration What to take into account when configuring
PROFINET networks
PROFINET System Description Installation and commissioning
Software

Software requirements of my S7-300 system CPU 31xC and CPU 31x: Technical
Data
Technical Data
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Supplementary features

Information about ... is available in ...
How can I implement operation and monitoring
functions?
(Human Machine Interface)
The relevant Manual:
For text-based displays
For Operator Panels
For WinCC
How to integrate process control modules Respective PCS7 manual
What options are offered by redundant and fail-
safe systems?
S7-400H Fault-Tolerant Systems
Failsafe systems
Information to be observed when migrating from
PROFIBUS DP to PROFINET IO
From PROFIBUS DP to PROFINET IO

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2

We will start by showing you the sequence of steps you have to follow to install your system.
Then we will go on to explain the basic rules that you should follow, and how you can modify
an existing system.
Installation procedure

Configuration
lnstallation
Wiring
Networking
YES
ls a subnet to be built up?
NO
Addressing
lnstallation completed,continue
with commissioning

Basic rules for trouble-free operation of the S7 system
In view of the many and versatile applications, we can only provide basic rules for the
electrical and mechanical installation in this section.
You have to at least keep to these basic rules in order to obtain a fully functional SIMATIC-
S7 system.
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Modifying the existing S7 system structure
To modify the configuration of an existing system, proceed as described earlier.

Note
When adding a new signal module, always refer to the relevant module information.

Reference
Also refer to the description of the various modules in the manual: SIMATIC S7-300
Automation Systems, Module Data Manual.
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S7-300 components
3
3.1 Example of an S7-300 configuration
SF
BUSF
DC5 V
FRCE
RUN
ST OP
SF
BUSF
DC5 V
FRCE
RUN
ST OP
5
4
1 2 3

Number Description
Power supply (PS) module
Central processing unit (CPU); the example in the diagram shows a CPU 31xC with
integrated I/O.
Signal module (SM)
PROFIBUS bus cable
Cable for connecting a programming device (PG)
You use a programming device (PG) to program the S7300 PLC. Use the PG cable to
interconnect the PG with the CPU.
To commission or program a CPU with PROFINET interface, you may also use an Ethernet
cable to interconnect the PG with the PROFINET connector of the CPU.
Several S7-300 CPUs communicate with one another and with other SIMATIC S7 PLCs via
the PROFIBUS cable. Several S7-300 are connected via the PROFIBUS bus cable.
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S7-300 components
3.2 Overview of the most important S7-300 modules
You can choose from a number of modules for installing and commissioning the S7-300. The
most important modules and their functions are shown below.
Table 3- 1 S7-300 components:
Component Function Illustration
Mounting rail
Accessories:
Shielding terminal
S7-300 racks

Power supply (PS) module The PS converts the line voltage
(120/230 VAC) into a 24 VDC operating
voltage, and supplies the S7-300 and
its 24 VDC load circuits.

A CPU 31xC, for example

A CPU 312, 314, or 315-2 DP, for
example
CPU
Accessories:
Front connectors (CPU 31xC only)
The CPU executes the user program,
supplies 5 V to the S7-300 backplane
bus, and communicates with other
nodes of an MPI network via the MPI
interface.
Additional features of specific CPUs:
DP master or DP slave on a
PROFIBUS subnet
Technological functions
Point-to-point connection
Ethernet communication via
integrated PROFINET interface

A CPU 317, for example
ITEM 3000
S7-300 components
Signal modules (SM)
Digital input modules
Digital output modules
Digital I/O modules,
Analog input modules
Analog output modules
Analog I/O modules

Accessories:
Front connectors
The SM matches different process
signal levels to the S7-300.

Function modules (FM)
Accessories:
Front connectors
The FM performs time-critical and
memory-intensive process signal
processing tasks.
Positioning or controlling, for example

Communication processor (CP)
Accessories: Connecting cable
The CP relieves the CPU of
communication tasks.
Example: CP 342-5 DP for connecting
to PROFIBUS DP

SIMATIC TOP connect
Accessories:
Front connector module with ribbon
cable terminals
Wiring of digital modules

Interface module (IM)
Accessories:
Connecting cable
The IM interconnects the various rows
in an S7-300

PROFIBUS cable with bus connector Interconnect the nodes of an MPI or
PROFIBUS subnet

PG cable Connects a PG/PC to a CPU

ITEM 3000
S7-300 components
RS 485 repeater
RS 485 Diagnostic Repeater
The repeater is used to amplify the
signals and to couple segments of an
MPI or PROFIBUS subnet.

Switch A switch is used to interconnect the
Ethernet nodes.

Twisted-pair cables with RJ45
connectors.
Interconects devices with Ethernet
interface (a switch with a CPU 317-2
PN/DP, for example)

Programming device (PG) or PC with
the STEP 7 software package
You need a PG to configure, set
parameters, program and test your S7-
300

ITEM 3000

Configuring
4
4.1 Overview
There, you can find all the necessary information
for the mechanical configuration of an S7-300,
for the electrical configuration of an S7-300,
that has to be observed in networking.
Reference
For more detailed information, refer to
the Communication with SIMATIC manual or
the SIMATIC NET Twisted-Pair and Fiber-Optic Networks Manual (6GK1970-1BA10-
0AA0)
ITEM 3000
Configuring
4.2 Basic engineering principles
Important information for engineering
WARNING
Open equipment
S7-300 modules are open equipment. That is, the S7-300 must be installed in a cubicle,
cabinet or electrical control room which can only be accessed using a key or tool. Only
trained or authorized personnel are allowed access to such cubicles, cabinets or electrical
operating rooms.

CAUTION
Operation of an S7-300 in plants or systems is defined by special set of rules and
regulations, based on the relevant field of application. Observe the safety and accident
prevention regulations for specific applications, for example, the machine protection
directives. This chapter and the appendix General rules and regulations on S7-300
operation provide an overview of the most important rules you need to observe when
integrating an S7-300 into a plant or a system.

Central Rack (CR) and Expansion Rack (ER)
An S7-300 PLC consists of a central unit (CU) and of one or multiple expansion modules.
The rack containing the CPU is the central unit (CU). Racks equipped with modules and
connected to the CU form the expansion modules (EMs) of the system.
Use of an expansion module (EM)
You can use EMs if the CU runs out of slots for your application.
When using EMs, you might require further power supply modules in addition to the extra
racks and interface modules (IM). When using interface modules you must ensure
compatibility of the partner stations.
Racks
The rack for your S7-300 is a mounting rail. You can use this rail to mount all modules of
your S7-300 system.
ITEM 3000
Configuring
Horizontal and vertical installation
You can mount an S7-300 either vertically or horizontally. The following ambient air
temperatures are permitted:
Vertical assembly: 0 C to 40 C
Horizontal assembly: 0 C to 60 C
Always install the CPU and power supply modules on the left or at the bottom.
DC5 V
FRCE
RUN
ST OP
D
C
5
F
R
C
E
R
U
N
S
T
O
P
SM
SM
SM
SM SM SM SM SM
SM
SM
SM
SM SM SM
SM
SM
CPU
CPU
PS
PS
1
2
3
3

Number Description
the vertical installation of an S7-300
the horizontal installation of an S7-300
The mounting rail

ITEM 3000
Configuring
4.3 Component dimensions
Length of the mounting rails
Table 4- 1 Mounting rails - Overview
Mounting rail length Usable length for modules Order No.
160 mm 120 mm 6ES7 390-1AB60-0AA0
482.6 mm 450 mm 6ES7 390-1AE80-0AA0
530 mm 480 mm 6ES7 390-1AF30-0AA0
830 mm 780 mm 6ES7 390-1AJ30-0AA0
2000 mm cut to length as required 6ES7 390-1BC00-0AA0
In contrast to other rails, the 2 m mounting rail is not equipped with any fixing holes. These
must be drilled, allowing optimal adaptation of the 2 m rail to your application.
Installation Dimensions of the Modules
Table 4- 2 Module width
Module Width
Power supply module PS 307, 2 A 50 mm
CPU For information on assembly dimensions,
refer to the Technical Data in CPU 31xC and
CPU 31x Manual, Technical Data.
Analog I/O modules 40 mm
Digital I/O modules 40 mm
Simulator module SM 374 40 mm
Interface modules IM 360 and IM 365 40 mm
Interface module IM 361 80 mm
Module height: 125 mm
Module height with shielding contact element: 185 mm
Maximum assembly depth: 130 mm
Maximum assembly depth of a CPU with an inserted DP connector with angled cable
feed: 140 mm
Maximum assembly depth with open front panel (CPU): 180 mm
Dimensions of other modules such as CPs, FMs etc. are found in the relevant manuals.
ITEM 3000
Configuring
Shielding contact element
The direct contact between the shielding contact element and the mounting rail makes it
easy for you to connect all shielded cables of your S7 modules to ground.
PS
CPU
1
2

Number Description
Shielding terminals
The bracket.
Mount the bracket (order number. 6ES7 390-5AA0-0AA0) to the rail using the two screw
bolts. If you use a shielding contact element, the specified dimensions are measured from
the base of the element.
Width of the shielding contact element: 80 mm
Mountable terminal elements per shield connecting element max. 4
Table 4- 3 Shielding terminals - Overview
Cable with shielding diameter Shielding terminal order no.
Cable with 2 mm to 6 mm shielding diameter 6ES7 390-5AB000AA0
Cable with 3 mm to 8 mm shielding diameter 6ES7 390-5BA000AA0
Cable with 4 mm to 13 mm shielding diameter 6ES7 390-5CA000AA0
ITEM 3000
Configuring
4.4 Specified clearances
4.4 Specified clearances
You must maintain the clearance shown in the figure in order to provide sufficient space for
installing the modules, and to allow the dissipation of heat generated by the modules.
The S7-300 assembly on multiple racks shown in the figure below shows the clearance
between racks and adjacent components, cable ducts, cabinet walls etc.
For example, when routing your module wiring through cable duct, the minimum clearance
between the bottom of the shield connection element and the cable duct is 40 mm.
40 mm
40 mm
40 mm
40 mm
200 mm + a
a
20 mm 20 mm
SM
SM
SM
SM SM CPU
PS
CPU
2
1

Number Description
Wiring with cable duct
Minimum clearance between the cable duct and the bottom edge of the shielding contact
element is 40 mm

ITEM 3000
Configuring
4.5 Arrangement of modules on a single rack
4.5 Arrangement of modules on a single rack
Reasons for using one or multiple racks
The number of racks you need will depend on your application.

Reasons for using a single rack: Reasons for distributing modules between
several racks
Compact, space-saving use of all your
modules
Local use of all modules
Fewer signals to be processed
More signals to be processed
Insufficient number of slots

Note
If you opt for the installation on a single rack, insert a dummy module to the right of the CPU
(order no.: 6ES7 370-0AA01-0AA0). This gives you the option of adding a second rack for
your application, simply by replacing the dummy module with an interface module, and
without having to reinstall and rewire the first rack.

Rules: Layout of modules on a single module rack
The following rules apply to module installations on a single rack:
No more than eight modules (SM, FM, CP) may be installed to the right of the CPU.
The accumulated power consumption of modules mounted on a rack may not exceed 1.2
A on the S7-300 backplane bus.
Reference
Further information is available in the technical data, for example, in the SIMATIC S7-300
Automation Systems Manual, Module data, or in the S7-300 Manual, CPU 31xC and
CPU 31x, Technical Data.
ITEM 3000
Configuring
4.6 Distribution of modules to several racks
Example
The figure below shows a layout with eight signal modules in an S7-300 assembly.
PS SM1 SM2 SM3 SM4 SM5 SM6 SM7 SM8 CPU

Exceptions
With CPU 312 and CPU 312C, only a single-row configuration on a rack is possible.
Using interface modules
If you are planning an assembly in multiple racks, then you will need interface modules (IM).
An interface module routes the backplane bus of an S7-300 to the next rack.
The CPU is always located on rack 0.
Table 4- 4 Interface modules - Overview
Properties Two or more rows Cost-effective 2-row configuration
Send IM in rack 0 IM 360
order no..: 6ES7 360-3AA01-0AA0
IM 365
order no..: 6ES7 365-0AB00-0AA0
Receiver IM in racks 1 to 3 IM 361
order no..: 6ES7 361-3CA01-0AA0
IM 365 (hard-wired to send IM 365)
Maximum number of expansion
modules
3 1
Length of connecting cables 1 m (6ES7 368-3BB01-0AA0)
2.5 m (6ES7 368-3BC51-0AA0)
5 m (6ES7 368-3BF01-0AA0)
10 m (6ES7 368-3CB01-0AA0)
1 m (hard-wired)
Remarks - Rack 1 can only receive signal modules;
the accumulated current load is limited to
1.2 A, whereby the maximum for rack 1 is
0.8 A
These restrictions do not apply to operation
with interface modules IM 360/IM 361
ITEM 3000
Configuring
Rules: Distribution of modules to several racks
Please note the following points if you wish to arrange your modules on multiple racks:
The IM always uses slot 3 (slot 1: power supply module; slot 2: CPU, slot 3: Interface
module)
It is always on the left before the first signal module.
No more than 8 modules (SM, FM, CP) are permitted per rack.
The number of modules (SM, FM, CP) is limited by the permitted current consumption on
the S7-300 backplane bus. The accumulated power consumption may not exceed 1.2 A
per row.

Note
For information on the current consumption of the modules, refer to the SIMATIC
Automation Systems S7-300, Module Specifications Manual.

Rules: Interference-proof interfacing
Special shielding and grounding measures are not required if you interconnect the CU and
EM using suitable interface modules (Send IM and Receive IM).
However, you must ensure
a low impedance interconnection of all racks,
that the racks of a grounded assembly are grounded in a star pattern,
that the contact springs on the racks are clean and not bent, thus ensuring that
interference currents are properly discharged to ground.
ITEM 3000
Configuring
Example: Full assembly using four racks
The figure shows the arrangement of modules in an S7-300 assembly on 4 racks.
lM PS SM 1 SM 2 SM 3 SM 4 SM 5 SM 6 SM 7 SM 8
lM PS SM 1 SM 2 SM 3 SM 4
SM 4
SM 5 SM 6 SM 7 SM 8
lM PS
PS
SM 1 SM 2 SM 3 SM 5 SM 6 SM 7 SM 8
SM 4 lM CPU SM 1 SM 2 SM 3 SM 5 SM 6 SM 7 SM 8 1
2
3
4
5
5
5
6

Number Description
Rack 0 (central unit)
Rack 1 (expansion module)
The connecting cable 368
Restriction for CPU 31xC. When this CPU is used, do not insert SM 8 into Rack 4.

ITEM 3000
Configuring
4.7 Selection and installation of cabinets
Reasons for installing an S7-300 in a cabinet
Your S7-300 should be installed in a cabinet,
if you plan a larger system,
if you are using your S7-300 systems in an environment subject to interference or
contamination, and
to meet UL/CSA requirements for cabinet installation.
Selecting and dimensioning cabinets
Take the following criteria into account:
ambient conditions at the cabinet's place of installation
the specified mounting clearance for racks (mounting rails)
accumulated power loss of all components in the cabinet.
The ambient conditions (temperature, humidity, dust, chemical influence, explosion hazard)
at the cabinet's place of installation determine the degree of protection (IP xx) required for
the cabinet.
Reference for degrees of protection
For further information on the degrees of protection, refer to IEC 529 and DIN 40050.
The power dissipation capability of cabinets
The power dissipation capability of a cabinet depends on its type, ambient temperature and
on the internal arrangement of devices.
Reference for power loss
For detailed information on dissipatable power loss, refer to the Siemens catalogs. You can
find these at: https://mall.automation.siemens.com/de/guest/guiRegionSelector.asp
ITEM 3000
Configuring
Specification of cabinet dimensions
Note the following specifications when you determine the dimensions of a cabinet for your
S7-300 installation:
Space required for racks (mounting rails)
Minimum clearance between the racks and cabinet walls
Minimum clearance between the racks
Space required for cable ducts or fan assemblies
Position of the stays

WARNING

Modules may get damaged if exposed to excess ambient temperatures.

Reference for ambient temperatures
For information on permitted ambient temperatures, refer to the S7-300 Automation System,
Module Data Manual.
ITEM 3000
Configuring
Overview of typical cabinet types
The table below gives you an overview of commonly used cabinet types. It shows you the
applied principle of heat dissipation, the calculated maximum power loss and the degree of
protection.
Table 4- 5 Cabinet types
Open cabinets Closed cabinets
Through-ventilation by
natural convection
Increased through-
ventilation
Natural convection Forced convection with
rack fan, improvement
of natural convection
Forced convection with
heat exchanger,
internal and external
auxiliary ventilation

Mainly inherent heat
dissipation, with a
small portion across
the cabinet wall.
Higher heat dissipation
with increased air
movement.
Heat dissipation only
across the cabinet
wall; only low power
losses permitted. In
most cases, the heat
accumulates at the top
of the cabinet interior.
Heat dissipation only
across the cabinet
wall. Forced
convection of the
interior air improves
heat dissipation and
prevents heat
accumulation.
Heat dissipation by
heat exchange
between heated
internal air and cool
external air. The
increased surface of
the pleated profile of
the heat exchanger
wall and forced
convection of internal
and external air
provide good heat
dissipation.
IP 20
IP 20
IP 54
IP 54
IP 54
Typical power dissipation under following marginal conditions:
Cabinet size: 600 mm x 600 mm x 2,200 mm
Difference between the outer and inner temperature of the cabinet is 20 C (for other temperature differences refer to
the temperature charts of the cabinet manufacturer)
up to 700 W up to 2,700 W (with
fine filter up to
1,400 W)
up to 260 W up to 360 W up to 1,700 W
ITEM 3000
Configuring
4.8 Example: Selecting a cabinet
4.8 Example: Selecting a cabinet
Introduction
The sample below clearly shows the maximum permitted ambient temperature at a specific
power loss for different cabinet designs.
Installation
The following device configuration should be installed in a cabinet:
Central unit, 150 W
Expansion modules, each with 150 W
Load power supply under full load, 200 W
This results in an accumulated power loss of 650 W.
Power loss dissipated
The diagram in the figure below shows guide values for the permitted ambient temperature
of a cabinet with the dimensions 600 mm x 600 mm x 2000 mm, based on the accumulated
power loss. These values only apply if you maintain the specified assembly and clearance
dimensions for racks (rails).

60
50
40
30
20
200 400 600 800 1000 1200 1400
Ambient temperature in C
Power loss in W
1
2
3

Number Description
Closed cabinet with heat exchanger (heat exchanger size 11/6 (920 mm x 460 mm x 111
mm))
Cabinet with through-ventilation by natural convection
Closed cabinet with natural convection and forced convection by equipment fans
ITEM 3000
Configuring
4.9 Electrical assembly, protective measures and grounding
Result
The figure below shows the resultant ambient temperatures, based on an accumulated
power loss of 650 W:
Table 4- 6 Cabinet selection
Cabinet design Maximum permitted ambient
temperature
Closed with natural convection and forced convection
(trend 3)
Operation not possible
Open with through-ventilation (trend 2) approx. 38
Closed with heat exchanger (trend 1) approx. 45 C
Cabinet types suitable for horizontal installation of the S7-300:
open, with closed ventilation
closed, with heat exchanger
4.9.1 Grounding concept and overall structure
This section contains information about the overall configuration of an S7-300 connected to a
grounded TN-S network:
Circuit-breaking devices, short-circuit and overload protection to VDE 0100 and VDE
0113
Load power supplies and load circuits
Grounding concept

Note
An S7-300 can be used in many different ways, so we can only describe the basic rules
for the electrical installation in this document. Those basic rules are a must in order to
achieve a fully functional S7-300 system.

Definition: Grounded mains
In a grounded mains network, the neutral conductor is always bonded to ground. A short-
circuit to ground of a live conductor, or of a grounded part of the system, trips the protective
devices.
ITEM 3000
Configuring
Specified components and protective measures
A number of components and protective measures are prescribed for plant installations. The
type of components and the degree of compulsion pertaining to the protective measures will
depend on the VDE specification applicable to your particular plant.
The table below shows components and protective measures.
Table 4- 7 VDE specifications for the installation of a PLC system
Compare ... 1) VDE 0100 VDE 0113
Disconnect devices for control
systems, signal generators and
final control elements
(1) ...Part 460:
Master switch
... Part 1:
Load disconnect switch
Short-circuit / overload
protection:
In groups for signal generators
and final control elements
(2) ...Part 725:
Single-pole fusing of
circuits
... Part 1:
With grounded secondary
power circuit: single-pole
fusing
Otherwise: fusing of all poles
Load power supply for AC load
circuits with more than five
electromagnetic devices
(3) Galvanic isolation by
transformer
recommended
Electrical isolation by transformer
mandatory
1) This column refers to the indexes of the figure in the chapter "Overview: Grounding".
Reference
For further information on protective measures, refer to the Appendix.
See also
Overview display: Grounding (Page 50)
ITEM 3000
Configuring
4.9.2 Installing an S7-300 with grounded reference potential
Introduction
When the S7-300 is configured with a grounded reference potential, any interference
currents are discharged to the grounding conductor / ground. A grounding slide contact is
used for this except with CPU 31xC.

Note
Your CPU is supplied with grounded reference potential. Therefore, if you wish to install an
S7-300 with grounded reference potential, you do not need to modify your CPU!

Grounded reference potential of the CPU 31x
The figure shows an S7-300 configuration with grounded reference potential (factory state.)
10M
M
L+
M
M
<100nF
1
2
3

Number Description
Grounding slide contact in grounded state
Ground of the internal CPU circuitry
The mounting rail

Note
Do not pull out the grounding slide contact when you install an S7-300 with grounded
reference potential.

ITEM 3000
Configuring
4.9.3 Installing an S7-300 with ungrounded reference potential (not CPU 31xC)
Introduction
When the S7-300 is configured with an ungrounded reference potential, interference currents
are discharged to the ground conductor / to ground via an RC combination integrated in the
CPU.

Note
An S7-300 with a CPU 31xC cannot be configured ungrounded.

Application
In large systems, the S7-300 may require a configuration with grounded reference potential
due to ground-fault monitoring. This is the case, for example, in chemical industry and power
stations.
Ungrounded reference potential of the CPU 31x
The figure shows an S7-300 configuration with floating potential
10M
M
L+
M
M
<100nF
2
3
1

Number Description
How to implement an ungrounded reference potential in your CPU: Use a screwdriver with 3.5 mm blade width to
push the grounding slide contact forwards in the direction of the arrow until it snaps into place.
Ground of the internal CPU circuitry
The mounting rail.

Note
You should set up the ungrounded reference potential before you mount the device on the
rail. If you have already installed and wired up the CPU, you may have to disconnect the MPI
interface before you pull out the grounding slide contact.

ITEM 3000
Configuring
4.9.4 Isolated or non-isolated modules?
Isolated modules
Isolated modules are installed with galvanic isolation between the reference potentials of the
control circuit (Minternal) and load circuit (Mexternal.)
Use isolated modules for:
All AC load circuits
DC load circuits with separate reference potential
Examples:
DC load circuits containing sensors which are connected to different reference
potentials (for example, if grounded sensors are located at a considerable distance
from the control system and equipotential bonding is not possible)
DC load circuits with grounded positive pole (L+) (battery circuits.)
Isolated modules and grounding concept
You can always use isolated modules, irrespective of the grounding state of the control
system's reference potential.
Example: Assembly with CPU 31xC and isolated modules
The figure below shows an example of such a configuration: A CPU 31xC with isolated
modules. The CPU 31xC (1) is automatically grounded.
PS Dl DO S7-300 CPU
L1 L+
L+
P
N
L1
L1
N
N
PE
Data
M
U internal
Mintern
Mexternal
230 VAC load current supply
24 VDC load current supply
Grounding busbar in
cabinet
1

ITEM 3000
Configuring
Common potential modules
In a configuration containing modules with common potential, the reference potentials of the
control circuit (Minternal) and analog circuit (Manalog) are not galvanically isolated.
Example: Installing an S7-300 with common potential modules
When using an SM 334 AI 4/AO 2 analog I/O module, connect one of the grounding
terminals Manalog to the CPU's chassis ground.
The figure below shows an example of such a configuration: An S7-300 with common
potential modules
PS S7-300 CPU
1 mm
2
+ +
Data
V
A
A A
D D
P
M
M
L+
L+
L1
L1
N
N
PE
Manalog
U internal
Mintern
M
external
Grounding busbar in
cabinet
24 VDC load current supply

ITEM 3000
Configuring
4.9.5 Grounding measures
Bonding to ground
Low-impedance connections to ground reduce the risk of electric shock as a result of a
short-circuit or system fault. Low-impedance connections (large surface, large-surface
contact) reduce the effects of interference on the system or the emission of interference
signals. An effective shielding of cables and devices is also a significant contribution.

WARNING
All protection class 1 devices, and all larger metal parts, must be bonded to protective
ground. That is the only way to safely protect operators from electrical shock. This also
discharges any interference transmitted from external power supply cables, signal cables or
cables to the I/O devices.

Measures for protective grounding
The table below shows an overview of the most important measures for protective
grounding.
Table 4- 8 Measures for protective grounding
Device Measures
Cabinet / mounting frame Connection to central ground (equipotential busbar, for example)
using cables with protective conductor quality
Rack / mounting rail Connection to central ground, using cables with a minimum cross-
section of 10 mm
2
, if the rails are not installed in the cabinet and not
interconnected with larger metallic parts.
Module None
I/O Device Grounding via grounding-type plug
Sensors and final control
elements
Grounding in accordance with regulations applying to the system
ITEM 3000
Configuring
Rule: Connect the cable shielding to ground
You should always connect both ends of the cable shielding to ground / system ground. This
is the only way to achieve an effective interference suppression in the higher frequency
range.
Attenuation is restricted to the lower frequency range if you connect only one end of the
shielding (that is, at the start or end of the cable) to ground. One-sided shielding connections
could be more favorable in situations
not allowing the installation of an equipotential bonding conductor,
where analog signals (some mA or A) are transferred,
or if foil shielding is used (static shielding).

Note
Potential differences between two grounding points might cause an equipotential current
flow across shielding connected at both ends. In this case, you should install an
additional equipotential bonding conductor.

CAUTION

Always avoid the flow of operating current to ground.

Rule: Load circuit grounding
You should always ground the load circuits. This common reference potential (ground)
ensures proper functioning.

Note
(not valid for CPU 31xC):
If you want to locate a fault to ground, provide your load power supply (terminal L or M) or
the isolating transformer with a removable connection to the protective conductor (see
Overview: Grounding section 4).

ITEM 3000
Configuring
Connecting the load voltage reference potential
A complex system containing many output modules requires an additional load voltage for
switching the final control elements.
The table below shows how to connect the load voltage reference potential Mexternal for the
various configurations.
Table 4- 9 Connecting the load voltage reference potential
Installation

common potential modules isolated modules Note
grounded Connect Mexternal with M on
the CPU
Connect or do not connect
Mexternal to the grounding
busbar
-
ungrounded Connect Mexternal with M on
the CPU
Connect or do not connect
Mexternal to the grounding
busbar
Ungrounded installation
with CPU 31xC is not
possible
ITEM 3000
Configuring
4.9.6 Overview display: Grounding
CPU 31xC
The figure below shows you the complete assembly of an S7-300 with CPU 31xC with a
power supply from TN-S mains. Apart from powering the CPU, the PS 307 also supplies the
load current for the 24 VDC modules. Remark: The layout of the power connections does not
correspond with their physical arrangement; it was merely selected to give you a clear
overview.
L1
L2
L3
N
PE
SM CPU PS
L1
N
L +
M
P
AC
AC
AC
AC
DC
DC
Low-voltage distribution
TN S system (3 x 400 V), for example
Cabinet
Signal modules
Mounting rail
Grounding busbar in cabinet
Load circuit
24 VAC to 230 VAC for AC modules
Load circuit
5 VDC to 60 VDC for non-isolated DC modules
Load circuit
5 VDC to 60 VDC for isolated DC modules
1
3
4
2
2
2

Number Description
The main switch
The short-circuit / overload protection
The load current supply (galvanic isolation)
This connection is made automatically for the CPU 31xC
Figure 4-1 Connecting the load voltage reference potential
ITEM 3000
Configuring
All CPUs except CPU 31xC
The figure below shows you the complete assembly of an S7-300 with TN-S mains supply
(does not apply to CPU 31xC). Apart from powering the CPU, the PS 307 also supplies the
load current for the 24 VDC modules.
Remark: The layout of the power connections does not correspond with their physical
arrangement; it was merely selected to give you a clear overview.
L1
L1
L+
M
M
N
L2
L3
N
PE
SM CPU
P
PS
Mounting rail
AC
Signal modules
Cabinet
Load circuit
Load circuit
Load circuit
24 VAC to 230 VAC for AC modules
5 VDC to 60 VDC for non-isolated DC modules
5 VDC to 60 VDC for isolated DC modules
AC
DC
DC
AC
AC
1
3
4
2
2
2
5

Number Description
The main switch
The short-circuit / overload protection
The load current supply (galvanic isolation)
The removable connection to the grounding conductor, for ground fault localization
The grounding slide contact of the CPU (not CPU 31xC)
Figure 4-2 Connecting the load voltage reference potential
ITEM 3000
Configuring
4.10 Selection of the load power supply
Task of the load power supply
The load power supply feeds the input and output circuits (load circuits), and the sensors
and actuators.
Features of load power supply units
You will have to adapt the load power supply unit to your specific application. The table
below shows a comparison of the various load power supply units and their features to help
you make your choice:
Table 4- 10 Features of load power supply units
Necessary for ... Feature of the load power
supply
Remarks
Modules requiring voltage
supplies 60 VDC or 25 VAC.
24 VDC load circuits
Safety isolation This is a common feature of the
Siemens power supply series
PS 307 and SITOP power
series 6EP1.

Output voltage tolerances:
20.4 V to 28.8 V
40.8 V to 57.6 V
51 V to 72 V
-
Load power supply requirements
Only an extra-low voltage of 60 VDC which is safely isolated from mains may be used as
load voltage. Safe isolation from mains can be achieved, for example, in accordance with
VDE 0100 Part 410 / HD 384-4-41 / IEC 364-4-41 (as functional extra-low voltage with safe
isolation) or VDE 0805 / EN 60950 / IEC 950 (as safety extra-low voltage SELV) or VDE
0106 Part 101.
Load current determination
The required load current is determined by the accumulated load current of all sensors and
actuators connected to the outputs.
A short-circuit induces a surge current at the DC outputs which is 2 to 3 times higher than
the rated output current, until the clocked electronic short-circuit protection comes into effect.
Make allowances for this increased short-circuit current when selecting your load power
supply unit. Uncontrolled load power supplies usually provide this excess current. With
controlled load power supplies, and particularly for low output power up to 20 A, always
ensure that the supply can handle this excess current.
ITEM 3000
Configuring
Example: S7-300 with load power supply from PS 307
The figure below shows the overall S7-300 configuration (load power supply unit and
grounding concept), with TN-S mains supply. The PS 307 supplies the CPU and the load
current circuit of the 24 VDC modules.

Note
The layout of the power connections does not correspond with their physical arrangement; it
was merely selected to give you a clear overview.

L1
L2
L3
N
PE
PS
L+
P
L1
N
M
M
CPU SM
Mounting rail
Cabinet
Signal modules
Load circuit 24 V DC for
DC module

Example: S7-300 with load power supply from PS 307
ITEM 3000
Configuring
4.11 Planning subnets
4.11.1 Overview
Subnets
Subnets available in SIMATIC for the various automation levels (process, cell, field and
actuator/sensor level ):
Multi-Point Interface (MPI)
PROFIBUS
PROFINET (Industrial Ethernet)
Point-to-point communication (PtP)
Actuator/Sensor Interface (ASI)
Multi-Point Interface (MPI)
Availability: For all CPUs described in this document.
MPI is a small area subnet containing a small number of nodes at the field/cell level. It is a
multipoint-capable interface in SIMATIC S7/M7 and C7, designed as PG interface, for
networking a small number of CPUs, or for low volume data exchange with PGs.
MPI always retains the last configuration of the transmission rate, node number and highest
MPI address, even after CPU memory reset, power failure or deletion of the CPU parameter
configuration.
It is advisable to use the PROFIBUS DP network components for your MPI network
configuration. The same configuration rules apply. Exception: OWG modules are not allowed
in the MPI network.
PROFIBUS
Availability: CPUs with the "DP" name suffix are equipped with a PROFIBUS interface (CPU
315-2 DP, for example).
PROFIBUS represents the network at the cell and field level in the SIMATIC open,
multivendor communication system.
PROFIBUS is available in two versions:
1. PROFIBUS DP field bus for high-speed cyclic data exchange, and PROFIBUS-PA for
intrinsically safe applications (requires DP/PA coupler).
2. The cell level as PROFIBUS (FDL or PROFIBUS FMS) for high-speed data exchange
with communication partners at the same authorization level (can only be implemented
via CP).
ITEM 3000
Configuring
PROFINET (Industrial Ethernet)
Availability: CPUs with the "PN" name suffix are equipped with a PROFINET interface (CPU
317-2 PN/DP or CPU 319-3 PN/DP for example). A PROFINET interface, or communication
processors, can be used to implement Industrial Ethernet in an S7-300 CPU system.
Industrial Ethernet, in an open multivendor communication system, represents the SIMATIC
network at the process and cell level. PROFINET CPUs, however, also support real-time
communication at the field level. This structure also supports S7 communication. Industrial
Ethernet is suitable for high-speed and high-volume data exchange, and for remote network
operations via gateway.
PROFINET is available in two versions:
PROFINET IO and
PROFINET CBA.
PROFINET IO is a communication concept for the implementation of modular, distributed
applications. PROFINET IO allows you to create automation solutions you are familiar with
from PROFIBUS.
PROFINET CBA (Component based Automation) is an automation concept for the
implementation of applications with distributed intelligence. PROFINET CBA lets you create
distributed automation solutions, based on default components and partial solutions. This
concept satisfies demands for a higher degree of modularity in the field of mechanical and
systems engineering by extensive distribution of intelligent processes.
Component-Based Automation allows you to use complete technological modules as
standardized components in complex systems.
Point-to-point communication (PtP)
Availability: CPUs with "PtP" name suffix are equipped with a second interface, namely the
PtP interface (CPU 314C-2 PtP, for example)
PtP does not represent a subnet in the common sense, because it is used to interconnect
only two stations.
If a PtP interface is not available, you require PtP Communication Processors (CP).
Implementation by means of communication processors (CP).
The ASI, or actuator/sensor interface, represents a subnet system on the lowest process
level for automation systems. It is designed especially for networking digital sensors and
actuators. The maximum data volume is 4 bits per slave station.
S7-300 CPUs require communication processor for the ASI connection.
Reference
For further information on communication, refer to the Communication with SIMATIC
manual.
ITEM 3000
Configuring
4.11.2 Configuring MPI and PROFIBUS subnets
4.11.2.1 Overview
The next section contains all the information you require to configure MPI, PtP and
PROFIBUS subnets:
Contents
MPI, PtP and PROFIBUS subnets
Multi-Point Interface
PROFIBUS DP
MPI and PROFIBUS network components
Example of networks - MPI
4.11.2.2 Basic principles of MPI and PROFIBUS subnets
Convention: device = node
All devices you interconnect on the MPI or PROFIBUS network are referred to as nodes.
Segment
A segment is a bus line between two terminating resistors. A segment may contain up to 32
nodes. It is also limited with respect to the permitted line length, which is determined by the
transmission rate.
Baud rate
Maximum transmission rates:
MPI:
CPU 315-2 PN/DP, CPU 317 and CPU 319-3 DP/DP 12 Mbps
All other CPUs: 187.5 Kbps
PROFIBUS DP: 12 Mbps
ITEM 3000
Configuring
Number of nodes
Maximum number of nodes per subnet:
Table 4- 11 Subnet nodes
Parameters MPI PROFIBUS DP
Number 127 126
1)

Addresses 0 to 126 0 to 125
Remark Default: 32 addresses
Reserved addresses:
Address 0 for PG
Address 1 for OP
of those:
1 master (reserved)
1 PG connection (address 0 reserved)
124 slaves or other masters
1
Note the CPU-specific maximum specifications in the relevant CPU manual.
MPI/PROFIBUS DP addresses
You need to assign an address to all nodes in order to enable intercommunication:
On the MPI network: an "MPI address"
On the PROFIBUS DP network: "a PROFIBUS DP address"
You can use the PG to set the MPI/PROFIBUS addresses for each one of the nodes (some
of the PROFIBUS DP slaves are equipped with a selector switch for this purpose).
Default MPI/PROFIBUS DP addresses
The table below shows you the default setting of the MPI/PROFIBUS DP addresses, and the
factory setting of the highest MPI/PROFIBUS DP addresses for the nodes.
Table 4- 12 MPI/PROFIBUS DP addresses
Node (device) Default
MPI/PROFIBUS DP
address
Default highest MPI
address
Default highest PROFIBUS DP
address
PG 0 32 126
OP 1 32 126
CPU 2 32 126
Rules: Assignment of MPI/PROFIBUS DP addresses
Note the following rules before assigning MPI/PROFIBUS addresses:
All MPI/PROFIBUS subnet addresses must be unique.
Highest MPI/PROFIBUS address physical MPI/PROFIBUS address, and must be
identical for each node. (Exception: connecting a PG to multiple nodes; refer to the next
chapter).
ITEM 3000
Configuring
Differences in the MPI addresses of CPs/FMs in an S7300 system
Table 4- 13 MPI addresses of CPs/FMs in an S7-300 system
Options Example
CPU CP CP SM

Example:
A system containing an S7-300 CPU and 2
CPs.
You have two options of assigning MPI
addresses to CPs/FMs installed in a system:
CPU CP CP
1st option: The CPU accepts the MPI addresses
you set for the CPs in STEP 7.
MPI addr. MPI
addr.+x
MPI
add.+y

2nd option: The CPU automatically assigns MPI
addresses to the CPs in its system, based on
the following syntax: MPI addr. CPU; MPI
addr.+1; MPI addr.+2.
(Default)
MPI addr. MPI
addr.+1
MPI
addr.+2

Special feature: CPU 315-2 PN/DP, CPU 317
and CPU 319-3 DP/DP
When the central rack of an S7-300 contains
FM/CPs with their own MPI address, the CPU
forms its own communication bus via the
backplane bus for these FM/CPs and separates it
from the other subnets.
The MPI address of those FM/CPs is thus no
longer relevant for the nodes on other subnets.
The MPI address of the CPU is used to
communicate with these FMs/CPs.
Recommendation for MPI addresses
Reserve MPI address "0" for a service PG, or "1" for a service OP, for temporary
connections of these devices to the subnet. You should therefore assign different MPI
addresses to PGs/OPs operating on the MPI subnet.
Recommended MPI address of the CPU for replacement or service operations:
Reserve MPI address "2" for the CPU. This prevents duplication of MPI addresses after you
connect a CPU with default settings to the MPI subnet (for example, when replacing a CPU).
That is, you should assign an MPI address greater than "2" to CPUs on the MPI subnet.
Recommendation for PROFIBUS addresses
Reserve PROFIBUS address "0" for a service PG that you can subsequently connect briefly
to the PROFIBUS subnet as required. You should therefore assign unique PROFIBUS
addresses to PGs integrated in the PROFIBUS subnet.
PROFIBUS DP: Electrical cables or fiber-optic cables?
Use fiber optic cables on a field bus with greater length, rather than copper conductors, in
order to be independent on the transmission rate, and to exclude external interference.
ITEM 3000
Configuring
For information on what to take into account with respect to equipotential bonding in your
network configuration, refer to the corresponding chapter in the appendix.
Reference
For further information, refer to the Communication section in CPU 31xC and CPU 31x
Manual, Technical Data.
4.11.2.3 Multi-Point Interface (MPI)
Availability
All the CPUs described here are equipped with an MPI interface
A CPU equipped with an MPI/DP interface is configured and supplied as
MPI interface.
Properties
The MPI (Multi-Point Interface) represents the CPU interface for PG/OP connections, or for
communication on an MPI subnet.
The default transmission rate of all CPUs is 187.5 Kbps. You can also set 19.2 Kbps for
communication with an S7-200. The
315-2 PN/DP, 317-2 and 319-3 PN/DP CPUs support transmission rates to 12 Mbps.
The CPU automatically broadcasts its bus configuration via the MPI interface (the
transmission rate, for example). A PG, for example, can thus receive the correct parameters
and automatically connect to a MPI subnet.
Devices capable of MPI communication
PG/PC
OP/TP
S7-300 / S7-400 with MPI interface
S7-200 (only at 19.2 Kbps)

NOTICE

You may only connect PGs to an MPI subnet which is in RUN.
Do not connect other stations (for example, OP, TP) to the MPI subnet while the system
is running. Otherwise, transferred data might be corrupted as a result of interference, or
global data packages may be lost.

ITEM 3000
Configuring
Clock synchronization
The CPU's MPI interface supports clock synchronization. The CPU can be programmed for
operation as time-of-day master (with default synchronization intervals) or slave clock.
Default setting: No clock synchronization
The synchronization mode is set in the "Clock" tab of the CPU or interface properties dialog
box in HW Config.
CPU as a time slave
When operated as a slave clock, the CPU receives a synchronization message frame from
exactly one time-of-day master and sets its internal time accordingly.
CPU as a time master
When operated as time-of-day master, the CPU broadcasts clock synchronization message
frames at programmed synchronization intervals at the MPI interface to other node stations
of the MPI subnet.
Condition: The CPU real-time clock may no longer be in the default state. It has to be set
once.

Note
The real-time clock of the CPU is not yet set in the state of delivery or after resetting to the
state of delivery using the mode selector or after a firmware update.

The clock synchronization starts as a time-of-day master:
As soon as you have set the time the first time using SFC 0 "SET_CLK" or the
programming device function.
By another time-of-day master if the CPU is also parameterized as a slave clock using
the MPI/DP or PROFINET interface.
Interfaces for clock synchronization
Clock synchronization is possible at the following interfaces:
At the MPI Interface
At the DP Interface
At the PROFINET Interface
In the automation system of the central configuration

Note
The CPU may only be operated as a slave clock at one of these interfaces.

ITEM 3000
Configuring
Example 1
A CPU operating as a slave clock on the DP interface can only operate as a time-of-day
master on the MPI interface and/or within the automation system.
Example 2
If the CPU time is already synchronized through clock synchronization by means of a
PROFINET interface via NTP (corresponds to the functionality as a slave clock), the CPU
can only be operated as a time-of-day master at the DP interface and/or the MPI interface
within the automation system.
4.11.2.4 PROFIBUS DP interface
Availability
CPUs with the "DP" have at least one DP interface.
The 315-2 PN/DP and 317-2 PN/DP CPUs feature an integrated MPI/DP interface.
The 317-2 DP and 319-3 PN/DP CPUs feature an MPI/DP interface plus an additional DP
interface. The factory setting of the CPU's MPI/DP interface is MPI mode. You need to set
DP mode in STEP 7 if you want to use the DP interface.
Operating modes for CPUs with two DP interfaces
Table 4- 14 Operating modes for CPUs with two DP interfaces
MPI/DP interface PROFIBUS DP interface
MPI
DP master
DP slave
1)

not configured
DP master
DP slave
1)

1)
simultaneous operation of the DP slave on both interfaces is excluded
ITEM 3000
Configuring
Properties
The PROFIBUS DP interface is mainly used to connect distributed I/O. PROFIBUS DP
allows you to create large subnets, for example.
The PROFIBUS DP interface can be configured for operation in master or slave mode, and
supports transmission rates up to 12 Mbps.
The CPU broadcasts its bus parameters (transmission rate, for example) via the PROFIBUS
DP interface when master mode is set. This functionality automatically provides the correct
parameters for online operation of a programming device, for example. In your configuration
you can specify to disable bus parameter broadcasting.

Note
(for DP interface in slave mode only)
When you disable the "Test, Commissioning, Routing" check box in the DP interface
properties dialog box in STEP 7, the transmission rate settings of the master automatically
override corresponding user-specific settings. This disables the routing function at this
interface.

Devices capable of PROFIBUS DP communication
PG/PC
OP/TP
DP slaves
DP master
Actuators/Sensors
S7-300/S7-400 with PROFIBUS DP interface
The CPU's DP interface supports clock synchronization. The CPU can be programmed for
operation as time master (with default synchronization intervals) or time slave.
Default setting: No clock synchronization
The synchronization mode is set in the "Clock" tab of the interface properties dialog box in
HW Config.
CPU as a time slave
When operated as a slave clock, the CPU receives a synchronization message frame from
exactly one time-of-day master and sets its internal time accordingly.
ITEM 3000
Configuring
CPU as a time master
When operated as time-of-day master, the CPU broadcasts clock synchronization message
frames at programmed synchronization intervals at the DP interface to other node stations of
the DP subnet.
Condition: The CPU real-time clock may no longer be in the default state. It has to be set
once.

Note
The real-time clock of the CPU is not yet set in the state of delivery or after resetting to the
state of delivery using the mode selector or after a firmware update.

The clock synchronization starts as a time-of-day master:
As soon as you have set the time the first time using SFC 0 "SET_CLK" or the
programming device function.
By another time-of-day master if the CPU is also parameterized as a slave clock using
the MPI/DP or PROFINET interface.
Interfaces for clock synchronization
Clock synchronization is possible at the following interfaces:
At the MPI Interface
At the DP Interface
At the PROFINET Interface
In the automation system of the central configuration

Note
The CPU may only be operated as a slave clock at one of these interfaces.

Example 1
A CPU operating as a slave clock on the DP interface can only operate as a time-of-day
master on the MPI interface and/or within the automation system.
Example 2
If the CPU time is already synchronized through clock synchronization by means of a
PROFINET interface via NTP (corresponds to the functionality as a slave clock), the CPU
can only be operated as a time-of-day master at the DP interface and/or the MPI interface
within the automation system.
Reference
Further information on the PROFIBUS can be found on the Internet.
ITEM 3000
Configuring
4.11.2.5 Network components of MPI/DP and cable lengths
MPI subnet segment
You can install cables with a length of up to 50 m in an MPI subnet segment. This length of
50 m is the distance between the first and the last node of the segment.
Table 4- 15 Permissible cable length of a segment on the MPI subnet
Baud rate S7-300 CPUs (non-isolated
MPI interface)
without CPU 315-2 PN/DP /
CPU 317 / CPU 319
CPU 315-2 PN/DP / CPU 317 /
CPU 319
19.2 Kbps
187.5 Kbps
50 m 1000 m
1.5 Mbps 200 m
3.0 Mbps
6.0 Mbps
12.0 Mbps
-
100 m
Segment on the PROFIBUS subnet
The maximum cable length of a segment on the PROFIBUS subnet is determined by the set
transmission rate.
Table 4- 16 Permissible cable length of a segment on the PROFIBUS subnet
Baud rate Maximum cable length of a segment
9.6 Kbps to 187.5 Kbps 1000 m
500 Kbps 400 m
1.5 Mbps 200 m
3 Mbps to 12 Mbps 100 m
Longer cable lengths via RS 485 Repeater / RS 485-Diagnostics Repeater
You need to install RS485 repeaters for segments requiring cable lengths longer than the
allowed length. For further information about the RS485 Repeater refer to the Module
Specifications Manual.
Stub cables
Make allowances for the maximum stub cable length when you connect bus nodes to a
segment by means of stub cables, for example, a PG via standard PG cable.
For transmission rates up to 3 Mbps, you can use a PROFIBUS bus cable with bus
connector as stub cable. For transmission rates higher than 3 Mbps, use the patch cord to
connect the PG or PC. You can connect several PG patch cords to the bus (for order
numbers see table 4-20). Other types of stub cables are not permitted.
ITEM 3000
Configuring
Length of stub cables
The table below shows the maximum permitted lengths of stub cables per segment:
Table 4- 17 Lengths of stub cables per segment
Number of nodes with stub cable length of ... Baud rate Max. length of stub
cables per segment
1.5 m or 1.6 m 3 m
9.6 Kbps to 93.75 Kbps 96 m 32 32
187.5 Kbps 75 m 32 25
500 Kbps 30 m 20 10
1.5 Mbps 10 m 6 3
3 Mbps to 12 Mbps
1)

1)

1)

1)
To connect PGs or PCs when operating at rates higher than 3 Mbps, use PG connecting
cable with the order number 6ES7 901-4BD00-0XA0. In your bus configuration, you can use
multiple PG patch cords with this order number. Other types of stub cables are not permitted.
PG connecting cable
Table 4- 18 PG connecting cable
Type Order No.
PG connecting cable 6ES7 901-4BD00-0XA0
PROFIBUS cables
For PROFIBUS DP or MPI networking we offer you the following bus cables for diverse fields
of application:
Table 4- 19 Available bus cables
Bus cable Order No.
PROFIBUS cable 6XV1 830-0AH10
PROFIBUS cable, halogen-free 6XV1 830-0LH10
PROFIBUS underground cable 6XV1 830-3AH10
PROFIBUS trailing cable 6XV1 830-3BH10
PROFIBUS cable with PUR sheath for environments subject to
chemical and mechanical stress
6XV1 830-0DH10
PROFIBUS cable with PE sheath for the food and beverages
industry
6XV1 830-0BH10
PROFIBUS cable for festooning 6XV1 830-3CH10
ITEM 3000
Configuring
Properties of PROFIBUS cables
The PROFIBUS bus cable is a 2-wire, shielded twisted-pair cable with copper conductors. It
is used for hardwired transmission in accordance with US Standard EIA RS485.
The table below lists the characteristics of these cables.
Table 4- 20 Properties of PROFIBUS cables
Properties Values
Wave impedance approx. 135 to 160 (f = 3 MHz to 20 MHz)
Loop resistance 115 /km
Effective capacitance 30 nF/km
Attenuation 0.9 dB/100 m (f = 200 kHz)
Permitted conductor cross-sections 0.3 mm
2
to 0.5 mm
2

Permitted cable diameter 8 mm 0.5 mm
Installation of bus cables
When you install PROFIBUS bus cables, you must not
twist,
stretch
or compress them.
When wiring indoor bus cables, also maintain the following marginal conditions (dA = outer
cable diameter):
Table 4- 21 Marginal conditions for wiring interior bus cables
Characteristics Condition
Bending radius (one-off) 80 mm (10 x dA)
Bending radius (multiple times) 160 mm (20 x dA)
Permitted temperature range during installation 5 C to +50 C
Shelf and static operating temperature range 30 C to +65 C (22 F to +149 F)
Reference
For information on the use of fiber-optic cables for PROFIBUS, refer to the SIMATIC NET,
PROFIBUS Networks Manual.
ITEM 3000
Configuring
Bus connector RS 485
Table 4- 22 Bus connector
Type Order No.
Bus connector RS 485 up to 12 Mbps
with 90 cable exit
without programming device interface
with programming device interface

6ES7 972-0BA11-0XA0
6ES7 972-0BB11-0XA0
Fast connect bus connector RS 485 up to 12 Mbps
with 90 cable outlet in insulation displacement method

6ES7 972-0BA50-0XA0
6ES7 972-0BB50-0XA0
Bus connector RS 485 up to 12 Mbps
with 35 cable outlet (not for CPU 31xC, 312, 314 and 315-2 DP)

6ES7 972-0BA40-0XA0
6ES7 972-0BB40-0XA0
You need bus connectors to connect the PROFIBUS bus cable to an MPI or PROFIBUS-DP
interface
You do not require a bus connector for:
DP slaves with degree of protection IP 65 (ET 200pro, for example)
RS 485 repeater.
RS485 Repeater 485

Type Order No.
RS 485 repeater 6ES7 972-0AA01-0XA0
RS 485 Diagnostic Repeater 6ES7 972-0AB01-0XA0

Note
SFC 103 "DP_TOPOL" can be used to initiate identification of the bus topology of a DP
master system by way of the interconnected diagnostic repeaters.

Purpose
RS485 repeaters are used to amplify data signals on bus lines and to couple bus segments.
You require this RS 485 Repeater in the following situations:
more than 32 network nodes
when interconnecting a grounded with an ungrounded segment
when exceeding the maximum line length in a segment
ITEM 3000
Configuring
Longer cable lengths
If you want to implement cable lengths above those permitted in a segment, you must use
RS485 repeaters. The maximum cable length between two RS 485 repeaters corresponds to
the maximum cable length of a segment. Please note that these maximum cable lengths
only apply if there is no further node interconnected between the two RS 485 repeaters. You
can connect up to nine RS 485 repeaters in series. Please note that you have to add the RS
485 repeater when you determine the number of nodes in your subnet, even if it is not
assigned its own MPI/PROFIBUS address.
Reference
For further information about the RS485 Repeater, refer to the Module Specifications
Manual.
ITEM 3000
Configuring
4.11.2.6 Cable lengths of MPI and PROFIBUS subnets
Example: Installation of an MPI subnet
The figure below shows you the block diagram of a MPI subnet.
PROFlBUS
4
3
1
5
PS CPU PS CPU
S7-300 S7-300
PG
CPU PS
S7-300
CP
OP 277
S7-300
1
2
2
3
CPU PS
S7-300
CP CPU PS CPU PS
S7-300
PG
OP 277
OP 277 OP 277
MPl addr. 2 MPl addr. 1 MPl addr. 5 MPl addr. 3 MPl addr. 4 MPl addr. 7 MPl addr. 6
MPl addr. 10 MPl addr. 11 MPl addr. 13
MPl addr. 0
MPl addr. MPl addr. 8 MPl addr. 12

Number Identifier
Terminating resistor enabled.
S7-300 and OP 277 have subsequently been connected to the MPI subnet using their default MPI address.
CPU 31xC, 312, 314, 315-2 DP:
You can also assign user-specific MPI addresses to the CPs/FMs at these CPUs.
CPU 317-2 DP, 315-2 PN/DP, 317-2 PN/DP, 319-3 PN/DP:
CPs and FMs do not have their own MPI address on this CPU.
In addition to the MPI address, the CP also has a PROFIBUS address (7 in this case).
Connected via stub cable using the default MPI address only for commissioning/maintenance.
ITEM 3000
Configuring
Example: Maximum distances in the MPI subnet
The figure below shows you:
a possible MPI subnet configuration
maximum distances possible in an MPI subnet
the principle of "Line extension" using RS 485 repeaters
3
3
3
RS 485
repeater
RS 485
repeater
MPl addr. 10
MPl addr. 4
MPl addr. 7
MPl addr. 0
max. 50 m
m
a
x
.

1
0
0
0

m
max. 50 m
1
PG
OP 277 OP 277
1
1
1
1
1
2
CPU PS
S7-300
CPU PS
S7-300
OP 277
CPU PS
S7-300
CPU PS
S7-300
CPU PS
S7-300
PG

Number Identifier
PG connected by means of stub cable for maintenance purposes
ITEM 3000
Configuring
Example: Terminating resistor in the MPI subnet
The figure below shows you an example of an MPI subnet and where to enable the
terminating resistor.
The figure below illustrates where the terminating resistors must be enabled in an MPI
subnet. In this example, the programming device is connected via a stub cable only for the
duration of commissioning or maintenance.
CPU PS
S7-300
CPU PS
S7-300
CPU PS
S7-300
CPU PS
S7-300
PG
PG
1
1
1
1
2
OP 277 OP 277
RS 485
repeater

Number Identifier

WARNING
Disturbance of data traffic might occur on the bus. A bus segment must always be
terminated at both ends with the terminating resistor. This, for example, is not the case if
the last slave with bus connector is off power. The bus connector draws its power from the
station, and the terminating resistor is thus disabled. Please make sure that power is
always supplied to stations on which the terminating resistor is active. Alternatively, the
PROFIBUS terminator can also be used as active bus termination.

ITEM 3000
Configuring
Example: Installation of a PROFIBUS subnet
The figure below shows you the basic principles of a PROFIBUS subnet installation.

CPU CPU
CPU
CPU PS ET200M CPU CPU CPU
CPU CPU
S7-300 S7-300
PS PS ET200M ET200M PS PS PS
PS
PROFlBUS PROFlBUS PROFlBUS PROFlBUS PROFlBUS PROFlBUS
PROFlBUS PROFlBUS PROFlBUS PROFlBUS PROFlBUS
PG
CPU
31x-2 DP
MASTER
DP-CPU
ET200S ET200S ET200S ET200S ET200M
ET200M
ET 200pro
1
2
1
1
Addr. 2 Addr. 3 Addr. 4 Addr. 5 Addr. 6 Addr. 7
Addr. 8 Addr. 9 Addr. 10 Addr. 12 Addr. 11
MPl addr. 3
MPl addr. 0

Number Identifier
ITEM 3000
Configuring
Example: CPU 314C-2 DP as MPI and PROFIBUS node.
The figure below shows you an assembly with a CPU 314C-2 DP integrated in an MPI
subnet and also operated as DP master in a PROFIBUS subnet.
CPU
CPU
9
CPU
CPU
S7-300
S7-300
S7-300
S7-300
PS CPU
PS CPU
PS CPU
PS CPU
PG
OP 277
OP 277
PS DP-CPU
ET200M ET200M
ET200M ET200M
ET200S ET200S
ET 200pro
ET 200pro
ET 200pro
S7-300 CPU
1
1
1
1
2
1
1
PROFlBUS subnet
MPl addr. 0
MPl addr. 2
MPl addr. 3
MPl addr. 4
MPl addr. 8
MPl addr. 5
MPl addr. 6
MPl addr. 7
with PROFlBUS DP
interface as DP master
DP addr. 2 DP addr. 3
DP addr. 7
MPl subnet
RS 485 repeater
DP addr. 4
DP addr. 5
DP addr. 6

Number Identifier
PG connected via a stub cable for maintenance or commissioning purposes

ITEM 3000
Configuring
4.11.3 Configuring PROFINET subnets
4.11.3.1 Overview
The next section contains all the information you require to configure PROFINET subnets:
Contents
PROFINET devices
Integration of field bus system into PROFINET
PROFINET IO and PROFINET CBA (Component-Based Automation)
PROFINET cable lengths
Ethernet bus cable and connector
Example of a PROFINET subnet
Example of a PROFINET IO system
4.11.3.2 PROFINET devices
Definition: Devices in the PROFINET environment
Within the context of PROFINET, "device" is the generic term for:
Automation systems (e.g. PLC, PC)
Field devices (for example, PLC, PC, hydraulic devices, pneumatic devices)
Active network components (for example, switches, gateways, routers)
PROFIBUS or other fieldbus systems
The main characteristics of a device is its integration into PROFINET communication by
means of Ethernet or PROFIBUS.
The following device types are distinguished based on their attachment to the bus:
PROFINET devices
PROFIBUS devices
Definition: PROFINET devices
A PROFINET device always has at least one Industrial Ethernet port. A PROFINET device
can also have a PROFIBUS port, that is, as master with proxy functionality.
Definition: PROFIBUS devices
A PROFIBUS device has at least one PROFIBUS link with an electric interface (RS485) or
an optical interface (polymer optical fiber, POF).
A PROFIBUS device cannot take part directly in PROFINET communication, but must be
implemented by means of PROFIBUS master with PROFINET link or Industrial
Ethernet/PROFIBUS link (IE/PB Link) with proxy functionality.
ITEM 3000
Configuring
Comparison of the terminology in PROFIBUS DP and PROFINET IO
The following schematic shows you the general names of the most important devices in
PROFINET IO and PROFIBUS DP. The table below shows the designation of the various
components in the PROFINET IO and PROFIBUS DP context.
2
3
4
5
6 6
1

Numb
er
PROFINET PROFIBUS Remark
IO system DP master system
IO controller DP master Device used to address the connected IO
devices/DP slaves.
That is: The IO controller/DP master exchanges
input and output signals with field devices.
The IO controller/DP master is often the
controller on which the automation program
runs.
PG/PC
(IO supervisor)
PG/PC
(Class 2 DP
master)
PG/PC/HMI device for commissioning and
diagnostics
Industrial Ethernet PROFIBUS Network infrastructure
HMI (Human Machine
Interface)
HMI Device for operating and monitoring functions.
IO device DP slave Distributed field device assigned to one of the IO
controllers/DP masters, for example, distributed
IO, valve terminal, frequency converter, and
switches with integrated PROFINET IO
functionality.
Figure 4-3 PROFINET and PROFIBUS devices
ITEM 3000
Configuring
Slots and Submodules
A PROFINET IO device is modularly structured - similar to a PROFIBUS DP slave.
In doing so, modules are fitted to slots and submodules to subslots. Channels are located on
the modules / submodules using which process signals can be read in and issued.
The following graphic illustrates the situation.
1 2 2 2
3
3
4
4
4
4
4
4
4
4
2

Figure 4-4 Module, Submodule, Slot, and Channel

Number Description
Interface module
Module with components
Submodule
Channel
In principle it is possible to divide a slot into additional subslots on which the submodules are
connected.
ITEM 3000
Configuring
4.11.3.3 Integration of fieldbuses into PROFINET
Fieldbus integration
PROFINET allows you to use a proxy to integrate existing fieldbus systems (for example,
PROFIBUS, ASI) into PROFINET. In this way, you can set up hybrid systems consisting of
fieldbus and Ethernet-based subsystems. A continuous technological transition to
PROFINET is thus possible.
Interconnecting PROFINET and PROFIBUS
You can interconnect PROFIBUS devices to the local PROFIBUS interface of a PROFINET
device. This allows you to integrate existing PROFIBUS configurations in PROFINET.
The following picture illustrates the network types that are supported for PROFINET:
Industrial Ethernet and
PROFIBUS.
1
2
3
PROFlBUS
lndustrial Ethernet

Figure 4-5 PROFINET devices, PROFIBUS devices, and proxy
Number Description
PROFINET devices
PROFINET device with proxy functionality
PROFIBUS devices
ITEM 3000
Configuring
PROFINET device with proxy functionality = substitute
The PROFINET device with proxy functionality is the substitute for a PROFIBUS device on
Ethernet. The proxy functionality allows a PROFIBUS device to communicate not only with
its master but also with all nodes on PROFINET.
With PROFINET, existing PROFIBUS systems can be integrated into the PROFINET
communication with the aid of an IE/PB link, for example. The IE/PB link then handles
communication via PROFINET on behalf of the PROFIBUS components.
In this way, you can link both DPV0 and DPV1 slaves to PROFINET.
Further information
For information on the differences and common features of PROFINET IO and PROFIBUS
DP and information on migrating from PROFIBUS DP to PROFIBUS IO, refer to the From
PROFIBUS DP to PROFINET IO programming manual.
4.11.3.4 PROFINET IO and PROFINET CBA
What is PROFINET IO?
As part of PROFINET, PROFINET IO is a communication concept that is used to implement
modular, distributed applications.
PROFINET IO allows you to create automation solutions, which are familiar to you from
PROFIBUS.
PROFINET IO is implemented using the PROFINET standard for programmable controllers.
The STEP 7 engineering tool helps you to structure and configure an automation solution.
In STEP 7 you have the same application view, regardless of whether you are configuring
PROFINET devices or PROFIBUS devices. You will program your user program in the same
way for both PROFINET IO and PROFIBUS DP since you will use the extended blocks and
system status lists for PROFINET IO.
Reference
Information on new and modified blocks and system status lists can be found in the From
PROFIBUS DP to PROFINET IO programming manual.
What is PROFINET CBA?
As part of PROFINET, PROFINET CBA (Component Based Automation) is an automation
concept that focuses on the following:
Implementation of modular applications
Machine - machine communication
PROFINET CBA lets you create distributed automation solutions, based on default
components and partial solutions. This concept meets the demand for a greater modularity in
the field of mechanical and systems engineering by extensive distribution of intelligent
processes.
With Component Based Automation you can implement complete technological modules as
standardized components that can be used in large systems.
You create the modular, intelligent components of the PROFINET CBA in an engineering
tool (which may differ according to the device manufacturer). Components that are formed
from SIMATIC devices are created with STEP 7, and are interconnected using the SIMATIC
iMAP tool.
ITEM 3000
Configuring
Interaction between PROFINET IO and PROFINET CBA
PROFINET CBA is used to integrate PROFINET IO systems into machine-to-machine
communication. A PROFINET component is created from a PROFINET IO system in STEP
7, for example. With SIMATIC iMap, you can configure systems consisting of several such
components. The communication connections between the devices are configured simply as
interconnection lines.
The following graphic illustrates a distributed automation solution with several components
which communicate via PROFINET. The components on the right have IO devices and an IO
controller on PROFINET IO.
iMAP
PROXY
Ethernet
PROFlBUS
PROFlNET lO lntelligent field
device on Ethernet
Component with
distributed lO on
PROFlBUS
Component with
distributed lO on
Ethernet
PROFlNET
Component
PROFlNET
communication

Figure 4-6 PROFINET CBA - modular concept
ITEM 3000
Configuring
Extent of PROFINET CBA and PROFINET IO
PROFINET IO and CBA represent two different views of automation devices on Industrial
Ethernet.
lO data view Component view
One cable, lT standards, standard applications
protocols, controller, etc.
- Distributed lOs
- Usual lO view in STEP 7
(PROFlNET Component Description) (Generic Station Description)
- Distributed intelligence
- Plant-wide engineering
GSD PCD
PROFlNET

PROFlNET CBA PROFlNET lO

Figure 4-7 Extent of PROFINET CBA and PROFINET IO
Component Based Automation divides the entire system into various functions. These
functions are configured and programmed.
PROFINET IO provides an image of the system that is very similar to the view obtained in
PROFIBUS. You continue to configure and program the individual automation devices.
ITEM 3000
Configuring
Controllers in PROFINET IO and PROFINET CBA
You can also use some PROFINET IO controllers for PROFINET CBA.
The following PROFINET devices act as a PROFINET CBA or IO controller:
Programmable logic controllers,
S7-300 CPU 31x-2 PN/DP, firmware version V2.3 or later
S7-300 CPU 319-3 PN/DP, firmware version V2.4.0 or later
CP 343-1 - version 6GK7 343-1EX21-0XE0 and 6GK7 343-1GX21-0XE0 or later
CP 443-1 Advanced with MLFB 6GK7 443-1EX40 version V2.1 and 6GK7 443-1EX41
version V1.0 or later.
The following PROFINET devices can only act as a PROFINET IO controller:
PCs that are linked to a PROFINET IO-compatible CP (CP 1616 for example) or via
SOFTNET PN IO (with CP 1612 for example). With the CP 1616 and SOFTNET PN IO,
the user program runs in the CPU of the PC.
SIMOTION devices for particularly stringent real-time requirements.
Some PROFINET devices can only be used as PROFINET CBA controllers, for example,
PCs with standard Ethernet interfaces and the WinLC software.
CP443-1 EX 40 V2.1 or later or CP443-1 EX41 V 1.0 or later
Proxy in PROFINET IO and PROFINET CBA
The proxies for PROFINET IO and proxies for PROFINET CBA are different.
In PROFINET IO, the proxy for PROFINET IO represents each connected PROFIBUS DP
slave as a PROFINET IO device on the PROFINET.
In PROFINET CBA, the proxy for PROFINET CBA represents every connected PROFIBUS
DP slave as one component, which can participate in PROFINET communication.
There are thus different IE/PB links for PROFINET IO and PROFINET CBA, for example. At
present you can currently only use a CPU 31x PN/DP as a proxy for PROFINET CBA.
Linking PROFIBUS devices via an IE/PB link
Please note that proxy functionality is available in both PROFINET IO and PROFINET CBA.
For the IE/PB link, this means that you must use different devices depending on the system
you are using.
Configuring and integrating components and devices in PROFINET communication
In Component Based Automation, an interconnection editor is used to incorporate the
components (SIMATIC iMap for example). The components are described in a PCD file.
With PROFINET IO, the devices are incorporated using an engineering system (STEP 7 for
example). The devices are described in a GSD file.
ITEM 3000
Configuring
Interaction between PROFINET CBA and PROFINET IO
PROFINET IO integrates field devices (IO devices) into PROFINET. The input and output
data of the IO devices are processed in the user program. The IO devices with their IO
controller can, in turn, be part of a component in a distributed automation structure.
Communication between a CPU as the IO controller and the assigned IO devices as
PROFINET IOs is configured in the same way as for a PROFIBUS DP master system in
STEP 7. The user program is also created in STEP 7. From the entire PN IO system, you
create a component in STEP 7 (see Figure PROFINET CBA).
You then configure communication between the components in user-friendly SIMATIC iMAP.
Update time
The IO controller (outputs) provides new data to all IO devices in the PROFINET IO system
within the update time. This means that all the IO devices have sent their latest data to the
IO controller (inputs).

Note
Send Cycles for Cyclical Data Exchange
STEP 7 determines the update time on the basis of the existing hardware configuration and
the resulting cyclical data traffic. During this time, a PROFINET IO device has exchanged its
user data with the associated IO controller.
You can set the update date either for a whole bus segment of an IO controller, or for an
individual IO device.
In STEP 7, the update time can be changed manually.
The smallest possible update time in a PROFINET system depends on the following factors:
Number of PROFINET IO devices
Quantity of configured user data
Volume of PROFINET IO communication traffic (compared to the volume of PROFINET
CBA communication traffic)

Additional cyclical PROFINET services
The update time dialog in STEP 7/HW Config is used to set an update date for the device to
be reserved for PROFINET IO.
See the STEP 7 Online Help for more information.

ITEM 3000
Configuring
Send clock
Period between two successive intervals for IRT or RT communication. The send clock is the
shortest possible transmit interval for exchanging data. The calculated update times are
multiples of the send clock.
The minimum possible update time thus depends on the minimum send clock of the IO
controller that can be set.
If both the IO controller and the IO device support a send clock of 250 s, you can achieve a
minimum update time of 250 s.
It is also possible to operate IO devices that only support a send clock of 1 ms on an IO
controller that works with a send clock of 250 s. The minimum update time for the IO
devices concerned is then at least 1 ms, however.
Update times of CPU 319-3 PN/DP
Programmable update times when using CPU 319-3 PN/DP:

Send
clock
Update time
250 s 250 s to 128 ms
500 s 500 s to 256 ms
1 ms 1 ms to 512 ms
The minimum update time depends on the number of IO devices used, and on the volume of
configured user data, and on the load in PROFINET IO communication. STEP 7
automatically considers these dependencies during configuration.
Details of the possible uses of the individual products
See also the documentation for the product concerned.
4.11.3.5 PROFINET cable lengths and network expansion
Network expansion options are based on various factors (hardware design used, signal
propagation delay, minimum distance between data packets, etc.)
Twisted-pair patch cables
TP Cords are used to interconnect terminal devices with the Industrial Ethernet FC cabling
system. It is designed for use in environments with low EMC load, for example, in offices or
in control cabinets.
The length of twisted-pair cords between two devices may not exceed 10 m.
Compared to Industrial Ethernet twisted-pair cables, the TP cords are significantly thinner
and more flexible due to the reduced effort for their shielding. The connectors used in
connecting industrial twisted-pair components are standardized RJ45 connectors and sub D
connectors.
ITEM 3000
Configuring
Product range
Twisted-pair patch cords available:
Table 4- 23 Data for twisted-pair patch cables
Cable designation Application Available
lengths
Order number
TP Cord RJ45/RJ45 TP connecting cable with two
RJ45 connectors
0.5 m
1.0 m
2.0 m
6.0 m
10.0 m
6XV1 850-2GE50
6XV1 850-2GH10
6XV1 850-2GH20
6XV1 850-2GH60
6XV1 850-2GN10
TP XP cord RJ45/RJ45 TP crossover cable with two
RJ45 connectors
0.5 m
1.0 m
2.0 m
6.0 m
10.0 m
6XV1 850-2HE50
6XV1 850-2HH10
6XV1 850-2HH20
6XV1 850-2HH60
6XV1 850-2HN10
TP cord 9/RJ45 TP patch cable with 9-pin
sub-D connector and
RJ45 connector
0.5 m
1.0 m
2.0 m
6.0 m
10.0 m
6XV1 850-2JE50
6XV1 850-2JH10
6XV1 850-2JH20
6XV1 850-2JH60
6XV1 850-2JN10
TP XP cord 9/RJ45 Crossover TP patch cable with
9-pin sub-D connector and RJ45
connector.
0.5 m
1.0 m
2.0 m
6.0 m
10.0 m
6XV1 850-2ME50
6XV1 850-2MH10
6XV1 850-2MH20
6XV1 850-2MH60
6XV1 850-2MN10
TP patch cable 9-
45/RJ45
TP patch cable with RJ45 connector
and sub-D connector, 45 cable exit
(only for OSM/ESM)
1.0 m 6XV1 850-2NH10
TP XP patch cable 9-
45/RJ45
Cross-over TP patch cable with RJ45
connector and sub-D connector with
45 cable exit (for OSM/ESM only)
1.0 m 6XV1 850-2PH10
TP XP patch cable 9/9 Crossover TP patch cable for direct
interconnection of two industrial
Ethernet network components with
ITP interface, with two 9-pin sub-D
connectors
1.0 m 6XV1 850-2RH10
TP cord RJ45/15 TP patch cable with 15-pin
sub-D connector and
RJ45 connector
0.5 m
1.0 m
2.0 m
6.0 m
10.0 m
6XV1 850-2LE50
6XV1 850-2LH10
6XV1 850-2LH20
6XV1 850-2LH60
6XV1 850-2LNN10
TP XP patch cable
RJ45/15
Crossover TP patch cable with
15-pin sub-D connector and RJ45
connector.
0.5 m
1.0 m
2.0 m
6.0 m
10.0 m
6XV1 850-2SE50
6XV1 850-2SH10
6XV1 850-2SH20
6XV1 850-2SH60
6XV1 850-2SN10
ITEM 3000
Configuring
Industrial Ethernet Fast Connect twisted-pair cables
The FastConnect Twisted-Pair cabling system is ideal for structured cabling in the production
hall. FastConnect cables allow for the quick and easy on-site assembly of patch cables. The
RJ45 cabling technology is the existing standard and is also available as an industrial
version which allows structured cabling.
Product range
Industrial Ethernet Fast Connect twisted-pair cables available:
Table 4- 24 Data for user assemblies using patch cables of the Fast Connect product family
Cable designation Application Available
lengths
Order number
SIMATIC NET IE
FC RJ 45
PLUG 145
RJ45 connector for Industrial Ethernet
with rugged metal housing and four
integrated insulation displacement
terminals for connecting Industrial
Ethernet FC installation cables; 145
cable outlet.
1 piece
10 items
50 items
6GK1 901-1BB30-0AA0
6GK1 901-1BB30-0AB0
6GK1 901-1BB30-0AE0
SIMATIC NET IE
FC RJ 45
PLUG 180
RJ45 connector for Industrial Ethernet
with rugged metal housing and four
integrated insulation displacement
terminals for connecting Industrial
Ethernet FC installation cables; 180
cable outlet.
1 piece
10 items
50 items
6GK1 901-1BB10-2AA0
6GK1 901-1BB10-2AB0
6GK1 901-1BB10-2AE0
Reference
Detailed information is available in the
SIMATIC NET Manual: Twisted-Pair and Fiber-Optic Networks (6GK1970-1BA10-0AA0)
On the Internet at http://www.siemens.com/automation/service&support.
Catalog IK PI, SIMATIC NET (E86060-K6710-A101-B5)
See also
Connecting the PG to a node (Page 148)
Connecting the PG to several nodes (Page 149)
ITEM 3000
Configuring
4.11.3.6 Connectors and other components for Ethernet
The selection of the bus cable, bus connector and other components for Ethernet (for
example, switches, etc.) depends on the intended application.
We offer a range of products covering a variety of applications for the installation of an
Ethernet connection.
Reference
SIMATIC NET: Twisted-Pair and Fiber-Optic Networks (6GK1970-1BA10-0AA0)
4.11.3.7 Example of a PROFINET subnet
Example: Installation of a PROFINET subnet
The graphic illustrates the combination of corporate level and process control level via
industrial Ethernet. PCs in a classical office environment can be used to acquire data of the
process automation system.
Subnet 2
Company network
Subnet 1
Switch 1 Switch 3 Switch 2 Router
CPU 31x PN/DP CPU 31x PN/DP
CPU 31x PN/DP
(DP-Master)
ET200
(DP-Slave)
PG
P
R
O
F
l
B
U
S
lNDUSTRlAL ETHERNET

Figure 4-8 Example of a PROFINET subnet
ITEM 3000
Configuring
Installation guidelines
PROFINET allows you to set up a high-performance and continuous communication system.
You can further increase performance by using the following installation guidelines.
Interconnect a router between the office network and the PROFINET system. Use the
router to define access privileges for your PROFINET system.
Set up your PROFINET in a star architecture where this is useful (for example: in a switch
cabinet).
Keep the number of switches low. This increases clarity of your PROFINET system
architecture.
Connect your programming device (PG) close to the communication partner (for example:
connect the PG and the communication partner to the same switch).
Modules with PROFINET interfaces may only be operated in LANs where all nodes are
equipped with SELV/PELV power supplies or protection systems of equal quality.
A data transfer device that ensures this safety must be specified for the coupling to the
WAN.
Reference
For detailed information on Industrial Ethernet networks or network components, refer to:
the Internet URL http://www.siemens.com/automation/service&support.
The STEP 7 Online Help. There you can also find further information on IP address
assignment.
The Communication with SIMATIC (EWA 4NEB 710 6075-01) manual
The SIMATIC NET manual: Twisted-Pair and Fiber Optic Networks (6GK1970-1BA10-
0AA0)
ITEM 3000
Configuring
4.11.3.8 PROFINET IO System
Functions of PROFINET IO
The following graphic shows the new functions in PROFINET IO:
PC
PC
PC
PC
PC PG/PC
PC
PC
lE/PB-Link
PN lO
P1
P2
P3
P4
P5
P6
P7
CPU 319-3
PN/DP
P1
lM 154-8
CPU
P1
P2
P3
PG
PB
lE
ET 200S
P1 P2
ET 200S
P1 P2
ET 200S
P1 P2
ET 200S
P1 P2
PN
PN PN
PN PN
PN
PROFlBUS
2
3
4
5 6
1
7
8
Switch 1 Switch 2
Company network lndustrial Ethernet
lO
Controller
DP master
lO
Controller
DP master
ET 200
(DP slave)
ET 200
(DP slave)
lO device lO device
lO device lO device
Router

ITEM 3000
Configuring
The graphic shows
Examples of connection paths
The connection of company
network and field level
You can access devices at the field level from PCs in your company network
Example:
PC - Switch 1 - Router - Switch 2 - CPU 319-3 PN/DP .
Connections between the
automation system and field
level
You can, of course, also access other areas on the Industrial Ethernet from a PG at the
field level.
Example:
PG - integrated switch IM 154-8 CPU - Switch 2 - integrated switch IO device ET
200S - on IO device: ET 200S .
The IO controller of the CPU
IM 154-8 CPU directly
controls devices on the
Industrial Ethernet and
PROFIBUS.
At this point, you can see the extended IO feature between the IO controller and IO
device(s) on the Industrial Ethernet:
The IM 154-8 CPU is operated as IO controller for the IO devices ET 200S and
ET 200S
The IM 154-8 CPU is also the IO controller for
ET 200 (DP slave) by way of IE/PB Link.
The CPU 319-3 PN/DP can
be operated as IO controller or
DP master
Here you can see that a CPU can be both the IO controller for an IO device and the DP
master for a DP slave:
The 319-3 PN/DP CPU is operated as IO controller for the IO devices
ET 200S and ET 200 S
The CPU 319-3 PN/DP is the DP master for a DP slave . The
DP slave is assigned locally to the CPU and is not visible on the Industrial
Ethernet.
Further information
You will find further information about PROFINET in the documents listed below:
in the System Description PROFINET.
In the From PROFIBUS DP to PROFINET IO programming manual.
This manual also provides a clear overview of the new PROFINET blocks and system
status lists.

ITEM 3000
Configuring
4.11.4 Routed network transitions
Example: Programming device access beyond network limits (routing)
A CPU with several interfaces can also serve as a router for intercommunication with
different subnets. With a PG you can access all modules on local and remote networks.
Requirements:
Implement STEP 7 starting with Version 5.0.
Note: For STEP 7 requirements with respect to the CPUs used, refer to the technical
specifications.
Assign the PG/PC to a network in your STEP 7 project (SIMATIC Manager, assigning a
PG/PC).
The various networks are interconnected using modules with routing functions.
After you configured all networks in NETPRO, initiated a new compilation for all stations,
and then download the configuration to all modules with routing function. This also
applies to all changes made in the network.
All routers therefore know all paths to a destination station.
ITEM 3000
Configuring
Access to remote networks
1
2
3
PG/PC 3
S7-300
PS
S7-300
PS
CPU
31x-2 DP
CPU
MPl
S7-400 S7-400
PS PS
CPU 416 CPU 417
MPl
PG/PC 1
PROFlBUS
ET200
PG/PC 2

Figure 4-9 Access to remote networks
Example 1
To access the CPU 31x-2 DP using PG/PC 1:
PG/PC 1 - MPI network - CPU 417 as router - PROFIBUS network - CPU 31x-2 DP
Example 2
To access the the S7-300 CPU (on the right in the figure) using PG/PC 2:
PG/PC 2 - PROFIBUS network - CPU 31x-2 DP as router - MPI network - S7-300 CPU
Example 3
To access the 416 CPU using PG/PC 3:
PG/PC 3 - MPI network - CPU 31x-2 DP as router - PROFIBUS network - CPU 417 as
router - MPI network - CPU 416

Note
Only for CPUs with DP interface:
If these CPUs are operated as I-slaves and you want to use routing functionality, set the
Commissioning / Debug Mode / Routing check box in the DP Interface for DP Slave dialog
box in STEP 7.
Reference
You can find more information on the subject of routing in the Communication with SIMATIC
manual.
ITEM 3000
Configuring
4.11.5 Point-to-point (PtP)
Availability
CPUs with the "PtP" name suffix have at least one PtP interface.
Properties
Using the PtP interface of your CPU, you can connect external devices with serial interface.
You can operate such a system at transmission rates up to 19.2 Kbps in full duplex mode
(RS 422), and up to 38.4 Kbps in half duplex mode (RS 485).
Baud rate
Half duplex: 38.4 Kbps
Full duplex: 19.2 Kbps
Drivers
PtP communication drivers installed in those CPUs:
ASCII drivers
3964(R) Protocol
RK 512 (CPU 314C-2 PtP only)
Devices capable of PtP communication
Devices equipped with a serial port, for example, barcode readers, printers, etc.
Reference
CPU 31xC: Technological functions manual
4.11.6 Actuator/sensor interface (ASI)
Implementation using communication processors (CP).
The ASI, or Actuator/Sensor Interface, represents a subnet system on the lowest process
level for automation systems. It is designed especially for networking digital sensors and
actuators. The maximum data volume is 4 bits per slave station.
S7-300 CPUs require communication processor for the ASI connection.
ITEM 3000

Installing
5
5.1 Installing a S7-300
Here we will explain the steps required for the mechanical assembly of an S7-300.

Note
Note the installation guidelines and notes on safety in this manual when mounting,
commissioning and operating S7-300 systems.

Open components
S7-300 modules are "Open Components" according to IEC 61131-2 and EC directive
2006/95/EC (low-voltage directive), and to UL/CSA Approval an "open type".
In order to conform with specifications on safe operation relating to mechanical strength,
inflammability, stability and touch-protection, the following alternative installation modes are
prescribed:
Installation in a suitable cubicle
Installation in a suitable cabinet
Installation in an appropriately equipped and closed operating area
Access to these areas must only be possible with a key or tool. Only trained or authorized
personnel are allowed access to these cubicles, cabinets or electrical operating rooms.
ITEM 3000
Installing
5.1 Installing a S7-300
Accessories included
Installation accessories are included with the module package. The appendix contains a list
of accessories and spare parts together with the corresponding order numbers.
Table 5- 1 Module accessories
Module Accessories included Explanation
1 x Slot number label For assigning slot numbers CPU
Inscription labels for the MPI address and
Firmware Version (all CPUs)
for labeling of integrated inputs
and outputs (CPU 31xC only)
1 Bus connector For electrical interconnection of
modules
Signal module (SM)
Function Module (FM)
1 Labeling strip For labeling module I/O
1 Bus connector For electrical interconnection of
modules
Communication module (CP)
1 Inscription label
(only CP 342-2)
For labeling the AS interface
connector

Interface module (IM) 1 x Slot number label (only
IM 361 and IM 365)
For assigning slot numbers on
racks 1 to 3
Tip: Templates for the labeling strips are available on the Internet
(http://support.automation.siemens.com/WW/view/en/11978022).
Tools and material required
To install the S7-300, you require the tools and materials listed in the table below.
Table 5- 2 Installation tools and materials
You require ... for ...
cutting the 2 m rail to length commonly available tool
scribing and drilling holes on the 2 m rail commonly available tool, 6.5 mm diameter drill bit
screw-mounting the rail wrench or screwdriver, matching the selected
fixing screws
diverse M6 screws (length depends on the place
of installation) with nuts and spring lock washers
screw-fastening the modules on the rail screwdriver with 3.5 mm blade width (cylindrical
design)
pulling out the grounding slide contact to achieve
ungrounded state
screwdriver with 3.5 mm blade width (cylindrical
design)
ITEM 3000
Installing
5.2 Installing the mounting rail
Mounting rail versions available
Ready-to-use, four standard lengths (with 4 holes for fixing screws and 1 ground
conductor bolt)
One meter mounting rail
May be shortened to any special length. Supplied without holes for fixing screws and
without ground conductor bolt.
Requirement
Prepare the 2 m mounting rail for installation.
Preparing the 2 m mounting rail for installation
1. Cut the 2 m mounting rail to the required length.
2. Mark out:
four bores for the fixing screws (for dimensions, refer to "Dimensions for fixing holes")
one hole for the protective conductor bolt.
3. If the length of your rail exceeds 830 mm, you must stabilize it by providing additional
holes for fixing it with more screws.
Mark out these holes along the groove in the middle section of the rail (see the Figure
below). The pitch should be approx. 500 mm.
4. Drill the marked holes, bore diameter = 6.5
+0,2
mm for M6 screws.
5. Mount an M6 bolt for fixing the ground conductor.
2
1
3
4
5

Number Identifier
Hole for the ground conductor bolt
Groove for drilling additional holes for mounting screws
Hole for the mounting screw
Additional hole for mounting screw
Hole for the mounting screw
ITEM 3000
Installing
Dimension of the mounting holes
The mounting hole dimensions for the mounting rail are shown in the table below.
Table 5- 3 Mounting holes for rails
"Standard" mounting rail 2 m mounting rail
32,5 mm
57,2 mm
b a

32,5 mm
57,2 mm
15 mm 15 mm
~ 500 mm ~ 500 mm

Length of rail Dimension a Dimension b
160 mm 10 mm 140 mm
482.6 mm 8.3 mm 466 mm
530 mm 15 mm 500 mm
830 mm 15 mm 800 mm

Fixing screws
You can use the following screw types for mounting the rails:

For ... you can use ... Explanation
Cylindrical head screw M6 to
ISO 1207/ISO 1580
(DIN 84/DIN 85)
outer fixing screws
M6 hexagonal head screw to
ISO 4017 (DIN 4017)
Additional fixing screws
(only 2 m mounting rail)
Cylindrical head screw M6 to
ISO 1207/ISO 1580
(DIN 84/DIN 85)
Choose a suitable screw length
for your assembly.
You also need size 6.4 washers
to ISO 7092 (DIN 433)
ITEM 3000
Installing
Installing the mounting rail
1. Install the mounting rails so that sufficient space is available for installing modules and to
allow heat dissipation (clearance of at least 40 mm above and below the modules. See
the figure below).
2. Mark up the mounting holes on the mounting surface. Drill the holes, diameter = 6.5
+0.2
mm.
3. Screw the rail (M6 screws) onto the mounting surface.

Note
Always make sure of a low-impedance contact between the rail and a mounting surface,
if the latter is a grounded metal panel or equipment mounting panel. On varnished or
anodized metals, for instance, use a suitable contacting agent or contact washers.

The figure below shows the clearance required for the installation of an S7-300.
40 mm
40 mm
20 mm 20 mm

ITEM 3000
Installing
5.3 Installing modules on the mounting rail
Rules governing
The table below shows you points to follow when wiring, installing or removing S7-300
modules.

Rules for the tightening torque of.. ... power supply, CPU,SM, FM, CP
Fixing modules to the mounting rail from 0.8 N/m to 1.1 N/m
Requirements for module installation
The configuration of the automation system is completed.
The mounting rail is installed.
Mounting order of the modules
Hang the modules onto the rail, starting at the left and in the following order:
1. Power supply module
2. CPU
3. SMs, FMs, CPs, IMs

Note
Please check before you insert any SM 331 analog input modules whether you have to
reposition the measuring range submodules at the side of the module. For more
information see the "Analog Modules" chapter in the Module Data Manual.

Note
When installing an S7-300 system with ungrounded reference potential, make the
relevant settings on the CPU. You ideally do so before you mount any modules onto the
rail.

ITEM 3000
Installing
Installation steps
The various steps in module installation are explained below.

1. Plug the bus connectors into the CPU and SMs
/ FMs / CPs / IMs.
Except for the CPU, each module is supplied
with a bus connector.
Always start at the CPU when you plug in
the bus connectors. Remove the bus
connector from the "last" module of the
assembly.
Plug the bus connectors into the other
modules.
The "last" module does not receive a bus
connector.

2. Add all modules to the rail in the specified order
, slide them up to the module on the left ,
then swing them down .
2
3
1

3. Screw-tighten the modules.

See also
Installing an S7-300 with ungrounded reference potential (not CPU 31xC) (Page 44)
ITEM 3000
Installing
5.4 Labeling modules
Assign slot numbers
You should assign a slot number to each one of the mounted modules, thus making it easier
to assign the modules in the configuration table in STEP 7. The table below shows the slot
number assignment.
Table 5- 4 Slot numbers for S7 modules
Slot numbes Module Remark
1 Power supply (PS) module
2 CPU
3 Interface module (IM) to the right of the CPU
4 1. Signal module (SM) to the right of the CPU or IM
5 2. Signal module (SM)
ITEM 3000
Installing
Attach the slot numbers to the modules.
1. Hold the corresponding slot number in front of the relevant module.
2. Place the tongue in the opening on the module .
3. Press the slot number into the module . The slot number breaks off from the wheel.
The figure below illustrates this procedure. The slot number labels are included with the
CPU.
2
1

ITEM 3000
Installing
ITEM 3000

Wiring
6
6.1 Requirements for wiring the S7-300
This chapter
describes the requirements for wiring the power supply, CPU and front connectors.
Accessories required
The following accessories are required for wiring the S7-300.
Table 6- 1 Wiring accessories
Accessories Explanation
Front connectors for connecting the sensors / actuators of the
system to the S7-300
Labeling strips for labeling the module I/Os
Shielding contact element, shielding terminals
(matching the shielding diameter)
for connecting cable shielding
Tools and material required
Tools and materials required for wiring the S7-300.
Table 6- 2 Tools and material for wiring
To ... you need ...
Connect the protective conductor to the rail Wrench (size 10)
Protective conductor cable (cross-
section 10 mm
2
) with M6 cable lug
M6 nut, washer, spring lock washer
Adjust the power supply module to mains voltage Screwdriver with a blade width of 4.5 mm
Wire the power supply module and the CPU Screwdriver with a 3.5-mm blade, side-cutters,
stripping tool
Flexible cable, for example, sheathed flexible
cable 3 x 1.5 mm
2

Wire end ferrules to DIN 46228
Wire the front connector Screwdriver with a 3.5-mm blade, side-cutters,
stripping tool
Flexible cables, 0.25 mm
2
to 0.75/1.5 mm
2

Shielded cables as required
ITEM 3000
Wiring
6.1 Requirements for wiring the S7-300
Wiring conditions for power supply and CPU
Table 6- 3 Wiring conditions for power supply and CPU
Connectable cables to power supply and CPU
Solid conductors No
Flexible conductors
without wire end ferrule
With wire end ferrule

0.25 mm
2
to 2.5 mm
2

0.25 mm
2
to 1.5 mm
2

Number of conductors per terminal 1 or 2, up to 1.5 mm
2
(total) in a common wire
end ferrule
Diameter of the conductor insulation max. 3.8 mm
Stripped length 11 mm
without insulating collar
with insulating collar

Design A, 10 mm to 12 mm length
Design E, up to 12 mm length
Tightening torque from 0.5 N/m to 0.8 N/m
Wiring conditions for front connectors
Table 6- 4 Wiring conditions for front connectors
Front connectors Connectable cables
20-pole 40-pole
Solid conductors No No
Flexible conductors
without wire end ferrule
with wire end ferrule

0.25 mm
2
to 1.5 mm
2

0.25 mm
2
to 1.5 mm
2

0.25 mm
2
to 0.75 mm
2

0.25 mm
2
to 0.75 mm
2

Mains feed 1.5 mm
2

Number of conductors per
terminal
1 or 2, up to 1.5 mm
2
(total) in a
common wire end ferrule
1 or 2, up to 0.75 mm
2
(total) in a
common wire end ferrule
Diameter of the conductor
insulation
max. 3.1 mm max. 2.0 mm for 40-pole
cables
max. 3.1 mm for 20-pole
cables
Stripped length 6 mm 6 mm
Wire end ferrules to DIN
46228
without insulating collar
with insulating collar


Tightening torque from 0.4 N/m to 0.8 N/m
ITEM 3000
Wiring
6.2 Bonding the Protective Conductor to the Mounting Rail
6.2 Bonding the Protective Conductor to the Mounting Rail
Requirement
The mounting rail is fixed onto the mounting surface.
Connecting the protective conductor
Connect the mounting rail to the protective conductor.
The mounting rail is provided with a M6 protective conductor screw for this purpose.
Minimum cross-section of the protective conductor: 10 mm
2

The figure below shows how the protective conductor has to be bonded to the rail.

Note
Always make sure of a low-impedance contact between the protective conductor and the rail.
You can achieve this by using a low-impedance cable, keeping it as short as possible and
contacting it to a large surface.
For example, an S7-300 mounted on a hinged frame must be connected to ground using a
flexible grounding strap.

ITEM 3000
Wiring
6.3 Adjusting the Power Supply Module to Local Mains Voltage
6.3 Adjusting the Power Supply Module to Local Mains Voltage
Introduction
You can operate the S7-300 power supply module on 120 VAC or 230 VAC. The default
setting for the PS 307 is 230 VAC.
Setting the mains voltage selector switch
Verify that the setting of the voltage selector switch matches your local mains voltage.
To set the selector switch:
1. Remove the protective cap with a screwdriver.
2. Set the selector switch to match the local line voltage.
3. Reinsert the protective cap.
2
1
2

Numb
er
Identifier
Remove the protective cap with a screwdriver
Set selector switch to mains voltage
ITEM 3000
Wiring
6.4 Wiring the Power Supply Module and the CPU
Requirement
All modules are mounted onto the rail.
Wiring the PS and CPU
Note
The PS 307 power supply module is equipped with two additional 24 VDC terminals L+ and
M for the supply to I/O modules.

Note
The power supply connector of your CPU is a plug-in device and can be removed.

WARNING
There is a risk of contact to live wires if the power supply module, or any additional load
power supply units, are connected to the mains.
You should therefore isolate the S7-300 from power before you start wiring it. Always use
crimp ferrules with insulating collars for the conductors. Close all front panels of the
modules when you completed the wiring. This is conditional before you reconnect the S7-
300 to power.

1. Open the PS 307 power supply module and CPU front panels.
2. Open the strain relief on the PS 307.
3. Strip the power cable to a length of 11 mm and connect it to L1, N and to the protective
earth (PE) terminal of the PS 307.
4. Screw-tighten the strain relief again.
5. Next, wire the PS and CPU
The power supply connector of the CPUs is a removable plug-in device.
Strip the connecting cables for the CPU power supply to a length of 11 mm. Wire the
lower terminal M on the PS 307 to the terminal M of the CPU and the lower terminal L+
on the PS 307 to terminal L+ of the CPU.

WARNING

Reversing the polarity of the M and L+ terminals trips the internal fuse on your CPU.
Always interconnect the M and L+ terminals of the power supply module and of the
CPU.

6. Close the front panels.
ITEM 3000
Wiring
The figure below illustrates the procedures described earlier.
l
L+
M
M
M
L+
L+
N
L1
230V/120V
1 2 3

Numb
er
Identifier
Strain relief of the power supply cable
Connection cables between the PS and CPU
Removable power supply connector

Note
The PS 307 power supply module is equipped with two additional 24 VDC terminals L+ and
M for the supply to I/O modules.

ITEM 3000
Wiring
6.5 Wiring front connectors
Introduction
The sensors and actuators of your system are connected to the S7-300 AS by means of
front connectors. Wire the sensors and actuators to the relevant front connector and then
plug it into the module.
Front connector versions
Front connectors come in 20-pin and 40-pin versions with screw contacts or spring terminals.
You require 40-pin front connectors for the CPUs 31xC and 32-channel SMs.
Use the following front connectors as required for the module:
Table 6- 5 Assignment of front connectors to modules
Module Front connector with screw
terminals, order no.:
Front connector with spring
terminals, order no.:
Signal modules
(not 32-channel),
Function modules,
Communication module
CP 342-2
6ES7 392-1AJ00-0AA0 6ES7 392-1BJ00-0AA0
Signal modules
(32-channel) and
CPU 31xC
6ES7 392-1AM00-0AA0 6ES7 392-1BM01-0AA0
Connecting on spring terminals
It is quite easy to wire a front connector with spring terminals: Simply insert the screwdriver
vertically into the opening with the red opening mechanism, insert the wire into the terminal
and remove the screwdriver.

WARNING
You might damage the spring clamp mechanism of the front connector if you turn the
screwdriver sideways or use the wrong size of screwdriver. Always slide a matching
screwdriver vertically into the desired opening until it reaches the mechanical stop. This
ensures that the spring terminal is fully open.

Tip
There is a separate opening for test probes up to 2 mm in diameter to the left of the opening
for the screwdriver.
Requirement
The modules (SM, FM, CP 342-2) are mounted on the rail.
ITEM 3000
Wiring
Preparing the front connectors and cables
WARNING
There is a risk of contact to live wires if the power supply module, or any additional load
power supply units, are connected to the mains.
You should therefore isolate the S7-300 from power before you start wiring it. Close all front
panels of the modules when you completed the wiring. This is conditional before you
reconnect the S7-300 to power.

1. Switch off the power supply.
2. Open the front door.
3. Place the front connector into wiring position.
Push the front connector into the signal module until it latches. In this position, the front
connector still protrudes from the module.
Advantage of this wiring position: Comfortable wiring.
The front connector pins do not contact the module in this wiring position.
4. Strip the conductors to a length of 6 mm.
5. Crimp the wire end ferrules, for example, to terminate two conductors at one terminal.
1
2
3

Number Identifier
The switched off power supply module (PS)
The opened module
The front connector in wiring position
ITEM 3000
Wiring
Wiring front connectors
Table 6- 6 Wiring front connectors
Step 20-pin front connector 40-pin front connector
1. Place the included cable strain relief into the front
connector.

Cable exit at the bottom of the module?
If yes:
Starting at terminal 20, work your way down to
terminal 1.

Start wiring at terminal 40 or 20, and work in alternating
passes from terminals 39, 19, 38, 18 etc. until you have
reached terminals 21 and 1.
2.
If not:
Start wiring at terminal 1, and work your way up to
terminal 20.

Start wiring at terminal 1 or 21, and work in alternating
passes from terminals 2, 22, 3, 23 etc. until you have
reached terminals 20 and 40.
3. Front connectors with screw terminals:
Always screw-tighten the unused terminals.
4. Place the strain relief around the cable harness and the
front connector.
5. Tighten the strain relief for the cable harness. Push in the strain relief to the left to increase cable space.

1
2

2
1
3 4

The work step numbers are shown in the figure above
Insert the strain relief.
Wire the terminals.
to Wire the terminals.
Tighten the strain relief clamp.
Reference
For information on wiring the integrated I/O of 31xC CPUs, refer to the CPU 31xC and CPU
31x, Technical Data manual.
ITEM 3000
Wiring
6.6 Plugging the front connectors into modules
6.6 Plugging the front connectors into modules
Requirement
The front connectors are completely wired.
Inserting the front connector
Table 6- 7 Inserting the front connector
Step 20pin front connector 40pin front connector
Push in the unlocking mechanism on top of
the module.
Keeping the locking mechanism pressed,
insert the front connector into the module.
Provided the front connector is seated
correctly in the module, the unlocking
mechanism automatically returns to the
initial position when you release it.
Tighten the mounting screw in the center
of the connector.

This pulls the front connector completely
into contact with the module.
1.
Note
When you insert the front connector into the module, an encoding mechanism engages in
the front connector, thus ensuring that the connector can only be inserted into modules of
the same type.
2. Close the front panel. Close the front panel.

1
2
3

1
2

The work step numbers are shown in the figure above
Keep the release mechanism pressed
Insert the front connector
Only then close the front panel
Tighten the mounting screw,
Only then close the front panel
ITEM 3000
Wiring
6.7 Wiring I/O modules and compact CPUs with Fast Connect
Order numbers for Fast Connect Connectors
20-pin connector: 6ES7392-1CJ00-0AA0
40-pin connector: 6ES7392-1CM00-0AA0

ITEM 3000
Wiring
Wiring I/O modules and compact CPUs with Fast Connect
I/O modules and compact CPUs can be wired with Fast Connect. The individual wires are
connected by means of the front connector using Fast Connect technology, which
requires no stripping.
Fast Connect is a connection method that requires no conductor preparation (i.e., the
conductor insulation does not have to be stripped).
Each terminal with Fast Connect has a test opening (e.g. for measuring the voltage). The
test opening is suitable for test probes with a maximum diameter of
1.5 mm.
Wire end ferrules are not permitted.
1
2
3
4
5
1
2
3
4
5

Figure 6-1 Schematic representation of Fast Connect connectors
Numb
er
Identifier
Opening for testing: max. 1.5 mm
Opening for a conductor: 0.25 mm
2
to 1.5 mm
2

Toothing for opening the terminal
Guide clip opened (the wire can be inserted)
Guide clip closed (the wire is connected)
Wiring rules for front connector with Fast Connect

20-pin front connector 40-pin front connector
Solid wires No No
Connectable wire cross-section of flexible wires
Without wire end ferrule 0.25 mm
2
to 1.5 mm
2
0.25 mm
2
to 1.5 mm
2

With wire end ferrule - - - - - -
Number of wires per terminal 1 1
Number of terminating cycles for the same conductor
cross-section
25
1
25
1

Maximum external diameter of the wire insulation 3.0 mm 3.0 mm
1
For 1.5 mm
2
only 10 terminating cycles are possible. If different conductor cross-sections are used in a connecting
terminal as a result of rewiring, it can be wired a maximum of 10 times.
ITEM 3000
Wiring
Required tools
Screwdriver, 3.0 mm or 3.5 mm.
Connectable wires
Flexible conductors with PVC insulation and a conductor cross-section of: 0.25 mm
2
to
1.5 mm
2

A list of the tested conductors can be found at: http://www .weidmueller.de
UL-compliant cables and connections
Wiring range for insulating piercing connection 22 -16 AWG solid/stranded PVC insulated
conductors, UL style no. 1015 only.
ITEM 3000
Wiring
Procedure for wiring with Fast Connect
1. Insert the unstripped wire into the round opening until it stops (the insulation and
conductor must form a flat surface) and secure the conductor in this position.
For 20-pin connector: at a 90 angle
For 40-pin connector: at a 45 angle
2. Insert the screwdriver into the indentation on the topside of the guide clip.
3. Press the screw driver downwards until the guide clip is engaged in the end position. The
wire is connected.
3 mm
1
2+3
2+3
1
90
45

Note
If you would like to reuse a conductor after it was already connected once then it must be
trimmed beforehand.

ITEM 3000
Wiring
Procedure for disconnecting the wiring with Fast Connect
1. Insert the screwdriver into the opening next to the guide clip until it stops.
2. Using the screwdriver, apply upward leverage to the guide clip by means of the
appropriate toothing.
Repeat this action until the guide clip is engaged in the top position.
3. The wiring is disconnected. Remove the wire.
1
1
2
3

Figure 6-2 Disconnecting the wiring of a 40-pin Fast Connect connector

1
1
2
3

Figure 6-3 Disconnecting the wiring of a 20-pin Fast Connect connector
ITEM 3000
Wiring
6.8 Labeling the module I/Os
6.8 Labeling the module I/Os
Introduction
The labeling strips are used to document the assignment of module I/Os to the sensors /
actuators of your system.
You have to use the following labeling strips, depending on the module:
Table 6- 8 Assignment of labeling strips to modules
Module Labeling strip
Order no.:
SMs (not 32-channel),
Function modules,
Communication module CP 342-2
6ES7 392-2XX00-0AA0
SMs (32-channel) 6ES7 392-2XX10-0AA0
Filling out and inserting labeling strips
1. Label the strips with the addresses of the sensors / actuators.
2. Slide the labeled strips into the front panel.

Tip
Templates for labeling strips are available on the Internet at
http://www.siemens.com/automation/csi_en_WW, under entry ID 11978022.
ITEM 3000
Wiring
6.9 Terminating shielded cables on the shielding contact element
Application
The shield connecting element allows easy grounding of all shielded cables of S7 modules,
due to its direct contact to the mounting rail.
Design of the shielding contact element
The shielding contact element consists of:
a bracket with two screw bolts for rail mounting (order no.: 6ES5 390-5AA00-0AA0) and
the shielding terminals.
You must use the following shielding terminals, based on the shielding diameter of your
cables:
Table 6- 9 Shielding diameter assignment to shielding terminals
Cable with shielding diameter Shielding terminal order no.:
2 cables, each with shielding diameter of 2 mm to 6 mm 6ES7 390-5AB00-0AA0
1 cable, shielding diameter 3 mm to 8 mm 6ES7 390-5BA00-0AA0
1 cable, shielding diameter 4 mm to 13 mm 6ES7 390-5CA00-0AA0
The shielding contact element width is 80 mm and provides two rows, each with 4 shielding
terminals.
ITEM 3000
Wiring
Installing the shield connecting element underneath two signal modules
1. Push the two screw bolts of the bracket into the guide on the underside of the mounting
rail.
2. Place the bracket underneath the modules whose shielded cables are to be terminated.
3. Screw-tighten the bracket onto the rail.
4. The shielding terminal is equipped with a slotted web underneath. Place the shielding
terminal at this position onto the edge of the bracket (see figure below). Push the
shielding terminal down and pivot it into the desired position.
You can install up to 4 shielding terminals on each of the two rows of the shielding
contact element.
2
1
3

Number Identifier
Bracket of shielding contact element
Edge of the bracket where the shielding terminal(s) has to be placed.
Shielding terminals
ITEM 3000
Wiring
Terminating 2-wire cables on shielding contact elements
Only one or two shielded cables may be terminated per shielding terminal (see the figure
below). The cable is clamped down at the stripped cable shielding.
1. Strip the cable shielding to a length of at least 20 mm.
2. Clamp in the stripped cable shielding underneath the shielding terminal.
Push the shielding terminal towards the module and feed the cable through the clamp
opening ..
If you need more than four shielding terminals, start wiring at the rear row of the shielding
contact element.
1
2
2

Number Identifier
Magnified view of the shielding terminal
Wiring of the shielding terminal
Tip
Provide a sufficient cable length between the shielding terminal and the front connector. This
allows you to disconnect the front connector for repairs, without having to disconnect the
shielding terminal also, for example.
See also
Cable shielding (Page 251)
ITEM 3000
Wiring
6.10 Wiring the MPI / PROFIBUS connectors
6.10.1 Connecting the bus connector
Introduction
You need to network all the nodes you integrate into a subnet of your system. Information on
how to wire the bus connector can be found in the article below.
Wiring a bus connector with screw terminals
1. Strip the bus cable.
Details on stripped lengths are found in the product information supplied with the bus
connector.
2. Open the bus connector housing.
3. Insert the green and the red wire into the screw-terminal block.
Always connect the same wires to the same terminal (green wire to terminal A, red wire to
terminal B, for example).
4. Press the cable sheath into the clamp. Make sure that the shielding directly contacts the
shielding contact surfaces.
5. Screw-tighten the wire terminals.
6. Close the bus connector housing.
Wiring a Fast Connect bus connector
1. Strip the bus cable.
Details on stripped lengths are found in the product information supplied with the bus
connector.
2. Open the strain relief of the bus connector.
3. Insert the green and red wire into the open contacting covers.
Always connect the same wires to the same terminal (green wire to terminal A, red wire to
terminal B, for example).
4. Close the contacting cover.
This presses the conductors into the insulation displacement terminals.
5. Screw-tighten the strain relief clamp. Make sure that the shielding directly contacts the
shielding contact surfaces.

Note
Use a bus connector with 90 cable exit.

ITEM 3000
Wiring
See also
Network components of MPI/DP and cable lengths (Page 64)
6.10.2 Setting the terminating resistor on the bus connector
Inserting a bus connector in a module
1. Connect the wired bus connector to the module.
2. Screw the bus connector tightly onto the module.
3. If the bus connector is at the start or end of a segment, you have to switch on the
terminator resistance (Switch position "ON"; see following figure).

Note
6ES7 972-0BA30-0XA0 bus connectors are not equipped with a terminating resistor. You
cannot insert this type of bus connector at the beginning or end of a segment.

Please make sure during startup and normal operation that power is always supplied to
nodes where the terminating resistor is active.
The figure below shows the switch settings of a bus connector:
on
off
on
off
On On
Off Off
Terminating resistor activated Terminating resistor not activated

Removing the fiber-optic cable
You can unplug a bus connector with a looped-through bus cable at any time from the
PROFIBUS DP interface without interrupting data exchange on the bus.
ITEM 3000
Wiring
Possible data traffic errors
WARNING
Data traffic error might occur on the bus!
A bus segment must always be terminated at both ends with the terminating resistor. For
example, this is not the case when the last slave with the bus connector is deactivated.
Because the bus connector takes its voltage from the station, this terminating resistor is
ineffective. Please make sure that power is always supplied to stations on which the
terminating resistor is active.

ITEM 3000

Addressing
7
7.1 Slot-specific addressing of modules
Introduction
In slot-specific addressing (default addressing if configuration data was not loaded to the
CPU yet), each slot number is assigned a module start address. This is a digital or analog
address, based on the type of module.
This section shows you which module start address is assigned to which slot number. You
need this information to determine the start addresses of the installed modules.
Maximum assembly and the corresponding module start addresses
The figure below shows you an S7-300 assembly on four racks, and the optional slots with
their modules.Start addresses
The input and output addresses for I/O modules begin at the same module start address.

Note
On a CPU 31xC system you cannot insert any modules into slot 11 of rack 3. The address
range is reserved for the integrated I/O.

ITEM 3000
Addressing
7.1 Slot-specific addressing of modules
The figure below shows the slots of an S7-300 and the corresponding module start
addresses:
SF
BUSF
DC5V
FRCE
RUN
STOP
SM
SM
SM
SM
3
3
1 2 3
3
lM SM SM SM SM SM SM SM SM
lM PS CPU SM SM SM SM SM SM SM SM
4
640
96
4
512
64
5
528
68
7
560
76
11
368
28
10
352
24
9
336
20
8
320
16
7
304
12
6
288
8
5
272
4
4
256
0
11
496
60
10
480
56
9
464
52
8
448
48
7
432
44
6
416
40
5
400
36
4
384
32
11
624
92
10
608
88
9
592
84
8
576
80
6
544
72
5
656
100
6
104
672
7
688
108
9
116
720
10
120
736
11
124
752
8
112
704
Slot number
Module initial address digital
Module initial address analog
Slot number
Slot number
Rack 3 (EM)
Not CPU 31xC
Rack 2 (EM)
Rack 1 (EM)
Rack 0 (CU)
Slot number

ITEM 3000
Addressing
7.2 User-specific addressing of modules
7.2.1 User-specific addressing of modules
User-specific addressing
User-specific addressing means that you can assign an address of your choice to any
module (SM/FM/CP). The addresses are assigned in STEP 7. There you specify the module
start address that forms the basis for all other addresses of the module.
Advantages in user-specific addressing:
Optimization of available address space as there are no "address gaps" between the
modules.
In your standard software configuration, you can define addresses which are independent
of the relevant S7300 configuration.

Note
You always configure the hardware in HW Config of STEP 7 when using PROFIBUS DP
or PROFINET IO field devices. User-specific addressing is automatically set in this case.
There is no fixed slot addressing for such a configuration.

ITEM 3000
Addressing
7.2.2 Addressing digital modules
This section describes how to assign addresses to digital modules. You need this
information in order to be able to address the channels of the digital module in the user
program.
Addresses of digital modules
The address of an input or output of a digital module consists of a byte address plus a bit
address.
Example: I 1.2
The example consists of:
input I,
byte address 1 and
bit address 2
The byte address is based on the module start address.
The bit address is the number printed on the module.
When the first digital module is located in slot 4, its default start address is 0. The start
address of each further digital module increments by the count of 4.
The figure below shows you how the scheme by which the addresses of the various
channels of a digital module are derived.
0
1
2
3
4
5
6
7
0
1
2
3
4
5
6
7
Byte address:
Module start address
Byte address:
Module start address + 1
Bit address

ITEM 3000
Addressing
An example of digital modules
The example in the figure below shows which default addresses are derived when a digital
module is located in slot 4 (that is, when the module start address is 0). Slot number 3 is not
assigned, because the example does not contain an interface module.
:
:
:
:
:
:
PS CPU SM
0
1
2
3
4
5
6
7
0
1
2
3
4
5
6
7
4 1 2
Address 0.0
Address 1.7
Address 1.1
Address 1.0
Address 0.7
Address 0.1
Slot
number

ITEM 3000
Addressing
7.2.3 Addressing analog modules
This section describes how to address analog modules. You need this information in order to
be able to address the channels of the analog modules in your user program.
Addresses of analog modules
The analog input or output channel is always assigned a word address. The channel address
is based on the module start address. When the first analog is located in slot 4, its default
start address is 256. The start address of each further analog module increments by the
count of 16.
An analog I/O module has the same start addresses for its input and output channels.
An example of analog modules
The example in the figure below shows you which default channel addresses are derived for
an analog module located at slot 4. As you can see, the input and output channels of an
analog I/O module are addressed starting at the same address, namely the module start
address.
Slot number 3 is not assigned, because the example does not contain an interface module.
:
:
:
:

lnputs
Outputs
Channel 0: Address 256
Slot
number
PS CPU SM
1 2 4

Figure 7-1 I/O addresses of an analog module at slot 4

ITEM 3000
Addressing
7.2.4 Addressing the integrated I/Os of CPU 31xC
CPU 312C
Addresses of the integrated I/Os of this CPU:
Table 7- 1 Integrated I/Os of CPU 312C
Inputs / outputs Default addresses Remarks
10 digital inputs 124.0 to 125.1
of which 8 Inputs are for
technological functions:
124.0 to 124.7
6 digital outputs 124.0 to 124.5
of which 2 inputs are for
124.0 to 124.1
All digital inputs can be assigned an
interrupt function.

Optional technological functions:
Counting
Frequency measurement
Pulse width modulation
CPU 313C
Addresses of the integrated I/Os of this CPU:
Table 7- 2 Integrated I/Os of CPU 313C
Inputs / outputs Default addresses Comments
124.0 to 125.0
125.4 to 125.6
124.0 to 124.2
4+1 analog inputs 752 to 761
2 analog outputs 752 to 755
interrupt function.

Counting
ITEM 3000
Addressing
CPU 313C-2 PtP and CPU 313C-2 DP
Addresses of the integrated I/Os of these CPUs:
Table 7- 3 Integrated I/Os of CPU 313C-2 PtP/DP
124.0 to 125.0
125.4 to 125.6
124.0 to 124.2
interrupt function.

Counting
CPU 314C-2 PtP and CPU 314C-2 DP
Addresses of the integrated I/Os of these CPUs:
Table 7- 4 Integrated I/Os of CPU 314C-2 PtP/DP
124.0 to 125.7
124.0 to 124.3
4+1 analog inputs 752 to 761
2 analog outputs 752 to 755
interrupt function.

Counting
Positioning
Special features
You cannot influence outputs with transfer instructions if they are assigned to technological
functions.
I/Os not configured for technological functions can be used as standard I/Os.
ITEM 3000
Addressing
7.3 Addressing on PROFIBUS DP
7.3 Addressing on PROFIBUS DP
Overview
The corresponding DP slaves must be commissioned for operation on PROFIBUS DP in
order to enable addressing of distributed I/O in the user program.
This commissioning includes
the assignment of DP slaves to PROFIBUS addresses
the assignment of slots or address ranges to the I/O modules in order to enable their
addressing in the user program. Slots which do not contain user date are assigned
diagnostics addresses.
This applies likewise when the CPU is operated as DP slave.
Further information about CPU operation in DP master or DP slave mode is available in the
chapter Commissioning PROFIBUS DP.
User-specific addressing of distributed PROFIBUS IO
Distributed PROFIBUS DP IO requires user-specific addressing.
Further information is available in the User-specific addressing of modules chapter.
Addressing consistent user data areas
The table below shows items to be taken into consideration in terms of communication in a
PROFIBUS DP master system when transferring I/O areas with "Total length" consistency.

Rule for 1 byte to 32 bytes data consistency on PROFIBUS DP:
The address range of consistent data in the process image is automatically updated.
You can also use SFC14 "DPRD_DAT" and SFC15 "DPWR_DAT" to read and write consistent data.
SFC14 and SFC15 are required to read and write consistent data of address ranges which are not
available in the process image.
The length of areas with "Total length" consistency accessed by the SFC must match the
programmed range.
Direct access to consistent areas is also possible (L PEW or T PAW, for example).
PROFIBUS DP supports the transfer of up to 32 bytes of consistent data.
ITEM 3000
Addressing
7.4 Addressing on PROFINET
7.4 Addressing on PROFINET
Overview
The corresponding I/O devices must be commissioned for operation on PROFINET in order
to enable addressing of distributed peripherals on PROFINET IO in the user program.
This commissioning includes
the definitions of I/O device numbers and names
the definition of I/O device names in order to enable the assignment of IP addresses and
access to the IO devices by the CPU 31x PN/DP operated as IO controller.

Note
Name assignment at "Device replacement without removable medium"
If the functionality "Device replacement without removable medium" is configured in HW
Config, IO devices can be replaced without the user having to assign a name. To do so,
the IO device has to be reset to the state of delivery by using "Reset to factory setting".

Address ranges are assigned to the input/output modules or slots/subslots so that they
can be addressed from the user program. Slots which do not contain user date are
assigned diagnostics addresses.
Further information about CPU operation as I/O controller is available in the chapter
Commissioning PROFINET IO.
User-specific addressing of distributed PROFINET IO
Distributed peripherals on PROFINET IO require user-specific addressing.
Further information is available in the User-specific addressing of modules chapter.
Addressing consistent user data areas
The table below shows items to be taken into consideration in terms of communication in a
PROFINET IO system when transferring I/O areas with "Total length" consistency.

Rule for 1 byte to 254 bytes data consistency on PROFINET IO:
The address range of consistent data in the process image is automatically updated.
You can also use SFC14 "DPRD_DAT" and SFC15 "DPWR_DAT" to read and write consistent data.
SFC14 and SFC15 are required to read and write consistent data of address ranges which are not
available in the process image.
The length of areas with "Total length" consistency accessed by the SFC must match the
programmed range.
Direct access to consistent areas is also possible (L PEW or T PAW, for example).
PROFINET IO supports the transfer of up to 254 bytes of consistent data.
ITEM 3000

Commissioning
8
8.1 Overview
This section contains important notes on commissioning which you should strictly observe in
order to avoid injury or damage to machines.

Note
Your commissioning phase is determined primarily by your application, so we can only offer
you general information, without claiming completeness of this topic.

Reference
Note the information about commissioning provided in the descriptions of your system
components and devices.
8.2 Commissioning procedure
8.2.1 Procedure: Commissioning the hardware
Hardware requirements
S7-300 is installed
S7-300 is wired
With networked S7-300, the following applies to the interfaces:
MPI/ PROFIBUS
The MPI/PROFIBUS addresses are configured
The terminating resistors on the segments are enabled.
PROFINET
The integrated PROFINET interface of CPU 31x PN/DP is configured in STEP 7
(IP address and device name are set in HW Config)
The CPU is connected to the subnet.
ITEM 3000
Commissioning
Recommended procedure: Hardware
The S7-300 system can be very large and extremely complex due to its modular structure
and versatile expansion options. It is therefore inappropriate to initially start up an S7-300
with multiple racks and all inserted (installed) modules. Rather, we recommend a step-by-
step commissioning procedure.
We recommend the following initial commissioning procedure for an S7-300:
Table 8- 1 Recommended commissioning procedure: Hardware
Tasks Remarks Information can be found
An installation and wiring
check according to checklist
- in the chapter: Checklist for
commissioning
Disconnecting drive
aggregates and control
elements
This prevents negative effects on your system as a result
of program errors.

Tip: By redirecting data from your outputs to a data block,
you can always check the status at the outputs
-
Preparing the CPU Connecting the PG in the chapter: Connecting the
programming device (PG).
Commission the CU with inserted power supply module
and CPU.
First, switch on the expansion devices (EMs) which are
equipped with their own power supply module, and then
switch on the power supply module of the CU.
in the chapter: Initial power on Central unit (CU):
commission the CPU and
power supply, check the
LEDs
Check the LED displays on both modules. in the chapter: Debugging
functions, diagnostics and
troubleshooting
Reset CPU memory and
check the LEDs
- in the chapter: CPU memory
reset by means of mode
selector switch
CU:
commission the remaining
modules
Insert further modules into the CU and commission these,
working successively.
in the Module specifications
Manual
Expansion module (EM):
Connecting
Interconnect the CU with EMs as required: Insert only one
send IM into the CU, and insert the matching receive IM
into into the EM.
in the chapter: Installation
EM:
Commissioning
Insert further modules into the EMs and commission
these, working in successively.
See above.

DANGER
Proceed step-by-step. Do not go to the next step unless you have completed the previous
one without error / error message.
Reference
Important notes can also be found in the section Debugging Functions, Diagnostics and
Troubleshooting.
See also
Procedure: Software commissioning (Page 137)
ITEM 3000
Commissioning
8.2.2 Procedure: Software commissioning
Requirements
You must have installed and wired up your S7-300.
You are using the current programming package of STEP 7 in order to utilize the
complete functional scope of your CPU.
In case of networking of the S7-300 with MPI or PROFIBUS
The MPI/PROFIBUS addresses are configured
The terminating resistors on the segments are enabled
In case of networking of the S7-300 with PROFINET
The integrated PROFINET interface of CPU 31x PN/DP is configured in STEP 7 (IP
address and device names are set in HW Config)
The CPU is connected to the subnet.

Note
Observe the procedure for commissioning the hardware.
Recommended procedure: Software
Table 8- 2 Recommended commissioning procedure - Part II: Software
Tasks Remarks Information can be found ...
Switch on the PG and run
SIMATIC Manager
Download the
configuration and the
program to the CPU
- In the STEP 7 Programming
Manual
Debugging the I/Os Helpful functions are here:
Monitoring and controlling tags
Testing with program status
Forcing
Controlling outputs in STOP mode (PO enable)
Tip: Test the signals at the inputs and outputs using the
simulation module SM 374, for example.
In the STEP 7 Programming
Manual
Chapter: Debugging functions,
diagnostics and
troubleshooting
Commissioning PROFIBUS
DP or Ethernet
- in the chapter: Commissioning
PROFIBUS DP
in the chapter: Configuring
PROFINET interface X2
Commissioning PROFINET
IO
in the PROFINET System
Description System Manual
Connect the outputs Commissioning the outputs successively. -

DANGER
Proceed step-by-step. Do not go to the next step unless you have completed the previous
one without error / error message.
ITEM 3000
Commissioning
8.3 Commissioning check list
Reaction to errors
React to errors as follows:
Check the system with the help of the check list in the chapter below.
Check the LED displays on all modules. For information on their meaning, refer to the
chapters describing the relevant modules.
If required, remove individual components to trace the error.
Reference
Important notes can also be found in the section Debugging Functions, Diagnostics and
Troubleshooting.
See also
Procedure: Commissioning the hardware (Page 135)
Introduction
After you mounted and wired your S7-300, we advise you to check all previous steps once
again.
The check list tables below are a guide for your examination of the S7-300. They also
provide cross-references to chapters containing further information on the relevant topic.
Racks

Points to be examined are in the manual S7-300: Installation in chapter
Are the rails mounted firmly to the wall, in the frame or in the
cabinet?
Configuring, Installation
Have you maintained the free space required? Configuring, Installation
Are the cable ducts installed properly? Configuring
Is the air circulation OK? Installing
ITEM 3000
Commissioning
Concept of grounding and chassis ground

Have you established a low-impedance connection (large
surface, large contact area) to local ground?
Configuring, Appendix
Are all racks (rails) properly connected to reference potential
and local ground (direct electrical connection or ungrounded
operation)?
Configuring, Wiring, Appendix
Are all grounding points of electrically connected modules and
of the load power supply units connected to reference
potential?
Configuring, Appendix
Module installation and wiring

Are all modules properly inserted and screwed in? Installing
Are all front connectors properly wired, plugged, screw-
tightened or latched to the correct module?
Installation, Wiring
Mains voltage

Points to be examined S7-300:
Installation in
chapter
See manual;
Section ...
Is the correct mains voltage set for all components? Wiring Module data
Power supply module

Points to be examined S7-300:
Installation in
chapter
See manual;
Section ...
Is the mains plug wired correctly? Wiring -
Is mains voltage connected? - -
ITEM 3000
Commissioning
8.4 Commissioning the Modules
8.4.1 Inserting/Replacing a Micro Memory Card
SIMATIC Micro Memory Card (MMC) as memory module
The memory module used on your CPU is a SIMATIC Micro Memory Card. You can set up
the SIMATIC Micro Memory Card as a load memory or a portable data medium.

Note
A SIMATIC Micro Memory Card must be inserted for CPU operation.

Note
The CPU goes into STOP and requests a memory reset when you remove the SIMATIC
MMC while the CPU is in RUN state.

CAUTION
Data on a SIMATIC Micro Memory Card can be corrupted if you remove the card while it is
being accessed by a write operation. You may have to delete the SIMATIC Micro Memory
Card using the PG or format it in the CPU if you remove it from the live system.
DO NOT remove the SIMATIC Micro Memory Card when the system is in RUN state;
always shut down power or set the CPU to STOP state in order to prevent any write access
of a programming device. When the CPU is in STOP mode and you cannot not determine
whether or not a PG is writing to the card (e.g. load/delete block), disconnect the
communication lines.

WARNING
Make sure that the SIMATIC Micro Memory Card to be inserted contains a user program
which is suitable for the CPU (system). The wrong user program may have fatal processing
effects.

ITEM 3000
Commissioning
Inserting/replacing the SIMATIC Micro Memory Card
1. Switch the CPU to STOP mode.
2. Is a SIMATIC Micro Memory Card inserted?
If yes, ensure that no write operations are running on the PG (such as loading a block). If
you cannot ensure this state, disconnect all communication lines of the CPU.
Press the ejector and remove the SIMATIC MMC.
The frame of the module slot is equipped with an ejector for removing the SIMATIC MMC
(see CPU 31xC and CPU 31x Manual, Technical Data CPU31x Operator Control and
Display Elements).
You need a small screwdriver or ball-point pen to eject the SIMATIC Micro Memory Card.
3. Insert the ("new") SIMATIC MMC into the card slot with its beveled edge facing the
ejector.
4. Carefully push the SIMATIC MMC into the CPU slot to engage the interlock.
5. Reset CPU memory (see Resetting CPU memory by means of mode selector switch)

Inserting and removing a SIMATIC MMC when CPU power is switched off
After you replaced a SIMATIC MMC in POWER OFF state,
the CPUs
automatically detect a physically identical SIMATIC MMC with changed content
automatically detect a new MMC with contents to the previous SIMATIC MMC
It automatically performs a CPU memory reset after POWER ON.
Reference
Chapter Properties of the SIMATIC Micro Memory Card , CPU 31xC and CPU 31x
Manual, Technical data
Chapter Technical data of the SIMATIC Micro Memory Card (MMC), CPU 31xC and CPU
31x Manual, Technical data
ITEM 3000
Commissioning
8.4.2 Initial power on
Requirements
You must have installed and wired up the S7-300.
Insert the Micro Memory Card into the CPU
Your CPU's mode selector switch must be set to STOP.
Initial power on of a CPU with Micro Memory Card
Switch on the PS 307 power supply module.
Result:
The 24 VDC LED on the power supply module is lit.
On the CPU
The 5 VDC LED is lit.
The STOP LED flashes at 2 Hz when the CPU executes an automatic memory reset.
The STOP LED is lit after memory reset.
ITEM 3000
Commissioning
8.4.3 CPU memory reset by means of mode selector switch
When to reset CPU memory
You reset CPU memory
in order to clear all retentive memory bits, timers and counters, and to initialize work
memory with the start values of the retentive DBs in load memory.
if the new retentive new memory bits, timers and counters downloaded to the CPU user
program using the "Download user program to Memory Card" function are liable to cause
unwanted reactions.
Reason: the "Download user program to Memory Card" function does not delete any
retentive memory areas.
when the CPU requests a memory reset; indicated by the STOP LED flashing at 0.5 Hz
intervals
Table 8- 3 Possible reasons of a CPU request to reset memory
Causes of a CPU request to reset memory Special features
The SIMATIC MMC has been replaced.
RAM error in CPU
Insufficient work memory for loading all
user program blocks from a SIMATIC
MMC.
Attempts to load faulty blocks; if a wrong
instruction was programmed, for example.
CPU with inserted SIMATIC Micro Memory Card:
Recursive request of a CPU memory reset.
For further information on the behavior of the SIMATIC
MMC during CPU memory reset, refer to the CPU 31xC
and CPU 31x Manual, Technical data, Memory Reset
and Restart
How to reset memory
There are two ways to reset CPU memory:

CPU memory reset using the mode selector
switch
CPU memory reset using the PG
... is described in this chapter. ... is only possible when CPU is in STOP mode
(see STEP 7 Oneline Help ).
ITEM 3000
Commissioning
Resetting CPU memory using the mode selector switch
The table below shows the steps in resetting CPU memory.
Table 8- 4 Procedure for CPU memory reset
Step Reset CPU memory
1. Turn the key to STOP position .
2. Turn the key to MRES position Hold the key in this position until the STOP LED lights up
for the second time and remains on (this takes 3 seconds).
Now release the key.
3. You must turn the key to MRES position again within 3 seconds and hold it there until the
STOP LED flashes (at 2 Hz).
You can now release the switch. When the CPU has completed memory reset, the STOP
LED stops flashing and remains lit.
The CPU has reset the memory.
The procedure described earlier is only required to reset CPU memory when the CPU has
not requested (indicated by slow flashing of the STOP LED) a memory reset. If the CPU
requests a memory reset you only have to briefly set the mode selector switch to the MRES
position in order to initiate the memory reset.
The figure below shows how to use the mode selector switch to reset CPU memory:
1 2 3
STOP-
LED
on
off
3 s
t
CPU STOP
MRES
STOP
MRES
STOP
MRES
STOP
MRES
STOP
MRES
max. 3 s
min. 3 s

You may have to format the SIMATIC MMC if memory was successfully reset and the CPU
once again requests a memory reset (see Formatting the SIMATIC Micro Memory Card).
ITEM 3000
Commissioning
STOP LED does not flash during the memory reset
What should I do if the STOP LED does not flash during the memory reset or if other LEDs
are lit?
1. You must repeat steps and .
2. If the CPU still does not reset memory, evaluate the diagnostic buffer of the CPU.
What happens in the CPU during a memory reset
Table 8- 5 Internal CPU events on memory reset
Event Action in CPU
1. The CPU deletes the entire user program in the main memory.
2. The CPU deletes the retentive data.
3. The CPU tests its own hardware.
CPU activities
4. The CPU copies the runtime-relevant content of the SIMATIC Micro Memory Card (load
memory) to work memory.
Tip: If the CPU is unable to copy the contents from the SIMATIC MMC and requests a
memory reset:
Remove the SIMATIC Micro Memory Card.
Reset CPU memory
Read the diagnostic buffer.
Memory contents
after reset
The user program is once again transferred from the SIMATIC MMC to work memory. Memory
utilization is indicated accordingly.
Data in the diagnostics buffer.
You can read the diagnostic buffer with the PG (see STEP 7 Online Help).
The MPI parameters (MPI address and highest MPI address, transmission rate, configured MPI
addresses of CPs/FMs in an S7300).
Same applies to CPU 315-2 PN/DP /CPU 317 / CPU 319 if the MPI/DP interface of the CPU is
programmed for operation as DP interface (PROFIBUS address, highest PROFIBUS address,
baud rate, configured as active or passive interface).
Data retained
Content of elapsed time counter
Special feature: Interface parameters (MPI or MPI/DP interface)
The following parameters hold a special position when CPU memory is reset.
Parameters of interface (MPI parameters or MPI-/DP parameters for MPI-/DP interfaces).
The table below describes which interface parameters remain valid after a CPU memory
reset.

CPU memory reset ... MPI/DP parameters
with inserted SIMATIC Micro Memory Card: ...the MPI parameters on the SIMATIC Micro
Memory Card or integrated read-only load
memory are valid. If this location does not contain
any parameter data (SDB), the previously set
parameters stay valid.
without inserted SIMATIC Micro Memory Card: ... are retained and valid.
ITEM 3000
Commissioning
8.4.4 Formatting the Micro Memory Card
Situations which require formatting of the SIMATIC Micro Memory Card:
The SIMATIC Micro Memory Card module type is not a user module
The SIMATIC Micro Memory Card is not formatted
The SIMATIC Micro Memory Card is defective
Invalid content of the SIMATIC Micro Memory Card
The content of the SIMATIC Micro Memory Card has been marked invalid
The "Download user program" operation was interrupted as a result of Power Off.
The "Write to EPROM" operation was interrupted as a result of Power Off.
Error when evaluating the module content during CPU memory reset.
Formatting error, or formatting failed.
If one of these errors has occurred, the CPU prompts you for yet another memory reset,
even after a memory reset operation has been performed. The contents of the SIMATIC
MMC are retained until it is formatted, unless the "Download user program" or "Write to
EPROM" operation was interrupted due to Power Off.
The SIMATIC Micro Memory Card is only formatted if a specific reason is given (see above).
It is not formatted, for example, when the CPU requests a memory reset after module
replacement. In this case, a switch to MRES triggers a normal memory reset for which the
module content remains valid.
How to format your SIMATIC Micro Memory Card
If the CPU has requested a memory reset (STOP LED flashing slowly) you can format the
SIMATIC MMC using the mode selector switch as described below:
1. Toggle the switch to the MRES position and hold it there until the STOP LED lights up
and remains on (after approx. 9 seconds).
2. Within the next three seconds, release the switch and toggle it once again to MRES
position. The STOP LED flashes to indicate that formatting is in progress.

Note
Always perform these steps within the specified time, for the SIMATIC Micro Memory Card
will otherwise not be formatted and returns to memory reset status.

See also
CPU memory reset by means of mode selector switch (Page 143)
ITEM 3000
Commissioning
8.4.5 Connecting the programming device (PG)
8.4.5.1 Connect PG/PC to the integrated PROFINET interface of the CPU 31x PN/DP
Requirement
CPU with integrated PROFINET interface (CPU 319-3 PN/DP, for example)
PG/PC with network card
Connect PG/PC to the integrated PROFINET interface of the CPU 31x PN/DP
1. Connect the PG/PC to a switch, using a TP patch cable
.
2. In the same way, connect the switch to the integrated PROFINET interface of your CPU
.
2
1
CPU
PS
ET 200S
PN
PG/PC
lO device
Switch
lndustrial Ethernet

Result
You connected the PG/PC to the integrated PROFINET interface of the CPU.
Tip
Using an Ethernet crossover cable, you can also connect your PG/PC directly to the
integrated PROFINET interface of the CPU 31x PN/DP.
Reference
For information on PROFINET, refer to the PROFINET System Description.
For information on passive network components such as switches, refer to the SIMATIC
NET manual: Twisted Pair and Fiber-Optic Networks.
ITEM 3000
Commissioning
See also
Configuring and commissioning the PROFINET IO system (Page 170)
8.4.5.2 Connecting the PG to a node
Requirement
The PG must be equipped with an integrated MPI interface or an MPI card in order to
connect it via MPI.
Connecting a PG to the integrated MPI interface of the CPU
Interconnect the PG with the MPI interface of your CPU by way of a PG patch cable . You
can use a self-made PROFIBUS bus cable with bus connectors. The figure below illustrates
the connection between the PG and the CPU
1
PG
PS
MPl
CPU SM

Numb
er
Identifier
PG cable used to interconnect the PG with the CPU
Procedure for PROFIBUS DP
The procedure is basically the same, if the CPU interface is set to PROFIBUS DP mode
ITEM 3000
Commissioning
8.4.5.3 Connecting the PG to several nodes
Requirements
connect it to an MPI.
Connecting the PG to several nodes
Use bus connectors to connect a PG which is permanently installed on the MPI subnet to the
other nodes of the MPI subnet.
The figure below shows two networked S7-300s which are interconnected by means of bus
connectors.
1
2
2
PG
CPU PS SM
SM CPU PS

Numb
er
Identifier
PROFIBUS bus cable
Connectors with enabled terminating resistors

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8.4.5.4 Using the PG for commissioning or maintenance
Requirement
Using the PG for commissioning or maintenance
Use a stub cable to connect the commissioning and maintenance PG to the other subnet
nodes. The bus connector of these nodes must be equipped with a PG socket.
The figure below shows the interconnection of two networked S7-300 and a PG.
2
3
2
1
PS SM CPU
PS SM CPU
PG

Numb
er
Identifier
Stub cable used to interconnect the PG with the CPU
PROFIBUS bus cable used to network both CPUs
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MPI addresses for service PGs
If there is no stationary PG, we recommend:
To connect a PG to an MPI subnet with "unknown" node addresses, set the following
addresses on the service PG:
MPI address: 0
Highest MPI address: 126
IN STEP 7, you then determine the highest MPI address on the MPI subnet and match the
highest MPI address in the PG to that of the MPI subnet.
See also
Procedure: Commissioning the hardware (Page 135)
Procedure: Software commissioning (Page 137)
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8.4.5.5 Connecting a PG to ungrounded MPI nodes (not CPU 31xC)
Requirement
Connecting a PG to ungrounded nodes on an MPI subnet (not CPU 31xC)
Connecting a PG to ungrounded nodes
Always use an ungrounded PG to connect to ungrounded MPI subnet nodes or to
ungrounded S7-300 PLCs.
Connecting a grounded PG to the MPI
You want to operate with ungrounded nodes. If the MPI at the PG is grounded, you must
interconnect the nodes and the PG with an RS485 repeater. You must connect the
ungrounded nodes to bus segment 2 if the PG is connected to bus segment 1
(terminals A1 B1) or to the PG/OP interface (refer to chapter 9 in the Module Data Manual).
The figure below shows an RS485 repeater as interface between grounded and ungrounded
nodes of an MPI subnet.
1
2
1
CPU PS
PG
Bus segment 2
(ungrounded
signals)
Bus segment 1
(grounded signals)

Numb
er
Identifier
RS485 Repeaters, with activated terminating resistors

See also
PROFINET cable lengths and network expansion (Page 83)
Network components of MPI/DP and cable lengths (Page 64)
ITEM 3000
Commissioning
8.4.6 Starting SIMATIC Manager
Introduction
SIMATIC Manager is a GUI for online/offline editing of S7 objects (projects, user programs,
blocks, hardware stations and tools).
The SIMATIC Manager lets you
manage projects and libraries,
call STEP 7 tools,
access the PLC (AS) online,
edit Memory Cards.
Starting SIMATIC Manager
After installation, the SIMATIC Manager icon appears on the Windows desktop, and the Start
menu contains entry SIMATIC Manager under SIMATIC.
1. Run SIMATIC Manager by double-clicking the icon, or from the Start menu (same as with
all other Windows applications).
User interface
A corresponding editing tool is started up when you open the relevant objects. You start the
program editor by double-clicking the program block you want to edit (object-oriented start).
Online Help
The online help for the active window is always called by pressing F1.
ITEM 3000
Commissioning
8.4.7 Monitoring and modifying I/Os
The "Monitor and modify tags" tool
The STEP 7 "Monitor and modify tags" tool lets you:
monitor program tags in any format
edit the tag status or data in the CPU (modifying).
Creating a tag table
You have two options of creating a tag table (VAT):
in the LAD / FBD / STL editor by selecting the PLC > Monitor/Modify Variables command
This table is also available directly online.
in SIMATIC Manager with the Blocks container open via menu item Insert New Object >
Variable table
This table created offline can be saved for future retrieval. You can also test it after
switching to online mode.
VAT structure:
In the VAT, every address to be monitored or modified (e.g. inputs, outputs) occupies one
row.
The meaning of the VAT columns is as follows:

Column text This field ...
Address contains the absolute address of the tag
Icon contains the symbolic descriptor of the tag
This is identical to the specification in the Symbol Table.
Symbol comment shows the symbol comment of the Symbol Table
Status format contains the default format setting, e.g. HEX.
You can change the format as follows:
right-click in the format field. The Format List opens.
or
left-click in the format field until the relevant format appears
Status value shows the content of the tag at the time of update
Modify value is used to enter the new tag value (modify value)
Monitor tag
You have two options for monitoring tags:
updating the status values once via menu item Tag > Update Status Values
or
continuous update of status values via menu item Tag > Monitor
ITEM 3000
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Modifying tags
To modify tags , proceed as follows:
1. Left-click the field Modify value of the relevant tag.
2. Enter the modify value according to the data type.
3. To update modify values once, select the menu item Tag > Activate Modify Value.
or
Enable modify values permanently via menu item Tag > Modify.
4. In the Monitor test function, verify the modify value entry in the tag.
Is the modify value valid?
You can disable the modify value entered in the table. An invalid value is displayed same as
a comment. You can re-enable the modify value.
Only valid modify values can be enabled.
Setting the trigger points
Trigger points:
The "Trigger point for monitoring" determines the time of update for values of tags to be
monitored.
The "Trigger point for modifying" determines the time for assigning the modify values to
the tags to be modified.
Trigger condition:
The "Trigger condition for monitoring" determines whether to update values once when
the trigger point is reached or continuously every time the trigger point is reached.
The "Trigger condition for modifying" determines whether to assign modify values once or
permanently to the variable to be modified.
You can customize the trigger points using the tool "Monitor and modify tag" in the menu
item Tag > Set Trigger ... .
Special features
If "Trigger condition for monitoring" is set to once , the menu items Tag > Update Status
Values or Tag > Monitor have the same effect, namely a single update.
If "Trigger condition for modifying" is set to once , the menu items Tag > Update Status
Values or Tag > Modify have the same effect, namely a single assignment.
If trigger conditions are set to permanent , the said menu items have different effects as
described above.
If monitoring and modifying is set to the same trigger point, monitoring is executed first.
If Process mode is set under Debug > Mode, values are not cyclically updated when
permanent modification is set.
Remedy: Use the Force test function.
ITEM 3000
Commissioning
Saving/opening the variable table
Saving the VAT
1. After aborting or completing a test phase, you can save the variable table to memory. The
name of a variable table starts with the letters VAT, followed by a number from 0 to
65535; e.g. VAT5.
Opening VAT
1. Select the menu item Table > Open.
2. Select the project name in the Open dialog.
3. In the project window below, select the relevant program and mark the Blocks container.
4. In the block window, select the desired table.
5. Confirm with OK.
establishing a connection to the CPU
The variables of a VAT represent dynamic quantities of a user program. In order to monitor
or modify variables it is required to establish a connection to the relevant CPU. Every
variable tables can be linked to another CPU.
In menu item PLC > Connect to ... , establish a connection to one of the following CPUs:
configured CPU
directly connected CPU
available CPU ...
The table below lists the display of variables.

CPUs The CPU variables are displayed, ...
configured CPU in their S7 program (Hardware Station) in which the VAT is
stored.
directly connected CPU that is connected directly to the PG.
available CPU. that is selected in the dialog window.
Use the menu items PLC > Connect to ... > Available CPU ... to
connect to an available CPU. This can be used to connect to any
CPU available on the network.
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Modifying outputs in CPU STOP mode
The function Enable PO resets the output disable signal for the peripheral outputs (PO),
thus enabling modifying of the PO in CPU STOP mode.
In order to enable the POs, proceed as follows:
1. In menu item Table > Open the variable table (VAT), open the VAT that contains the PO
you want to modify, or activate the window containing the corresponding VAT.
2. To modify the PO of the active VAT, select the CPU connection in menu command PLC
> Connect to ... .
3. Use menu command PLC > Operating Mode to open the Operating Mode dialog and
switch the CPU to STOP mode.
4. Enter your values in the "Modify value" column for the PO you want to modify.
Examples:
PO: POB 7 modify value: 2#0100 0011
POW 2 W#16#0027
POD 4 DW#16#0001
5. Select Variable > Enable PO to set "Enable PO" mode.
6. Modify the PO by selecting Variable > Activate Modify Values. "Enable PO" mode
remains active until reset by selecting Variable > Enable PO once again.
"Enable PO" is also terminated when the connection to the PG goes down.
7. Return to step 4 if you want to set new values.

Note
For example, a message pops up to indicate a CPU mode transition from STOP to RUN
or START-UP.
A message also pops up when the "Enable PO" function is set while the CPU is in RUN
mode.

ITEM 3000
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8.5 Commissioning PROFIBUS DP
8.5.1 Commissioning PROFIBUS DP
Requirements
Requirements for commissioning a PROFIBUS DP network:
A PROFIBUS DP network is installed.
You have configured the PROFIBUS DP network using STEP 7 Standard Package and
have assigned a PROFIBUS DP address and the address space to all the participants.
Note that you must also set address switches at some of the DP slaves (see the
description of the relevant DP slave).
Software requirements are shown in the table below, based on the CPU used:
Table 8- 6 Software requirements
CPU Order No. Software required
313C-2 DP 6ES7313-6CF03-0AB0
314C-2 DP 6ES7314-6CG03-0AB0
STEP 7 V 5.2. or higher + SP1 + HSP
COM PROFIBUS V 5.0 or higher
315-2 DP 6ES7315-2AH14-0AB0 STEP 7, V 5.4 + SP6 or higher or
STEP 7, V5.2 + SP1 + HSP or higher
315-2 PN/DP 6ES7315-2EH13-0AB0 STEP 7 V5.4 + SP1 + HSP or higher
317-2 DP 6ES7317-2AJ10-0AB0 STEP 7 V5.2 + SP1 + HSP or higher
317-2 PN/DP 6ES7317-2EK13-0AB0 STEP 7 V 5.4 + SP2 or higher
319-3 PN/DP 6ES7318-3EL00-0AB0 STEP 7 V 5.4 + SP4 or higher
DP address ranges of the CPUs
Table 8- 7 DP address ranges of the CPUs
Address area 313C-2 DP
314C-2 DP
315-2 DP
315-2 PN/DP
317-2 DP
317-2 PN/DP
319-3 PN/DP
Entire address range of inputs
and of outputs
1024 bytes 2048 bytes 8192 bytes 8192 bytes
of these in the process image,
for inputs and outputs
respectively:
max. 128 bytes max. 2048 bytes max. 2048 bytes Max. 8192 bytes
Default 128 bytes
1
128 bytes 256 bytes 256 bytes
1
default cannot be changed
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DP diagnostics addresses
DP diagnostic addresses occupy 1 byte per DP master and DP slave in the input address
range. For example, at these addresses DP standard diagnostics can be called for the
relevant node (LADDR parameter of SFC 13). The DP diagnostic addresses are specified in
your configuration. If you do not specify any DP diagnostic addresses, STEP 7 assigns these
DP diagnostic addresses in ascending order, starting at the highest byte address.
In the case of a CPU 31xC-2 DP, CPU 31x-2 DP or CPU 31x PN/DP assigned as a master,
two different diagnostic addresses must be assigned for S7 slaves.
Diagnostic address of the slave (address for slot 0)
At this address all slave events are reported in the DP master (Node representative), e.g.
Node failure.
Diagnostic address of the module (address for slot 2)
All module (CPU 313C-2 DP as I-Slave, for example) events are reported in the master
(OB82) at this address. With a CPU as DP Slave, for example, diagnostic interrupts for
operating mode transitions are reported at this address.
See also
Connecting the PG to a node (Page 148)
Connecting the PG to several nodes (Page 149)
8.5.2 Commissioning the CPU as DP master
Requirements for commissioning
The PROFIBUS subnet has been configured.
The DP slaves are ready for operation (see relevant DP slave manual).
In order to operate the MPI/DP interface as DP interface it must be configured
accordingly (only CPU 315-2 PN/DP/ CPU 317 and CPU 319).
You must configure the CPU as DP master prior to commissioning. That is, in STEP 7
you have to
configure the CPU as a DP master,
assign a PROFIBUS address to the CPU,
assign a master diagnostic address to the CPU,
integrate the DP slaves into the DP master system.
Is the DP CPU a DP slave?
If so, this DP slave appears in the PROFIBUS-DP catalog as configured station. In the
DP master, assign a slave diagnostic address to this DP slave CPU. You must
interconnect the DP master with the DP slave CPU and specify the address ranges for
data exchange with the DP slave CPU.
ITEM 3000
Commissioning
Commissioning
Commission the DP CPU as a DP master in the PROFIBUS subnet as follows:
1. Download the PROFIBUS subnet configuration created with STEP 7 (preset
configuration) from the PG to the DP CPU.
2. Switch on all of the DP slaves.
3. Switch the DP CPU from STOP to RUN.
Startup of DP CPU as DP master
During startup, the DP CPU checks the configured preset configuration of its DP master
system against the actual configuration.
If preset configuration = actual configuration, the CPU switches to RUN mode.
If the preset configuration to the actual configuration, the configuration of parameter
Startup if preset configuration actual configuration determines the startup behavior of the
CPU.

Startup when the preset configuration actual
configuration = yes (default setting)
Startup when the preset configuration actual
configuration = no
DP CPU switches to RUN.
(BUSF LED flashes if any of the DP slaves
cannot be addressed)
DP CPU remains in STOP mode, and the BUS
LED flashes after the set Monitoring time for
transfer of parameters to modules.
The flashing BUSF LED indicates that at least
one DP slave cannot be accessed. In this case,
check whether all DP slaves are switched on or
correspond with your configuration, or read out
the diagnostic buffer with STEP 7.
Recognizing the operating state of DP slaves (Event recognition)
The table below shows how the DP CPU operating as a DP master recognizes operating
mode transitions of a CPU operating as a DP slave or data exchange interruptions.
Table 8- 8 Event recognition by CPUs 31xC-2 DP / 31x-2 DP / 31x PN/DP operating as DP master
Event What happens in the DP master?
Bus interruption
(short circuit,
connector removed)
Call of OB 86 with the message Station failure
(coming event; diagnostic address of the DP slave assigned to the DP
master)
With I/O access: call of OB 122
(I/O access error)
DP slave:
RUN STOP
Call of OB 82 with the message Module error
(incoming event; diagnostic address of the DP slave assigned to the DP
master; Variable OB82_MDL_STOP=1)
DP slave:
STOP RUN
Call of OB 82 with the message Module OK
(outgoing event; diagnostic address of the DP-Slave assigned to the DP
master; Variable OB82_MDL_STOP=0)
Tip:
When commissioning the CPU as DP master, always program OB82 and OB86. This helps
you to recognize and evaluate data exchange errors or interruption.
ITEM 3000
Commissioning
Programming, status/control via PROFIBUS
As an alternative to the MPI interface, you can program the CPU or execute the PG's status
and control functions via the PROFIBUSDP interface.

Note
The use of Status and Control function via the PROFIBUS-DP interface extends the DP
cycle.

Constant Bus Cycle Time
This is a property of PROFIBUS DP. The "Constant bus cycle time" function ensures that the
DP master always starts the DP bus cycle within a constant interval. From the perspective of
the slaves, this means that they receive their data from the master at constant time intervals.
In STEP 7 V 5.x or higher you can configure constant bus cycle times for PROFIBUS
subnets. Details on constant bus cycle times are found in the STEP 7 Online Help.
Isochronous updating of process image partitions
SFC126 "SYNC_PI" is used for the isochronous update of the process image partition of
inputs. An application program which is interconnected with a DP cycle (by means of OB61)
can use this SFC for consistent updates of data recorded in the process image partition of
inputs in synchronism with this cycle. SFC126 accepts interrupt control and can only be
called in OB61.
SFC 127 "SYNC_PO" is used for the isochronous update of the process image partition of
outputs. An application program which is interconnected to a DP cycle can use the SFC for
the consistent transfer of the computed output data of a process image partition of outputs to
the I/O in synchronism with this cycle. SFC 127 accepts interrupt control and can only be
called in OB 61.
The SFCs 126 and 127 are described in the STEP 7 Online Help and in the System
Software S7-300/400, System and Standard Functions Reference Manual.
The following CPUs support isochronous mode:
CPU 315-2 DP
CPU 315-2 PN/DP
CPU 317 DP
CPU 317-2 PN/DP
CPU 319-3 PN/DP
CPUs with two DP interfaces (CPU 317-2 DP and CPU 319-3 PN/DP) only support
isochronous mode on their second (DP) interface.
Reference
For further information on isochronous mode, refer to the "Isochronous mode" Manual.
ITEM 3000
Commissioning
Further information about time synchronization on PROFIBUS DP is available in the chapter
Interfaces > PROFIBUS DP.
Sync/Freeze
The SYNC control command is used to set sync mode on the DP slaves of selected groups.
In other words, the DP master transfers current output data and instructs the relevant DP
slaves to freeze their outputs. The DP slaves writes the output data of the next output frames
to an internal buffer; the state of the outputs remains unchanged.
Following each SYNC control command, the DP slaves of the selected groups transfer the
output data stored in the internal buffer to the process outputs.
The outputs are only updated cyclically again after you transfer the UNSYNC control
command using SFC11 "DPSYC_FR".
The FREEZE control command is used to set the relevant DP slaves to Freeze mode, in
other words, the DP master instructs the DP slaves to freeze the current state of the inputs.
It then transfers the frozen data to the input area of the CPU.
Following each FREEZE control command, the DP slaves freeze the state of their inputs
again.
The DP master receives the current state of the inputs cyclically again not until you have
sent the UNFREEZE control command with SFC11 "DPSYC_FR".
The SFCs 11 are described in the corresponding STEP 7 Online Help and in the System
Software S7-300/400, System and Standard Functions Reference Manual.
Startup of the DP master system

CPU 31xC-2 DP / 31x-2 DP / 31x PN/DP is DP master
The Parameter transfer to modules parameter is also used to define the startup monitoring time for
DP slaves.
That is, the DP slaves must startup and must have received all parameters from the CPU (as DP
master) within the defined time.
PROFIBUS address of the DP master
For the DP CPU, you must not set "126" as a PROFIBUS address.
ITEM 3000
Commissioning
8.5.3 Commissioning the CPU as DP Slave
Requirements for commissioning
The DP master is configured and programmed.
If the MPI/DP interface of your CPU must be a DP interface, you must configure the
interface as DP interface.
Prior to commissioning, you must set the relevant parameters and configure the DP CPU
for operation as DP slave. That is, in STEP 7 you have to
"power on" the CPU as DP slave,
assign a PROFIBUS address to the CPU,
assign a slave diagnostic address to the CPU,
specify whether the DP master is an S7 DP master or another DP master,
specify the address ranges for data exchange with the DP master.
All other DP slaves are programmed and configured.
GSD files
If you are working on an IM 308-C or third-party system, you require a GSD file in order to be
able to configure the DP CPU as a DP slave in a DP master system.
COM PROFIBUS V 4.0 or later includes this GSD file.
When working with an older version or another configuration tool, you can download the
GSD file from the Internet
(http://support.automation.siemens.com/WW/view/en/10805317/133100).

Note
This note applies to the CPUs 31xC-2 DP, CPU 315, CPU 317 and CPU 319.
If you wish to use the CPU as a standard slave using the GSD file, you must not set the
Commissioning / Test mode check box on the DP interface properties dialog box when you
configure this slave CPU in STEP 7.

Configuration and parameter assignment message frame
STEP 7 assists you during configuration and parameter assignment of the DP CPU. If you
need a description of the configuration and parameter assignment frame, for example in
order to use a bus monitor, you can find it on the Internet
(http://support.automation.siemens.com/WW/view/en/1452338).
ITEM 3000
Commissioning
Commissioning
Commission the DP CPU as a DP slave in the PROFIBUS subnet as follows:
1. Switch on power, but hold the CPU in STOP mode.
2. First, switch on all other DP masters/slaves.
3. Now switch the CPU to RUN mode.
Startup of DP CPU as DP slave
When the DP-CPU is switched to RUN mode, two mutually independent operating mode
transitions are executed:
The CPU switches from STOP to RUN mode.
The CPU starts data exchange with the DP master via the PROFIBUS DP interface.
Recognizing the Operating State of the DP master (Event Recognition)
The table below shows how the DP CPU operating as a DP slave recognizes operating state
transitions or data exchange interruptions.
Table 8- 9 Event recognition by CPUs 31xC-2 DP / 31x-2 DP / 31x PN/DP operating as DP slave
Event What happens in the DP slave?
Bus interruption
(short circuit,
connector removed)
Call of OB 86 with the message Station failure
(coming event; diagnostic address assigned to the DP slave)
With I/O access: Call of OB 122
(I/O access error)
DP master.
RUN STOP
Call of OB 82 with the message Module error
(coming event; diagnostic address assigned the DP slave; variable
OB82_MDL_STOP=1)
DP master
STOP RUN
Call of OB 82 with the message Module OK
(outgoing event; diagnostic address assigned to the DP slave; variable
OB82_MDL_STOP=0)
Tip:
When commissioning the CPU as DP slave, always program OB82 and OB86. This helps
you to recognize and evaluate the respective operating states or data exchange errors.
Status/control, programming via PROFIBUS
As an alternative to the MPI interface, you can program the CPU or execute the PG's status
and control functions via the PROFIBUS DP interface.

Note
The execution of status and control function via PROFIBUS DP interface extends the DP
cycle.

ITEM 3000
Commissioning
User data transfer by way of transfer memory
The DP CPU operating as intelligent DP slave provides a transfer memory for PROFIBUS
DP. User data are always exchanged between the CPU (DP slave) and the DP master by
way of this transfer memory. You can configure up to 32 address ranges for this function.
That is, the DP master writes its data to these transfer memory address ranges, the CPU
reads these data in the user program, and vice versa.
1
PROFlBUS
DP master CPU as DP slave
Transfer memory in the
l/O address space
l/O l/O

Numb
er
Description
The functions which control data exchange between transfer memory and the distributed I/O
of the slave CPU must be implemented in the user program. The DP master cannot access
this I/O directly.
address ranges of transfer memory
In STEP 7, configure the I/O address ranges:
You can configure up to 32 I/O address ranges.
Maximum length per address range is 32 bytes.
You can configure a maximum of 244 input bytes and 244 outputs bytes.
The table below shows the principle of address ranges. You can also find this figure in the
STEP 7 configuration.
Table 8- 10 Configuration example for the address ranges of transfer memory
Type Master
address
Type Slave
address
Length Unit Consistency
1 I 222 O 310 2 BYTE Unit
2 O 0 I 13 10 Word Total length
:
32
address ranges in the
DP master CPU
address ranges in the
DP slave CPU
These paramaters of the address ranges
must be the same for DP master and DP
slave.
ITEM 3000
Commissioning
Sample program
Below you will see a small sample program for data exchange between the DP master and
the DP slave. The addresses used in the example are found in the table above.

In the DP slave CPU In the DP master CPU
L 2 //Data preparation in the
//DP slave

T MB 6
L IB 0
T MB 7
L MW 6 //Forward data to
//DP master

T PQW 310

L PIB 222 //continued processing of
//received data in DP master
T MB 50
L PIB 223
L B#16#3
+ I
T MB 51
L 10 //Data preparation in the
//DP master
+ 3
T MB 60
CALL SFC 15 //Send data to the DP slave
LADDR:= W#16#0
RECORD:=P#M60.0
Byte20
//In the user program of the
masters
//a block of 20 bytes length
starting at MB60
//is written consistently to the
output area
//PAB0 to PAB19
//(transfer area from master to
//slave)
RET_VAL :=MW 22

CALL SFC 14 //Receive data from
//DP master

LADDR:=W#16#D //In the slave, the
//peripheral bytes PEB13
//to PEB32 (data
//transferred from master)
//are read consistently and
//stored in MB30
//to MB49

RET_VAL :=MW 20
RECORD:=P#M30.0 byte 20
L MB 30 //Received data
//continue processing

L MB 7
+ I
T MW 100
ITEM 3000
Commissioning
Working with transfer memory
Note the following rules when working with the transfer memory:
Assignment of address ranges:
Input data of DP slaves are always output data of the DP master
Output data of DP slaves are always input data of the DP master
The user can define these addresses. In the user program, access data with
load/transfer instructions or with SFC 14 and SFC 15. You can also define addresses of
the process image of inputs or outputs.
The lowest address of specific address ranges is their respective area start address.
The length, unit and consistency of the address ranges for DP master and DP slave must
be identical.
The master and slave addresses may differ in logically identical transfer memory
(independent logical I/O address spaces in the master and slave CPU).

Note
Assign addresses from the I/O address range of the DP CPU to the transfer memory.
You cannot use any addresses which have been assigned to transfer memory for other
I/O modules.

S5 DP master
If you use an IM 308-C as a DP master and the DP CPU as a DP slave, the following applies
to the exchange of consistent data.
Use IM 308-C in the S5 control to program FB192 for enabling exchange of consistent data
between the DP master and slave. With the FB192, the data of the DP CPU are only output
or read out in a consistent block.
S5-95 as DP master
If you set up an AG S5-95 for operation as DP master, you also have to set its bus
parameters for the DP CPU as DP slave.
User data transfer in STOP mode
User data is treated in transfer memory according to the STOP state of the DP master or DP
slave.
The DP slave CPU goes into STOP:
Data in transfer memory of the CPU are overwritten with "0" value, that is, the DP master
reads "0" in direct data exchange mode.
The DP master goes into STOP:
Current data in transfer memory of the CPU are retained and can be read by the CPU.
ITEM 3000
Commissioning
PROFIBUS address
For the DP CPU, you must not set "126" as a PROFIBUS address.
See also
User-specific addressing of modules (Page 127)
8.5.4 Direct data exchange
Requirements
STEP 7 V 5.x or higher lets you configure "Direct data exchange" for PROFIBUS nodes. DP
CPUs can take part in direct data exchange as senders and receivers.
Definition
"Direct data exchange" is a special communication relationship between PROFIBUS DP
nodes.
Characteristic of direct data exchange are the PROFIBUS DP nodes "Listening" on the bus
for data a DP slave returns to its DP master. This mechanism allows "Listening stations"
(receivers) direct access to modified input data of remote DP slaves.
address ranges
In your STEP 7 configuration of the relevant peripheral input addresses, specify which
address range of the receiving node is to receive data requested from the sending node.
The following types of DP-CPU are possible:
DP slave sending station
Receiving station, as DP slave or DP master, or as CPU not integrated in a master
system.
ITEM 3000
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Example: Direct data exchange via DP CPUs
The example in the figure below shows the relationships you can configure for direct data
exchange. In the figure all the DP masters and all the DP slaves that are marked as "CPU"
are each a DP CPU.
Note that other DP slaves (ET 200M, ET 200pro, ET 200S) can only operate as sending
nodes.

CPU CPU
CPU
CPU
CPU
PROFlBUS
CPU
DP master 1 DP master 2
DP slave 1 DP slave 2
DP slave 3
DP slave 4
DP slave 5
DP master
system 1
DP master
system 2

Figure 8-1 Direct data exchange via DP CPUs
ITEM 3000
Commissioning
8.6 Commissioning PROFINET IO
8.6.1 Requirements
Requirements
PROFINET IO is supported in STEP 7 V 5.3 SP1 or higher. A later version of STEP 7 may
be required to support specific CPU functionality. Information about the STEP 7 versions
required for specific CPUs is available in the CPU 31xC and CPU 31x, Technical Data
Manual.
PROFINET IO address ranges of the CPUs
Table 8- 11 PROFINET IO address ranges of the CPUs
address range 315-2 PN/DP 317-2 PN/DP 319-3 PN/DP
Entire address range of inputs and of outputs 2048 bytes 8192 bytes 8192 bytes
of these in the process image, for inputs and outputs
respectively:
max. 2048 bytes max. 2048 bytes Max. 8192 bytes
Default 128 bytes 256 bytes 256 bytes
Diagnostics addresses use 1 byte each in the input address space for
the IO controller, PROFINET interface and ports
each IO device (header module on slot 0, ports of the PROFINET interface) and all
internal modules / submodules of the device which do not contain any user data (power
module of ET 200S, or ports of the PROFINET interface, for example).
You can use these addresses, for example, to read module-specific diagnostics data records
by calling SFB52. STEP 7 assigns diagnostics addresses in descending order, starting at the
highest byte address.
Information about the structure of module-specific diagnostics data records is available in the
From PROFIBUS DP to PROFINET IO Programming Manual.
8.6.2 Configuring and commissioning the PROFINET IO system
Overview
There are several ways for you to start with commissioning the PROFINET IO interface of
the CPU, and then the PROFINET IO system:
Online via MPI/ DP interface
Online via switch and PROFINET interface
Offline, by saving the data to a Micro Memory Card in SIMATIC Manager on your
programming device, and then inserting the Micro Memory Card into the CPU
ITEM 3000
Commissioning
Commissioning a PROFINET IO system via MPI/DP
2
1
PG/PC
PS CPU
MPl PN
ET 200S
lndustrial Ethernet
Switch
lO device

Number Meaning
Use the PG cable to connect the PG to the integrated MPI/DP interface of the CPU.
Use the twisted-pair patch cable to interconnect the integrated PROFINET IO interface of
the CPU with the Industrial Ethernet (for example, connection to a switch).
Commissioning a PROFINET IO system directly via PROFINET interface
2
1
CPU
PS
ET 200S
PN
PG/PC
lO device
Switch
lndustrial Ethernet

Number Meaning
Use a twisted-pair patch cable to connect the PG/PC to a switch
In the same way, connect the switch to the integrated PROFINET interface of your CPU
Commissioning requirements:
The CPU is in STOP mode.
The IO devices are switched on.
The PROFINET subnet is installed, and the communication partners (for example, PD,
IO controller, IO devices) are connected to the PROFINET subnet.
ITEM 3000
Commissioning
Configuring the PROFINET IO system

Step Tasks
Configuring hardware in the STEP 7 SIMATIC Manager
1 Select File > New...
Assign a name to your project and confirm with OK.
2 Select Insert > Station > SIMATIC 300 Station to add an S7-300 station.
3 Double-click "Hardware."
Result: HW Config opens.
4 Insert your components by means of drag-and-drop:
Mounting rail
Power supply
CPU 31x PN/DP (CPU 317-2 PN/DP, for example)
Result: The "Properties Ethernet Interface PN-IO" dialog box opens. The properties of
the PROFINET X2 interface are shown in the Parameters tab.
Assigning the IP address
5 Click "New" on the "Properties Ethernet Interface PN-IO" dialog box to create a new
subnet.
Result: The "Properties New Industrial Ethernet Subnet" dialog box opens.
6 Assign a name and confirm with "OK."
Result: You are back to the "Properties Ethernet Interface PN-IO" dialog box.
7 Enter the IP address and the subnet mask in the dialog box. This information is available
from your network administrator.
Note: The worldwide unique MAC address is preset by the manufacturer and cannot be
changed.
8 If you setup a connection via router, you must also enter the address of the router. This
information is also available from your network administrator.
9 Click "OK" to close the properties dialog box.
Configuring the PROFINET IO system
10 Insert the IO devices at the PROFINET IO system, for example, an IM 151-3 PN
(ET 200S under PROFINET IO), then configure the slots and set their parameters by
means of drag-and-drop, based on the physical assembly.
11 Select Edit > Object properties to assign device names and numbers to the IO devices.
ITEM 3000
Commissioning
Step Tasks
12 When operating PROFINET IO and PROFINET CBA in parallel, set up the PROFINET IO
system properties by
activating the "Use this module for PROFINET CBA communication" check box
adapting the "Communication portion (PROFINET IO)" in the "Update time" tab
(change the communication portion of PROFINET IO to 87.5 %, for example).

13 Save your configuration with Station > Save and compile.
Configuration Download
14 Download the configuration to the CPU. You have three options:
Online via MPI/ DP interface (the PG and CPU must be located on the same subnet).
When you download the configuration in a system containing several node addresses,
select the appropriate MPI or PROFIBUS address of the destination CPU.
Online via switch and PROFINET interface When you download the configuration in a
system containing several nodes, select the appropriate IP address of the destination
CPU. The "available users" can be displayed in a download dialog box. Select the
MAC address of the CPU if you have not assigned it an IP address yet. In the next
dialog box, you can assign the configured IP address to the CPU.
The PG must be connected to the subnet. The PG interface must be set to TCP/IP
(Auto) mode. Setting in the IE-PG Access tab of the interface properties dialog box:
Assign Project-Specific IP Address.
Offline, by saving the data to a Micro Memory Card in SIMATIC Manager on your
programming device, and then inserting the Micro Memory Card into the CPU
ITEM 3000
Commissioning
Step Tasks
Assigning IO device names *
15 Requirements: The programming device must be connected to the subnet. The PG
interface must be set to TCP/IP (Auto) mode. Setting in the IE-PG Access tab of the
interface properties dialog box: Assign Project-Specific IP Address.
Procedure: In online mode, select the various IO devices in HW Config, then select PLC
> Ethernet > Assign Device Name to assign the corresponding device names.
Note: The CPU can only assign the IP address automatically, and thus enable its correct
communication with the IO device, after you assigned a device name to the latter.
If the configuration of the IO devices you downloaded to the CPU actually corresponds
with their physical configuration on the subnet, the CPU addresses the IO devices, and
the BF LED stops flashing both on the CPU and on the IO device.
You can now switch the CPU to RUN, provided there are no other conditions preventing a
startup, and the CPU and IO devices exchange data (read inputs, write outputs, for
example).
* If the functionality "Device replacement without removable medium" is configured in HW
Config and the setpoint topology of the PROFINET IO system has been specified using
the topology editor, IO devices can be replaced without the user having to assign a
device name to the IO device. Requirement: The IO device has been reset to the state of
delivery by using "Reset to factory setting" and the actual topology agrees with the
setpoint topology.
Result
You used STEP 7 to configure the PROFINET interface of your CPU and the and the
PROFINET IO system. The CPU can now be reached by other nodes in your Industrial
Ethernet subnet.
Reference
Detailed information about addressing of the PROFINET IO interface and on the
configuration of its properties and ports is available in the:
STEP 7 Online Help and
PROFINET System Description System Manual.
ITEM 3000
Commissioning
CPU startup for operation as IO controller
In its startup sequence, and based on the preset configuration, the CPU verifies the actual
configuration
of the local I/O,
of the distributed I/O on the PROFIBUS DP system, and
the PROFINET IO system.
The startup of the CPU is determined by the corresponding configuration in the "Startup" tab:
Table 8- 12 CPU startup for operation as IO controller
Preset Actual configuration Preset = Actual
configuration
Startup permitted when target
configuration does not match the
actual configuration
Startup not permitted when target
configuration does not match the
actual configuration
CPU goes into RUN. CPU goes into RUN. After POWER
ON, and after the parameter
monitoring time has expired, the
CPU goes into RUN.
If the BF2/BF3 LED flashes, this
means that at least one IO device
cannot be addressed. In this case,
verify that all IO devices are
switched on and correspond with
the set configuration. For further
information, read the diagnostics
buffer in STEP 7.
CPU startup fails
Detecting interruptions in the data transfer to the IO device
The following table shows, how the CPU 31x PN/DP recognizes interruptions of the data
transfer:
Table 8- 13 Even recognition of the CPU 31x PN/DP as IO controller
What happens in the IO controller? Event
CPU in RUN CPU in STOP
Bus interruption (short circuit,
connector removed)
Call of OB86 with the
message Station failure
(coming event; diagnostics
address of the IO device)
With I/O access: call of
OB 122
(I/O access error)
The event is written to the
diagnostics buffer
Tip:
Always program OB86 when you commission the CPU. This allows you to detect and
analyze interruptions in the data transfer.
ITEM 3000
Commissioning
Status/control, programming via PROFINET
As an alternative to the MPI /DP interface, you can program the CPU or execute the PG's
status and control functions via the PROFINET interface..
If you have not commissioned the PROFINET interface of the CPU yet, you can connect to
the CPU using its MAC address (see also Configuring the PROFINET IO System in the table
above).
To do so, use HW Config to download your project to the CPU. Address the CPU using its
MAC address. The CPU is also assigned the configured IP address after you downloaded
the configuration. With that you can then use all programming device functions, such as
download program, status/control etc., on the interface.
ITEM 3000

Maintenance
9
9.1 Overview
S7-300 is a maintenance-free automation system.
Thus, maintenance is considered
Backing up of the operating system on a SIMATIC Micro Memory Card
Updating of the operating system from a SIMATIC Micro Memory Card
Updating of the firmware online
Backing up of project data on a SIMATIC Micro Memory Card
Replacement of modules
Replacement of fuses in digital output modules
9.2 Backing up firmware on a SIMATIC Micro Memory Card
Situations which require backup of the firmware
It is advisable in certain situation to backup your CPU firmware:
You may want to replace the CPU in your system with a CPU out of storage. In this case you
should make sure that the firmware of the shelf CPU and of the system firmware are
identical.
It is also advisable to create an emergency backup copy of the firmware.
ITEM 3000
Maintenance
9.3 Updating the firmware
9.3.1 Backing up firmware on a SIMATIC Micro Memory Card
On which CPUs can you backup the firmware?
You can generate a backup copy of the the firmware as of the following CPU versions:

CPU Order No. Firmware as
of
Required Micro Memory Card
in MB
as of 6ES7312-1AD10-0AB0 V2.0.0
as of 6ES7312-1AE13-0AB0 V2.0.12
312
as of 6ES7312-1AE14-0AB0 V3.0
2
as of 6ES7314-1AF10-0AB0 V2.0.0
6ES7314-1AG13-0AB0 or
later
V2.0.12
314
as of 6ES7314-1AG14-0AB0 V3.0
2
as of 6ES7315-2AG10-0AB0 V2.0.0 315-2 DP
as of 6ES7315-2AH14-0AB0 V3.0
4
as of 6ES7312-5BD00-0AB0 V1.0.0 312C
as of 6ES7312-5BE03-0AB0 V2.0.12
2
as of 6ES7313-5BE00-0AB0 V1.0.0 313C
as of 6ES7313-5BF03-0AB0 V2.0.12
2
as of 6ES7313-6CE00-0AB0 V1.0.0 313C-2 DP
as of 6ES7313-6CF03-0AB0 V2.0.12
4
as of 6ES7313-6BE00-0AB0 V1.0.0 313C-2 PtP
as of 6ES7313-6BF03-0AB0 V2.0.12
2
as of 6ES7314-6CF00-0AB0 V1.0.0 314C-2 DP
as of 6ES7314-6CG03-0AB0 V2.0.12
4
as of 6ES7314-6BF00-0AB0 V1.0.0 314C-2 PtP
as of 6ES7314-6BG03-0AB0 V2.0.12
2
as of 6ES7315-2EG10-0AB0 V2.3.0 315-2 PN/DP
as of 6ES7315-2EH13-0AB0 V2.3.4
4
317-2 DP as of 6ES7317-2AJ10-0AB0 V2.1.0 4
as of 6ES7317-2EJ10-0AB0 V2.2.0 317-2 PN/DP
as of 6ES7317-2EK13-0AB0 V2.3.4
4
319-3 PN/DP as of 6ES7318-3EL00-0AB0 V2.4.0 8
ITEM 3000
Maintenance
Backing up the firmware of your CPU to the SIMATIC Micro Memory Card
Table 9- 1 Backing up the firmware to the SIMATIC Micro Memory Card
Step Action required: This happens in the CPU:
1. Insert the new SIMATIC Micro Memory
Card into the CPU.
The CPU requests memory reset
2. Turn the mode selector switch to MRES
position and hold it there.
-
3. POWER OFF / POWER ON. Hold the
mode selector switch in MRES position
until ...
... the STOP, RUN and FRCE LEDs start
flashing.
4. Mode selector switch to STOP. -
5. Mode selector switch briefly to MRES
position, then let it return to STOP.
The CPU starts to backup the operating
system on the SIMATIC MMC.
All LEDs are lit during the backup
operation.
The STOP LED flashes when the backup
is complete to indicate that the CPU
requires a memory reset.
6. Remove the SIMATIC Micro Memory
Card.
-
9.3.2 Firmware update using a Micro Memory Card
In which situations should I update the firmware?
After (compatible) function expansions, or after an enhancement of operating system
performance, the firmware of the CPU should be upgraded (updated) to the latest version.

Note
Prioritized startup
At a prioritized startup a firmware update using the Micro Memory Card is not possible.
A firmware update using the LAN network is possible.

Where do I get the latest version of the firmware?
You can order the latest firmware (as *.UPD files) from your Siemens partner, or download it
from the Siemens Internet homepage: http://www.siemens.com/automation/service&support
ITEM 3000
Maintenance
Firmware update using a SIMATIC Micro Memory Card
Table 9- 2 Firmware update using a SIMATIC Micro Memory Card
Step Action required: This happens in the CPU:
1. Recommendation
Before you update the CPU firmware, create a backup copy of the "old" firmware on an
empty SIMATIC Micro Memory Card. If problems occur during the update, you can reload
your old firmware from the SIMATIC Micro Memory Card.
2. Transfer the update files to a blank
SIMATIC Micro Memory Card using
STEP 7 and your programming
device.
-
3. Switch off CPU power and insert a
SIMATIC Micro Memory Card
containing the firmware update.
-
4. Switch on power. The CPU automatically detects the SIMATIC
Micro Memory Card with the firmware update
and runs the update.
All LEDs are lit during firmware update.
The STOP LED flashes when the FW update
is completed, and indicates that the CPU
requires a memory reset.
5. Switch off CPU power and remove a
SIMATIC Micro Memory Card
containing the firmware update.
-
Result
You updated the CPU with a new firmware version.
The address and baud rate of the 1st interface are retentive. All the other parameters have
been reset by the firmware update.
ITEM 3000
Maintenance
9.3.3 Updating the firmware online (via networks)
On which CPUs can you update the firmware online?
You can carry out a firmware update online at all the CPUs V 2.2 and higher.
Information about the firmware update online using MPI or DP networks for older modules is
available on the Service&Support pages (http://www.siemens.com/automation/service).
Requirements
An online firmware update is possible in STEP 7 V 5.3 or higher.
To update the firmware, you require the *.UPD files which contain the current firmware
version.
The files (*.UPD) containing the current firmware version must be available in the file
system on your PG/PC. A folder may contain only the files of one firmware version.
The CPU can be accessed online.
Performing a firmware update
1. Run STEP 7 and change to HW Config.
2. Open the station containing the CPU you want to update.
3. Select the CPU.
4. Select the menu command PLC > Update Firmware. The menu command can only be
executed if the selected CPU supports the "Update Firmware" function.
5. The Update firmware dialog box opens. Click Browse to select the path to the firmware
update files (*.UPD)
6. After you selected a file, the information in the lower fields of the Update Firmware dialog
box shows you the firmware file and version for the corresponding modules.
7. Click the Run button. STEP 7 verifies that the selected file can be interpreted by the
module, and then downloads the file to the CPU. If this requires changing the operating
state of the CPU, you will be asked to perform these tasks in the relevant dialog boxes.
The CPU then automatically updates the firmware.
8. In STEP 7 (reading the CPU diagnostics buffer), verify that the CPU can start with the
new firmware.
Result
You have updated the CPU online with a new firmware version.
The address and baud rate of the 1st interface are retentive. All the other parameters have
been reset by the firmware update.

ITEM 3000
Maintenance
9.4 Backup of project data to a Micro Memory Card
Function principles
Using the Save project to Micro Memory Card and Retrieve project from Micro Memory Card
functions, you can save all project data to a SIMATIC Micro Memory Card, and retrieve
these at a later time. The SIMATIC Micro Memory Card can be located in a CPU or in the
Micro Memory Card programming adapter of a PG or PC.
Project data is compressed before it is saved to a SIMATIC Micro Memory Card, and
uncompressed on retrieval.

Note
In addition to project data, you may also have to save your user data to the SIMATIC MMC.
Always select a SIMATIC Micro Memory Card with sufficient memory capacity.
A message warns you of insufficient memory capacity on your SIMATIC Micro Memory Card.

The volume of project data to be saved corresponds with the size of the project's archive file.

Note
For technical reasons, you can only transfer the entire contents (user program and project
data) using the Save project to Micro Memory Card action.

ITEM 3000
Maintenance
Handling the functions
How you use the Save project to memory card / Retrieve project from memory card functions
depends on the location of the SIMATIC micro memory card:
When the SIMATIC MMC is inserted in the MMC slot, select a project level (for example,
CPU, programs, sources or blocks) which is uniquely assigned to the CPU from the
project window in SIMATIC Manager. Select the PLC > Save project to Memory Card or
PLC > Retrieve project from Memory Card menu command. The program now writes all
configuration data to the SIMATIC Micro Memory Card, or retrieves these data from the
card.
If project data are not available on the currently used programming device (PG/PC) you
can select the source CPU from the "Available nodes" window. Select PLC > Show
available nodes command to open the "Available nodes" window. Select the
connection/CPU that contains your project data on SIMATIC Micro Memory Card. Now
select menu command Retrieve project from Memory Card.
If the SIMATIC MMC is located in the MMC programming unit of a PG or PC, open the
"S7 memory card window" using the File > S7 Memory Card > Open command. Select
the PLC > Save project to Memory Card or PLC > Retrieve project from Memory Card
menu command. to open a dialog in which you can select the source or target project.

Note
Project data can generate high data traffic. Especially in RUN mode with read/write
access to the CPU, this can lead to waiting periods of several minutes.

Sample application
When you assign more than one member of your service and maintenance department to
perform maintenance tasks on a SIMATIC PLC, it may prove difficult to provide quick access
to current configuration data to each staff member.
However, CPU configuration data available locally on any CPU that is to be serviced can be
accessed by any member of the service department. They can edit these data and then
release the updated version to all other personnel.
ITEM 3000
Maintenance
9.5 Resetting to the Delivery State
9.5 Resetting to the Delivery State
Delivery state of the CPU
Default values set at the CPU properties:
Table 9- 3 Properties of the CPU in the delivery state
Properties Value
MPI address 2
MPI baud rate 187.5 Kbps
Retentive bit memories, timers and counters All retentive bit memories, timers and counters are
deleted
Retentive range set for bit memories, timers
and counters
Default settings (16 memory bytes, no timers and 8
counters)
Contents of the diagnostics buffer deleted
IP address none
Operating hours counter 0
Time 1.1.94 00:00:00
Procedure
Proceed as follows in order to reset a CPU to the delivery state via the mode selector switch:
1. Switch off the supply voltage.
2. Remove the SIMATIC Micro Memory Card from the CPU.
3. Hold the mode selector switch in the MRES setting and switch the supply voltage on
again.
4. Wait until LED lamp image 1 from the subsequent overview is displayed.
5. Release the mode selector switch, set it back to MRES within 3 seconds and hold it in
this position.
6. Wait until LED lamp image 2 from the next overview is displayed.
This lamp image lights up for approximately five seconds, that is for the duration of
RESET. During this period you can abort the resetting procedure by releasing the mode
selector switch.
7. Wait until LED lamp image 3 from the subsequent overview is displayed and release the
mode selector switch again.
The CPU is now reset to the delivery state. It starts without buffering (all LEDs are lit) and
changes to the STOP mode
ITEM 3000
Maintenance
9.6 Module installation / removal
Lamp images while the CPU is being reset
While you are resetting the CPU to the delivery state, the LEDs light up consecutively in the
following lamp images:
Table 9- 4 Lamp images
LED Color Lamp image 1 Lamp image 2 Lamp image 3
STOP Yellow
RUN Green
FRCE Yellow
5 VDC Green
SF Red
BFx Red
= LED lit
= LED dark
= LED flashes at 0.5 Hz
Installation and wiring rules
The table below shows you points to follow when wiring, installing or removing S7-300
modules.

Rules governing ... Power supply ... CPU ... SM/FM/CP
Blade width of the screwdriver 3.5 mm (cylindrical design)
Tightening torque
Fixing modules to the mounting
rail
Connecting cables

from 0.8 N/m to 1.1 N/m



POWER OFF when replacing the ... Yes Yes
S7-300 operating mode when
replacing ...
STOP
Load voltage OFF when replacing
the ...
Yes Yes
ITEM 3000
Maintenance
Initial situation
The module you want to replace is still mounted and wired. You want to install the same type
of module.

WARNING
Disturbances can corrupt data if you insert or remove S7-300 modules while data are being
transferred via the integrated interface of your CPU. You should never replace any modules
of the S7-300 while data traffic is active at an integrated interface. If you are not certain
whether or not data transfer is active on the interface, unplug the connector at the interface
before you replace the module.
Removing the module (SM/FM/CP)
To remove the module:

Step 20-pin front connector 40-pin front connector
1. Switch the CPU to STOP.
2. Switch off the load voltage to the module.
3. Remove the labeling strip from the module.
Unlock the front connector and remove it. 5.
To do so, press down the unlocking
mechanism with one hand and pull out
the front connector at the grips using
the other hand.
Remove the fixing screw from the middle of the
front connector. Pull the front connector out,
holding it at the grips.
6. Undo the module fixing screw(s).
7. Swing the module out.
1
2
3
4

Number Identifier
Remove labeling strips.
Open module.
Press unlocking mechanism/loosen mounting screw, and pull out front connector.
Remove mounting screw of module and swing module out.
ITEM 3000
Maintenance
Removing the front connector coding from the module
Before you start installing the new module, remove the upper part of the front connector
coding pin from this module.
Reason: This part is already inserted in the wired front connector.

Installing a new module
To install the new module:
1. Hang in a new module of same type.
2. Swivel the module down into place.
3. Screw-tighten the module.
4. Slide the labeling strips into the module.
1
2
3
4

Number Identifier
Hang module onto rail.
Swivel module downward.
Screw-tighten the module
Insert labeling strips.
ITEM 3000
Maintenance
Removing the front connector coding from the front connector
You may take a "used" front connector to wire another module by removing its coding
mechanism:
Simply use a screwdriver to push out the front connector coding.
This upper part of the coding key must then be plugged back into the old module.
Putting a new module into service
Proceed as follows to put the new module into service:
2. Reinstall the front connector.
3. Close the front panel.
4. Switch the load voltage back on.
5. Reset the CPU to RUN mode.
1
2

Number Identifier
Move the front connector into operating position
Close front panel.
Reaction of the S7-300 after module replacement
After a module replacement, the CPU switches to run mode, provided no error has occurred.
If the CPU stays in STOP you can view the cause of error in STEP 7 (see the Programming
with STEP 7 User manual).
ITEM 3000
Maintenance
9.7 Digital output module AC 120/230 V: Changing fuses
Fuses for digital outputs
The digital outputs of the following digital output modules are short-circuit protected by fusing
of the channel groups:
Digit output module SM 322; DO 16 120 VAC
Digit output module SM 322; DO 8 120/230 VAC
System check
Eliminate the causes of fuse tripping.
Replacement fuses
If replacement is required, you can use the following fuses:
8 A, 250 V fuse
Wickmann 19 194-8 A
Schurter SP001.013
Littlefuse 217.008
Fuse holder
Wickmann 19 653

WARNING

Improper handling of digital output modules could result in injury or damage to
property.
There are dangerous voltages > 25 VAC or > 60 VDC beneath the covers to the
right of the module.
Before you open these covers, make sure that you have either unplugged the front
connector from the module or isolated the module from power.

WARNING

Improper handling of front connectors could result in injury or damage to property.
When you remove the front connector while the system is in RUN, beware of
dangerous live voltage > 25 VAC or > 60 VDC across the pins.
If the front connector is wired to such voltages, hot swapping of modules must
always be carried out by skilled or instructed electrical staff, in order to avoid
unintentional contact to the module pins.

ITEM 3000
Maintenance
Location of fuses in the digital module 120/230 VAC
Digital output modules are equipped with 1 fuse per channel group. The fuses are located at
the left side of the digital output module. The following figure shows you where to find the
fuses on the digital output modules.
1
1

Replacing fuses
The fuses are located at the left side of the module. Replace the fuses as follows:
1. Switch the CPU to STOP.
2. Switch off the load voltage of the digital output module.
3. Remove the front connector from the digital output module.
4. Loosen the fixing screw of the digital output module.
5. Swing out the digital output module.
6. Remove the fuse holder from the digital output module .
7. Replace the fuse.
8. Screw the fuse holder back into the digital output module.
9. Reinstall the digital output module.
ITEM 3000

Debugging functions, diagnostics and
troubleshooting
10
10.1 Overview
This chapter helps you to get acquainted with tools you can use to carry out the following
tasks:
Hardware/software error diagnostics.
Elimination of hardware/software errors.
Testing the hardware/software for example, during commissioning.

Note
It would go beyond the scope of this manual to provide detailed descriptions of all the
tools you can use for diagnostics, testing and troubleshooting functions. Further notes are
found in the relevant hardware/software manuals.

10.2 Reading out service data
Application (for CPUs V2.8)
In the case of a service, for example if the CPU signals the state "DEFECTIVE" (all LEDs
blinking), you have the option of saving special information for analyzing the CPU state.
This information is stored in the diagnostic buffer and in the actual service data.
Select the Target system -> Save service data command to read and this information and
save the data to a file to forward to Customer Support.
Procedure
1. If the CPU is in the state "DEFECTIVE" (all LEDs blinking), switch the power supply off
and on (power off/on).
Result: The CPU is now in STOP mode.
2. As soon as the CPU goes to "STOP" mode, select the corresponding CPU with the menu
command in the SIMATIC Manager: Target system > Available nodes".
3. Use the SIMATIC Manager menu command "Target system > Save service data" to save
the service data.
Result: A dialog box opens in which you specify the storage location and name of the two
files.
4. Save the file.
5. Forward these files to Customer Support on request.
ITEM 3000
Debugging functions, diagnostics and troubleshooting
10.3 Identification and maintenance data of the CPU
Definition and properties
Identification and maintenance data (I&M) is information that is stored in a module for the
purpose of providing you with support when
checking the system configuration
locating modified plant hardware
troubleshooting a plant
Identification data (I data) is information about the module (some of which may be printed on
the module housing) such as the order and serial number.
I data is manufacturers information about the module. It is fixed and can only be read.
Maintenance data (M data) represent system-specific information such as the installation
location. M data is created during configuration and written to the module.
I&M data can be used to identify modules uniquely on the network.
Reading and writing I&M data with STEP 7
Read
STEP 7 returns I&M data in "Module status" ("General" and Identification" tab) and in
"Available nodes" (detail view). See the STEP 7 Online Help.
You can read I&M data by calling SFC51 in the user program. Declare the SSL parts list
number and index at the input parameters of SFC51 (see the table below).
CPUs which support reading of I&M data on the "Start page" and "Identification" page
using the web server:

CPU Firmware
CPU 315-2 PN/DP as of V 2.5
Write
You always required STEP 7 HW Config to write M-data of the modules.
Data you can enter in the course of configuration , for example:
Name of the AS (station name)
The station name is assigned in SIMATIC Manager when you create the station. The
program generates a default station, for example, "SIMATIC 300(1)". You can always
change this name.
Data you can enter in STEP 7 HW Config, "CPU properties", "General" tab:
Name of the module
HW Config assigns a default name
Plant ID of the module
No default setting
Location identifier (LID) of a module
No default setting
ITEM 3000
Reading the I&M data in the user program
In order to read I&M data of the CPU in the user program, define the SSL ID and index and
read the corresponding SSL by calling SFC51. The table below shows the SSL IDs and
associated indexes.
SSL partial lists with I&M data
The I&M data are available in the SSL partial lists at the defined indexes.
Table 10- 1 SSL partial lists with I&M data
SSL-ID
W#16#
Index
W#16#
Meaning
Module identification
an identification data record
0001 Identification of the module
The module order number and release version are stored here.
0006 Identification of the basic software
Returns information about the SW version of the module. (These identification data
are identical to index 0001, as a basic software is not available for S7-300 CPUs.)
0111
0007 Identification of the basic firmware
Indicates the firmware version of the module.
Component identification
Component identification
0001 Name of the AS
Returns the name of the AS (station name).
0002 Name of the module
Returns the name of the module.
0003 Plant ID of the module
Returns a unique identifier for the module.
011C
000B Location identifier (LID) of a module
Returns the installation location of the module.
Reference
For detailed information about the structure an content of the SSLs, refer to the System
Software for S7-300/400, System and Standard Functions Manual and to the STEP 7 Online
Help.
I&M data of connected I/O
Information about the I&M data of I/O connected to the CPU is available in the manuals of
the corresponding I/O modules.
ITEM 3000
10.4 Overview: Debugging functions
Determining addressed nodes with "Node flashing test" (for CPUs >= V2.2.0)
To identify the addressed node, select PLC > Diagnostics/Setting > Node/Flashing Test in
STEP 7.
A dialog appears in which you can set the flashing time and start the flashing test. The
directly connected node can be identified by a flashing FORCE LED. The flashing test
cannot be performed if the FORCING function is active.
Debugging functions of the software: Monitoring and controlling tags, stepping mode
STEP 7 offers you the following testing functions you can also use for diagnostics:
Monitoring and controlling tags
Can be used for PG/PC monitoring of specific CPU or user program tags. You can also
assign constant values to the tags.
Testing with program status
You can test your program by viewing the program status of each function (result of
logical links, status bit) or the data of specific registers in real-time mode.
For example, if you have selected the programming language LAD in STEP 7 for your
presentation, the color of the symbol will indicate a closed switch or an active circuit.

Note
The STEP 7 testing function with program status extends the CPU cycle time!
For CPUs < V2.8 you have the option of setting a maximum cycle increase in STEP 7. To
do this, set process mode and the desired maximum cycle increase for the CPU
parameters in STEP 7, HW Config.
The option of adjusting the maximum cycle increase is not required for CPUs V2.8, as
the effect on the cycle time during set process mode is generally very low with these
CPUs.

Stepping mode
When testing in single-step mode, you can process your program instructions in
sequence (= single-step) and set breakpoints.
This is only possible in testing mode and not in process mode.
For the CPUs 312, 314, 315-2 DP, V3.0; CPU 319-3 PN/DP, V2.8, however, the
parameters of testing and process mode are not assigned in HW Config, but instead the
changeover is made directly in the LAD/FBD/STL editor under "Test/Mode".

Tip
Number of blocks and breakpoints that can be monitored with status block
CPU 312, 314, 315-2 DP, V3.0; CPU 319-3 PN/DP, V2.8
With these CPUs, you can monitor two blocks at the same time and set up to four
breakpoints in stepping mode.
All other CPUs of the range of validity
With these CPUs, you can monitor one block set up to two breakpoints in stepping
mode.
ITEM 3000
Debugging functions of the software: Forcing tags
The Force function can be used to assign the tags of a user program or CPU (also: inputs
and outputs) constant values which can not be overwritten by the user program.
For example, you can use it to jumper sensors or switch outputs permanently, irrespective of
the user program.

DANGER
This could result in severe injury or even death, and damage to property.
Incorrect use of the Force function could result in death or severe injury, and damage to
machinery or even the entire plant. Always follow the safety instructions in the STEP 7
manuals.

DANGER
Forcing with S7-300 CPUs
The force values in the process image of the inputs can be overwritten by write commands
(such as T IB x, = I x.y, Copy with SFC, etc.) and by read I/O commands (such as L PIW x)
in the user program, or by write PG/OP functions! Outputs initialized with forced values only
return the forced value if not accessed by the user program via peripheral write instructions
(TPQB x, for example) or by PG/OP write functions!
Always ensure that forced values in the I/O process image cannot be overwritten by the
user program or PG/OP functions!

TPAW
OS
Pll
transfer
User program
by T PAW
PlO
transfer
OS
Pll
transfer
by T PAW
PlO
transfer
Forcing value
overwritten by T
PQW
OS: Operating system processing
With S7-300 CPUs, forcing corresponds to "cyclical controlling"
Execution of
forcing job for
inputs
Execution of
forcing job for
inputs
Execution of
forcing job for
outputs
Execution of
forcing job for
outputs

Figure 10-1 Principle of forcing in S7-300 CPUs

ITEM 3000
10.5 Overview: Diagnostics
Differences between forcing and controlling tags
Table 10- 2 Differences between forcing and controlling tags
Characteristics/function Forcing Controlling tags
Memory bit (M) - Yes
Timers and counters (T, C) - Yes
Data blocks (DB) - Yes
Inputs and outputs (I, O) Yes Yes
Peripheral inputs (PI) - -
Peripheral outputs (PO) - Yes
User program can overwrite modify/force values Yes Yes
Maximum number of force values 10 -
Power off retentive Yes No
Reference
Details on debugging functions of the software are available in the STEP 7 Online Help and
in the Programming with STEP 7 Manual.
For additional information on the cycle times, please refer to the "Cycle time" chapter.
Introduction
System errors can occur especially in the commissioning phase. Tracking these errors might
be a time-consuming effort, since they can occur both on the hardware and software side.
Here, the multitude of testing functions ensures commissioning without problems.

Note
Errors during operation are almost always a result of faults or damage to the hardware.

Type of error
Errors the S7 CPUs can recognize and to which you can react with the help of organization
blocks (OBs) can be split into the following categories:
Synchronous error: Errors you can relate to a specific point in the user program (error
when accessing a peripheral module, for example).
Asynchronous error: Errors you can not relate to a specific point in the user program
(cycle time exceeded, module error, for example).
ITEM 3000
Troubleshooting
Programming with foresight and, above all, knowledge and proper handling of diagnostic
tools puts you into an advantageous position in error situations:
You can reduce the effects of errors.
It makes it easier for you to locate errors (by programming error OBs, for example).
You can limit downtimes.
Diagnostics with LED display
SIMATIC S7 hardware offers diagnostics with LEDs.
These LEDs are implemented in three colors:

LED color State of CPU
Green Regular operation.
Example: Power is on.
Yellow Non-regular operating status.
Example: Forcing is active.
Red Fault.
Example: Bus error
LED flashing Special event
Example: CPU memory reset
Two LEDs are used for Ethernet:

LED designation Color State Meaning
LINK Green Off No other device is connected with the integrated
PROFINET interface of the CPU.
On Another device (in most cases a switch) is connected to
the integrated PROFINET interface of the CPU, and the
physical connection is in place.
RX/TX Yellow Off No activity:
No data are transferred via the integrated PROFINET
interface of the CPU.
On Activity:
Data are transferred via the integrated PROFINET
interface of the CPU.
Note: The LED flickers when small data volumes are
transferred.
Reference
Notes on diagnostics of I/O modules capable of diagnostics are found in the relevant
Manual.
ITEM 3000
Diagnostic buffer
If an error occurs, the CPU writes the cause of error to the diagnostic buffer. In STEP 7 you
use the programming device to read the diagnostic buffer. This location holds error
information in plain text.
Other modules capable of diagnostics can be equipped with their own diagnostic buffer. In
STEP 7 (HW Config -> Diagnosing hardware) you can use the programming device to read
this buffer.
Diagnosable modules without diagnostic buffer write their error information to the CPU's
diagnostic buffer.
When an error or an interrupt event occurs, (e.g. time-of-day interrupt), the CPU switches to
STOP mode, or you can react in the user program via error/interrupt OBs. For a diagnostics
interrupt you would call OB82.
Diagnostics of field devices on PROFINET
Further information:
PROFINET System Description System Manual.
From PROFIBUS DP to PROFINET IO Programming Manual
The topics in the next chapters are focused on the diagnostics of local or distributed modules
on PROFIBUS.
ITEM 3000
Diagnostics with system functions
If the following CPUs are used, we recommend that you use the more user-friendly SFB 54
RALRM (called in diagnostic OB82) to evaluate the diagnostics from centralized or
distributed modules or DP slaves:

CPU As of firmware version
31xC,
312, 314, 315-2 DP
V 2.0.0
315-2 PN/DP V 2.3.0
317-2 DP V 2.1.0
317-2 PN/DP V 2.2.0
319-3 PN/DP V 2.4.0
Further options for diagnostics with system functions are listed below:
Using SFC 51 "RDSYSST" to read an SSL partial list or an extract thereof.
Reading the diagnostic data (slave diagnostics) of a DP slave, using SFC 13
"DPNRM_DG"
Every DP slave provides slave diagnostic data according to EN 50 170 Volume 2,
PROFIBUS. You can use SFC 13 "DPNRM_DG" to read these diagnostic data. Error
information is stored in hex code. Refer to the relevant module manual for information on
the meaning of the read code.
For example, the entry of the value 50H (= dual 0101 0000) in byte 7 of the slave
diagnostics for the distributed I/O module ET 200B indicates a faulty fuse or missing load
voltage in channel group 2 and 3.
Reading data records by calling SFC52 "RDREC"
You can call SFC52 "RDREC" (read record) to read a specific data record from the
addressed module. Data records 0 and 1 are especially suitable for reading diagnostic
information from a diagnosable module.
Data record 0 contains 4 bytes of diagnostic data describing the current state of a signal
module. Data record 1 contains the 4 bytes of diagnostic data also stored in data record
0, plus module-specific diagnostic data.
Reading out the start information of the current OB, using the SFC 6 "RD_SINFO"
Error information is also found in the start information of the relevant error OB.
You can use SFC 6 "RD_SINFO" (read start information) to read the start information of
the OB that was last called and not yet processed completely, and of the start-up OB that
was last called.
Triggering detection of the bus topology in a DP master system with the SFC103
"DP_TOPOL"
The diagnostics repeater improves the ability to locate faulty modules or an interruption
on the DP cable when failures occur in ongoing operation. It operates in slave mode and
is capable of logging faults based on the determination of the DP segment topology.
You can use SFC103 "DP_TOPOL" to trigger the identification of the bus topology of a
DP master system by the diagnostic repeater. The SFCs 103 are described in the
corresponding STEP 7 Online Help and in the System Software S7-300/400, System and
Standard Functions Reference Manual. The diagnostic repeater is described in the
manual Diagnostic Repeater for PROFIBUS DP.
ITEM 3000
10.6 Diagnostics functions available in STEP 7
10.6 Diagnostics functions available in STEP 7
Diagnostics using the "Diagnosing Hardware" function
Locate the cause of a module error by viewing the online information on the module. You
can locate the cause of an error in the user program cycle with the help of the diagnostic
buffer and of the stack content. You can also check whether a user program will run on a
specific CPU.
Hardware diagnostics give you an overview of the PLC status. In an overview
representation, a symbol can display the error status of every module. A double-click on the
faulty module opens detailed error information. The scope of this information depends on the
specific module. You can view the following information:
Display of general information on the module (e.g. order No., version, designation) and
module status (e.g. error).
Indication of module errors (channel error, for example) at local I/O and PROFIBUS DP
slaves or PROFINET IO devices.
Display of messages from the diagnostic buffer.
Maintenance information: Maintenance demanded and maintenance required
In addition, diagnostics data about the PROFINET interface are presented.
For CPUs you can also view the following module status information:
Cause of an error in the user program cycle.
Indication of the cycle time (longest, shortest and last cycle).
Options and utilization of MPI communication.
Indication of performance data (number of possible I/O, memory bits, counters, timers
and blocks).
Diagnostics (network connection, communications diagnostics and statistics, for example)
of the PROFINET interface and of its ports
For details on diagnostic functions in STEP 7 and on procedures, refer to the Programming
with
STEP 7 Manual and to the HW Config Online Help.
ITEM 3000
10.7 Network infrastructure diagnostics (SNMP)
Availability
As an open standard, you can use any SNMP-based systems or software solutions for
diagnostics in PROFINET.
Network diagnostics
SNMP (Simple Network Management Protocol) makes use of the connectionless UDP
transport protocol. It consists of two network components, similar to the client/server model.
The SNMP manager monitors the network nodes and the SNMP agents collect the various
network-specific information in the individual network nodes and stores it in a structured form
in the MIB (Management Information Base). This information allows a network management
system to run detailed network diagnostics.
MIB
An MIB (Management Information Base) is a data base of a device. SNMP clients access
this data base in the device. The S7 device family supports, among others, the following
standard MIBs:
MIB II, standardized in the RFC 1213
LLDP MIB, standardized in the international standard IEE 802.1AB
LLDP PNIO-MIB, standardized in the international standard IEE 61158-6-10
Detecting the network topology
LLDP (Link Layer Discovery Protocol) is a protocol that is used to detect the closest
neighbors. It enables a device to send information about itself and to save information
received from neighboring devices in the LLDP MIB. This information can be looked up via
the SNMP. This information allows a network management system to determine the network
topology.
Integrating HMI devices via the SNMP OPC server
Configuration of the OPC server is integrated in the STEP 7 hardware configuration
application. The communication with the OPC server is carried out without an S7 connection.
You therefore do not need to configure S7 connections.
Stations that have already been configured in the STEP 7 project can be transferred directly.
As an alternative to STEP 7, the configuration can also be run with the NCM PC (included on
the SIMATIC NET CD) or can be determined automatically and transferred to the project
configuration.
ITEM 3000
Use of SNMP in the SIMATIC NET environment
SNMP-compliant devices from the SIMATIC NET family can be monitored and operated via
a conventional standard Internet browser.
The management system known as web-based management offers a range of device-
specific information (network statistics, status of redundant supply, for example).
Diagnostics with the SIMATIC NET SNMP OPC server
The SNMP OPC server software enables the diagnostics and configuration of any SNMP
devices, even via, e.g. HMI devices that cannot read SNMP variables from other devices.
The OPC server uses the SNMP protocol to exchange data with these devices.
All information can be integrated into OPC-compatible systems, into WinCC HMI system for
example. This enables process and network diagnostics to be combined in the HMI system.
Uses of SNMP
SNMP can be used as follows:
By users to integrate network diagnostics into a central HMI / SCADA system using the
SNMP OPC server.
By the IT administration of machines and plant owners to monitor their Industrial Ethernet
network using standard network management systems.
By the IT administration, to primarily monitor the office network, but often also the
automation network using standard network management systems
(for example, HP Open view).
Additional information
Information relating to SNMP in the network management standardization group can be
found at Internet (http://www.snmp.org/).
Additional information on SNMP can be found on the Internet
(http://www.profibus.com/rpa/germany/).
Additional information on SNMP OPC servers can be found on the Internet
(http://www.automation.siemens.com/net/html_76/produkte/040_snmp.htm).
ITEM 3000
10.8 Diagnostics using status and error LEDs
10.8.1 Introduction
Diagnostics with LEDs is an initial tool for error localization. Usually, you evaluate the
diagnostic buffer for further error localization.
The buffer contains plain text information on the error that has occurred. For example, you
will find the number of the appropriate error OB here. You can prevent the CPU from going
into STOP mode by generating this OB and downloading it to the CPU.
10.8.2 Status and error displays of all CPUs
Table 10- 3 Status and error displays
LED Meaning
SF 5 VDC FRCE RUN STOP
Off Off Off Off Off CPU power supply missing.
Remedy:
Check whether the power supply module is connected to mains and
switched on.
Off On X (see
the
descripti
on)
Off On The CPU is in STOP mode.
Remedy: Start the CPU.
On On X Off On The CPU is in STOP mode as a result of error.
Remedy: refer to the tables below, evaluation of the SF LED
X On X Off Flashes
(0.5 Hz)
The CPU requests memory reset.
X On X Off Flashes
(2 Hz)
The CPU executes memory reset.
X On X Flashes
(2 Hz)
On The CPU is in startup mode.
X On X Flashes
(0.5 Hz)
On The CPU was halted by a programmed break point.
For details refer to the Programming with STEP 7 Manual.
On On X X X Hardware or software error
Remedy: refer to the tables below, evaluation of the SF LED
X X On X X You enabled the Force function
For details refer to the Programming with STEP 7 Manual.
X X Flashes
(2 Hz)
X X Node flashing test was activated.
Flash
es
Flashes Flashes Flashes Flashes Your CPU has an internal system error. The procedure is as follows:
1. Set the mode selector switch to STOP.
2. Perform POWER ON/OFF.
3. Read the diagnostics buffer with STEP 7.
4. Contact your local SIEMENS partner.
Explanation of the State X:
This status is irrelevant for the current CPU function.
ITEM 3000
Reference
Details on the OBs and on SFCs required for their evaluation can be found in the STEP 7
Online Help and in the Manual System Software for S7-300/400 - System and Standard
Functions.

10.8.3 Evaluating the SF LED in case of software errors
Table 10- 4 Evaluation of the SF LED (Software error)
Possible problem Response of the CPU Remedies
TOD interrupt is enabled and
triggered. However, a matching
block is not loaded.
(Software/configuration error)
Call of OB85.
CPU goes into STOP if
OB85 is not loaded.
Load OB10 (OB number is apparent
from the diagnostic buffer).
Start time of the enabled TOD
interrupt was jumped, e.g. by
advancing the internal clock.
Call of OB80.
goes into STOP if OB80
is not loaded
Disable the TOD interrupt before you
set the time-of-day with SFC 29.
Delay interrupt triggered by
SFC 32. However, a matching
Call of OB85.
OB85 is not loaded.
Load OB 20 or 21 (CPU 317 only) (the
OB number can be viewed in the
diagnostic buffer).
Process interrupt is enabled and
triggered. However, a matching
Call of OB85.
OB85 is not loaded.
Load OB40 (OB number is apparent
from the diagnostic buffer).
Status alarm is generated, but
the appropriate OB55 is not
loaded.
Call of OB85.
OB85 is not loaded.
Load OB55
Update alarm is generated, but
the appropriate OB 56 is not
loaded.
Call of OB85. CPU goes
to STOP if OB 85 is not
loaded.
Load OB56
Vendor-specific alarm is
generated, but the appropriate
OB57 is not loaded.
Call of OB85.
OB85 is not loaded.
Load OB57
Access to missing or defective
module upon updating the
process image (software or
hardware error)
Call OB 85 (depending
on the configuration in
HW Config). CPU goes
into STOP if OB 85 is not
loaded.
Load OB85, the start information of the
OB contains the address of the relevant
module. Replace the relevant module
or eliminate the program error.
ITEM 3000
Possible problem Response of the CPU Remedies
The cycle time was exceeded.
Probably too many interrupt
OBs called simultaneously.
Call of OB80.
OB80 is not loaded. The
CPU switches to STOP
despite loaded OB80 if
the doubled cycle time
was exceeded without
retriggering cycle time
80.
Extension of the cycle time (STEP 7
Hardware configuration), changing the
program structure. Remedy: If
necessary, retrigger cycle time
monitoring by calling SFC 43
Programming error
Block not loaded
Wrong block number
Wrong timer/counter number
Read/write access to wrong
area
etc.
Calls OB121. CPU does
not STOP if OB121 is
loaded.
Eliminate the programming error. The
STEP 7 testing function helps you to
locate the error.
I/O access errors
An error has occurred when
module data was accessed
Calls OB122. CPU does
not STOP if OB122 is
loaded.
Check module addressing in HW
Config or whether a module/DP slave
has failed.
Global data communication
error, e.g. insufficient length of
the DB for global data
communication.
Call of OB87.
OB87 is not loaded.
Check global data communication in
STEP 7. If required, correct the DB
size.
Tip:
You can use SFC 39 to disable all interrupts and asynchronous error events.

Note
The shorter the selected cyclic interrupt period, the more likely it is that cyclic interrupt
errors will occur. You must take into account the operating system times of the CPU in
question, the user program runtime and extension of the cycle time by active PG
functions, for example.

Reference
Details on the OBs and on the SFCs required for their evaluation are available in the STEP 7
Online Help and in the System Software for S7-300/400 - System and Standard Functions
Reference Manual.

ITEM 3000
10.8.4 Evaluating the SF LED in case of hardware errors
Table 10- 5 Evaluation of the SF LED (Hardware error)
Possible problem CPU reaction Possible remedies
A module was removed or
inserted while the system was
in RUN.
CPU goes into STOP. Screw-tighten the modules and
restart the CPU.
A distributed module was
removed or inserted on
PROFIBUS DP while the
system was in RUN.
Call of OB86.
CPU goes into STOP if OB86 is
not loaded.
When the module is integrated
by means of GSD file:
Call of OB 82. CPU goes into
STOP when OB 82 is not loaded.
Load OB86 or OB82.
A distributed module was
removed or inserted on
PROFINET IO while the
system was in RUN.
Call of OB83.
not loaded.
OB 86 is also called when one or
several modules of an ET 200S
(IO device) are removed or
inserted while the system is in
RUN. CPU switches to STOP if
OB 86 is not loaded.
Load OB 83 and OB 86.
A diagnosable module reports
a diagnostic interrupt.
Call of OB82.
not loaded.
Reaction to the diagnostic event,
based on the module
configuration.
Attempt to access a missing
or faulty module. Loose
connector (software or
hardware error).
Call of OB85, if access was
attempted during update of the
process image (OB 85 call must
be enabled accordingly in the
parameters). Call of OB 122 with
direct I/O access. CPU switches
to STOP if the OB is not loaded.
Load OB 85, the start information
of the OB contains the address of
the relevant module. Replace the
relevant module, tighten the plug
or eliminate the program error.
Faulty SIMATIC MMC. The CPU goes into STOP mode
and requests memory reset.
Replace the SIMATIC MMC, reset
CPU memory, transfer the
program again, then set the CPU
to RUN mode.
Reference
Details on the OBs and on the SFCs required for their evaluation are available in the STEP 7
Online Help and in the System Software for S7-300/400 - System and Standard Functions
Reference Manual.
ITEM 3000
10.8.5 Status and Error Indicators: CPUs with DP Interface
Description of the BF, BF1 and BF2 LEDs
Table 10- 6 LEDs BF, BF1 and BF2
LED Meaning
SF 5 VDC BF BF1 BF2
On On On/ flashes - - PROFIBUS DP interface error.
Remedy: See the table below
On On - On/ flashes X Fault at the second PROFIBUS DP interface of
CPU 317 or CPU 319-3 PN/DP.
On On - X On/ flashes Error on the second PROFIBUS DP interface of the
CPU 317-2 DP or CPU 319-3 PN/DP.
Remedy: See the tables below
Explanation of the State X:
The LED can assume the On or Off state. This status, however, is irrelevant for the current
CPU function. For example, the Force On or Off states do not influence the CPU STOP
status
Table 10- 7 BF LED is lit
Bus fault (hardware fault).
DP interface error.
Different transmission rates in
multiple DP master mode.
If the DP slave / master interface is
active: short-circuit on the bus.
With passive DP slave interface:
transmission rate search, i.e. there are
no other active nodes on the bus (a
master, for example)
Call of OB 86, if CPU is in RUN mode
and if the communication between the
DP master and DP slave functioned
properly before the error occurred.
CPU switches to STOP if OB 86 is not
loaded.
Check the bus cable for short-circuit
or breaks.
Analyze the diagnostic data. Edit
the configuration.

Table 10- 8 BF LED flashes
The CPU is DP master:
Failure of a connected station
At least one of the configured
slaves cannot be accessed.
Bad engineering configuration
and operated DP slaves before the
error occurred.
loaded.
Verify that the bus cable is connected
to the CPU, or that the bus is not
interrupted.
Wait until the CPU has completed its
startup. If the LED does not stop
flashing, check the DP slaves or
evaluate the diagnostic data for the DP
slaves.
The CPU is active DP slave
Possible causes:
The response monitoring time has
elapsed.
PROFIBUS DP communication is
down.
Wrong PROFIBUS address.
and communicated as a DP slave with
the DP master before the error
occurred.
loaded.
Check the CPU.
Verify that the bus connector is
properly seated.
Check for breaks in the bus cable to
the DP master.
Check the configuration data and
parameters.
ITEM 3000
Reference
Details on the OBs and on the SFCs required for their evaluation are available
in the STEP 7 Online Help
in the System Software for S7-300/400, System and Standard Functions Reference
Manual
10.8.6 Status and error indicators: CPUs with PROFINET interface for the S7-300
Status and Error Indicators: PROFINET devices
Note
The RX and TX LEDs can also be grouped in one LED, as with the CPU 319-3 PN/DP. The
RX/TX LED on this device is located, for example, under the front cover.

LED status Description of the status LED
Not lit Flashes Lit
X There is no connection between the PROFINET
interface of your PROFINET device and a
communication partner in the Ethernet (a switch, for
example).
X Only with an IO device:
The user activated flashing from STEP 7.
LINK
X The Ethernet connection between the PROFINET
interface of the PROFINET device and the
communication partner is down.
X
(flickers)
At the current time, data are being received from a
communication partner on Ethernet via PROFINET
interface of the PROFINET device.
RX
X No data are currently received via the PROFINET
interface.
X
(flickers)
Data are currently sent to a communication partner on
Ethernet via the PROFINET interface of the PROFINET
device.
TX
X No data are currently transmitted via the PROFINET
interface.
X Error on the PROFINET interface, communication no
longer possible (for example, with a CPU as IO
controller, when the connection to the switch is down)
X Error on the PROFINET interface (for example, due to
station failure of one or more IO devices)
BF2 or
BF3
X No error at the PROFINET interface
ITEM 3000
Remedy of faults at the PROFINET interface - BF2/ BF3 LED is lit
Table 10- 9 BF2 / BF3 LED is lit
Possible problem Reaction based on the
example of a CPU
Possible remedies
Bus fault (no cable connection to a
subnet/switch)
Wrong transmission speed
Full duplex mode not set
Call of OB 86, if CPU is in
RUN mode and operated
PNIO slaves before the error
occurred.
CPU switches to STOP if
Check the bus cable for a short-circuit or
break.
Check that the module is connected to a
switch and not to a hub.
Check that data are being transmitted at 100
Mbps and in full duplex mode.
Analyze the diagnostic data. Edit the
configuration.
Remedy of faults at the PROFINET interface of an IO controller - BF2 / BF3 LED flashes
Table 10- 10 BF2 / BF3 LED flashes at a PROFINET IO controller
Possible problem Reaction based on the
example of a CPU
Possible remedies
Failure of a connected IO device
At least one of the assigned IO
devices cannot be addressed
Call of OB 86, if CPU is in
RUN mode and operated
PNIO slaves before the error
occurred.
CPU switches to STOP if
Check that the Ethernet cable is connected to
the module or whether the bus is interrupted.
Wait until the CPU has completed its startup. If
the LED does not stop flashing, check the IO
devices or evaluate its diagnostic information.
Verify that the configured device name
matches its actually assigned name.
10.8.7 Status and Error Indicators: PROFINET IO Devices
Remedy with faults at the PROFINET interface of an IO Device - BF LED flashes
Table 10- 11 BF LED flashes on a PROFINET IO device
Possible problem Possible remedies
The IP address is incorrect
Bad parameter assignment
IO controller not found / switched off, but
there is an Ethernet connection.
Bad or no device name
The response monitoring time has elapsed.
Check that the Ethernet cable is correctly
connected.
Check whether the Ethernet cable to the
controller is interrupted.
Check the configuration data and parameters.
On the IO device: Switch on the IO controller.
Check whether the expected configuration
matches the actual configuration.
Check the physical communication
connection for interruption
Tip: Identification of the PROFINET device in the cubicle
When they are first commissioned, PROFINET IO devices must be assigned a device name.
In STEP 7/HW Config, you can make the LINK LED of a PROFINET IO device you are
naming flash usingPLC > Ethernet > Assign Device Name. This allows you, for example, to
clearly identify a PROFINET IO device among several identical devices in a control cabinet.
ITEM 3000
10.9 Diagnostics of DP CPUs
10.9.1 Diagnostics of DP CPUs operating as DP Master
Evaluate diagnostics in the user program
The figure below illustrates the procedure for evaluating diagnostics data in the user
program.
Diagnostic event
OB82 is called
Read out OB82_MDL_ADDR and
OB82_lO_FLAG (=lD of l/O
module)
Enter bit 0 of OB82_lO_FLAG as bit
15 in OB82_MDL_ADDR.
Result: Diagnostics address
"OB82_MDL_ADDR*"
For diagnostics of the entire DP
slave:
ln the LADDR parameter, enter
diagnostic address
"OB82_MDL_ADDR*"
Call SFB13
Note:
lnitial call in OB82, finishing in the
cycle
SFC 13 is asynchronous, which means
that it may be called multiple times until
its state has changed to BUSY=0.
For diagnosing affected components:
Set MODE=1. Diagnostic data is entered in the
TlNFO and AlNFO parameters
Call SFB54
For diagnostics of the affected modules: Call
SFC51
ln parameter SZL_lD, enter the lD W#16#00B3
(=diagnostics data of a module)
ln the lNDEX parameter, enter diagnostic address
"OB82_MDL_ADDR*".
Evaluation with SFB54
(easiest option)
Evaluation with
SFC13 or SFC51

ITEM 3000
Diagnostic addresses for DP masters and DP slaves
At a CPU 31x-2, you assign diagnostic addresses for PROFIBUS DP. Verify in your
configuration that the DP diagnostic addresses are assigned once to the DP master and
once to the DP slave.
PROFlBUS
Diagnostics address
CPU 31x-2 as transmitter CPU 31x-2 as receiver

Description of the DP master
configuration
Description of the DP slave
configuration
When you configure the DP master, assign two
different diagnostic addresses for an intelligent
slave, that is, one diagnostic address for slot 0,
and one for slot 2. Functions of those two
addresses:
The diagnostic address for slot 0 reports in
the master all events relating to the entire
slave (station representative), for example,
node failure.
The diagnostic address for slot 2 is used to
report events concerning this slot. For
example, if the CPU is acting as an intelligent
slave, it returns the diagnostic interrupts for
operating state transitions.
Hereinafter, these diagnostic addresses are
referred to as assigned to the DP master.
These diagnostic addresses are used by the DP
master to obtain information about the status of
DP slave, or about bus interruptions.
When you configure the DP slave, you also
assign it a diagnostic address (in the associated
DP slave project).
Below, this diagnostic address is labeled
assigned to DP slave.
This diagnostic addresses is used by the DP
slave to obtain information on the status of the
DP master, or on bus interruptions.
ITEM 3000
Event detection
The table below shows how a CPU 31x-2 operating as DP master detects operating mode
transitions of a CPU operating as DP slave, or data exchange interruptions.
Table 10- 12 Event detection of CPU 31x2 operating as DP master
Event What happens in the DP master?
Bus interruption (short-
circuit, connector
removed)
Call of OB 86 with the message Station failure (incoming event;
diagnostic address of Slot 0 of the DP slave that is assigned to the
DP master)
with I/O access: call of OB 122 (I/O access error)
DP slave: RUN STOP Call of OB 82 with the message Module error
(incoming event; diagnostic address of Slot 2 of the DP slave that is
assigned to the DP master; Variable OB82_MDL_STOP=1)
DP slave: STOP RUN Call of OB 82 with the message Module OK
(outgoing event; diagnostic address of Slot 2 of the DP slave that is
assigned to the DP master; Variable OB82_MDL_STOP=0)
Evaluation in the user program
The table below shows how you can, for example, evaluate RUN to STOP transitions of the
DP slave in the DP master.
Table 10- 13 Evaluating RUN to STOP transitions of the DP slave in the DP master
In the DP master In the DP slave (CPU 31x-2 DP)
Diagnostic addresses: (Example)
Master diagnostic address =1023
Slave diagnostic address =1022
(Slot 0 of slave)
(Diagnostic) address for "Slot 2"=1021
(Slot 2 of slave)
Diagnostic addresses: (Example)
Master diagnostic address = irrelevant
The CPU calls OB82 with the following information:
OB82_MDL_ADDR:=1021
OB82_EV_CLASS:=B#16#39 (incoming event)
OB82_MDL_DEFECT: = Module error
Tip: The CPU diagnostic buffer also contains this
information
In the user program you should also include SFC
13 "DPNRM_DG" for reading out DP slave
diagnostic data.
CPU: RUN -> STOP
The CPU generates a DP slave diagnostics
message frame
ITEM 3000
10.9.2 Reading out slave diagnostic data
The slave diagnostic data is compliant with EN 50170, Volume 2, PROFIBUS. Depending on
the DP master, diagnostic data for all DP slaves conforming to standard can be read with
STEP 7.
Diagnostic addresses for the receiving station with direct data exchange
For direct data exchange, you assign a diagnostic address in the receiving station:
PROFlBUS
Diagnostics address

Figure 10-2 PROFIBUS DP diagnostics address
In this figure, you see that assign a diagnostic address to the receiving station in your
configuration. The receiving station receives information about the status of the transmitting
station or about a bus interruption by means of this diagnostic address.
Reading out the diagnostic data
The table below shows you how the various DP master systems can read diagnostic
information from a slave.
Table 10- 14 Reading out diagnostic data in the master system, using STEP 5 and STEP 7
Automation system with DP
master
Blocks or registers in STEP 7 Application Further Information
SIMATIC S7/M7 "DP Slave Diagnostics" tab Output of slave
diagnostic data in plain
text to a STEP 7 user
interface
Found under the keyword
Hardware diagnostics in the
STEP 7 Online Help and in the
Programming with STEP 7
Manual
SFB 54 "RALRM" Reading additional
interrupt information from
a DP slave or local
module from the relevant
OB.
System and Standard
Functions Reference Manual
SFC13 "DP NRM_DG" Reading out slave
diagnostics
(store in the data area of
the user program)
System and Standard
ITEM 3000
Automation system with DP
master
Blocks or registers in STEP 7 Application Further Information
SFC 51 "RDSYSST" Reading SSL sublists. In
the diagnostic interrupt,
call SFC 51 with the SSL
ID W#16#00B4, and then
read out the SSL of the
slave CPU.
System and Standard
SFB 52
RDREC andSFC 59
RDREC
Reading the data records
of S7 diagnostics (stored
in the data area of the
user program)
System and Standard
FB 125/FC 125 Evaluating slave
diagnostic data
On the Internet under
http://www.siemens.com/auto
mation/csi_en_WW7Product
under the entry ID. 387 257
SIMATIC S5 with IM 308-C
operating in DP master
mode
FB 192 "IM308C" Reading slave diagnostic
data (store in the data
area of the user program)
Distributed I/O System ET 200
Manual
Example for reading the slave diagnosis with FB 192 "IM308C"
This shows you an example of how to use FB 192 in the STEP 5 user program to read out
slave diagnostics data for a DP slave.
Assumptions regarding the STEP 5 user program
For this STEP 5 user program it is assumed that:
The IM 308-C operating in DP master mode uses the page frames 0 to 15 (number 0 of
IM 308-C).
The DP slave is assigned PROFIBUS address 3.
Slave diagnostics data should be stored in DB 20. You may also use any other DB.
Slave diagnostics data consist of 26 bytes.
ITEM 3000
STEP 5 user program

STL Explanation
:A DB 30
:SPA FB 192
Name :IM308C
DPAD : KH F800
IMST : KY 0, 3
FCT : KC SD
GCGR : KM 0
TYP : KY 0, 20
STAD : KF +1
LENG : KF 26
ERR : DW 0

//Default address range of IM 308-C
//IM no. = 0, PROFIBUS address of the DP slave = 3
//function: Read slave diagnostics
//not evaluated
//S5 data area: DB 20
//Diagnostic data starting at data word 1
//Length of diagnostic data = 26 bytes
//Error code storage in DW 0 of DB 30
Example of reading out S7 diagnostic data with SFC 59 "RD REC"
Here you will find an example of how to use SFC 59 in the STEP 7 user program to read S7
diagnostics data records for a DP slave. The process of reading the slave diagnostics is
similar to SFC 13.
Assumptions regarding the STEP 7 user program
Exceptions for this STEP 7 user program:
Diagnostic data for the input module at address 200H is to be read.
Data record 1 is to be read out.
Data record 1 is to be stored in DB 10.
STEP 7 user program

STL Explanation
CALL SFC 59

REQ :=TRUE
IOID :=B#16#54
LADDR :=W#16#200
RECNUM :=B#16#1
RET_VAL :=MW2
BUSY :=MO.0
RECORD :=P# DB10.DBX 0.0 BYTE 240

//Request to read
//Identifier of the address range, here the I/O input
//Logical address of the module
//Data record 1 is to be read
//An error code is output if an error occurs
//Read operation not finished
//DB 10 is target area for the read data record 1
Note:
Data is only returned to the target area if BUSY is reset to 0 and if no negative RET_VAL has
occurred.
ITEM 3000
Diagnostic addresses
At a CPU 31x-2, you assign diagnostic addresses for PROFIBUS DP. Verify in your
configuration that the DP diagnostic addresses are assigned once to the DP master and
once to the DP slave.
PROFlBUS
Diagnostics address

Figure 10-3 PROFIBUS DP diagnostics address

Description of the DP master
configuration
Description of the DP slave
configuration
When you configure the DP master, assign two
different diagnostic addresses for an intelligent
slave, that is, one diagnostic address for slot 0,
and one for slot 2. Functions of those two
addresses:
The diagnostics address for slot 0 reports in
the master all events relating to the entire
slave (station representative), for example,
node failure.
The diagnostics address for slot 2 is used to
report events concerning this slot. For
example, if the CPU is acting as an intelligent
slave, it returns the diagnostic interrupts for
operating state transitions.
From now on, these diagnostic addresses are
referred to as assigned to the DP master.
These diagnostic addresses are used by the DP
master to obtain information about the status of
DP slave, or about bus interruptions.
When you configure the DP slave, you also
assign it a diagnostic address (in the associated
DP slave project).
Below, this diagnostic address is labeled
assigned to DP slave.
This diagnostic addresses is used by the DP
slave to obtain information on the status of the
DP master, or on bus interruptions.
ITEM 3000
Event recognition
The table below shows how CPU 31x-2 operating as DP slave recognized operating state
transitions or data exchange interruptions.
Table 10- 15 Event recognition of CPUs 31x-2 operating in DP slave mode
Event What happens in the DP slave?
Bus interruption (short circuit,
connector removed)
Calls OB86 with the message Station failure (incoming event;
diagnostic address of the DP slave, assigned to the DP slave)
With I/O access: call of OB 122 (I/O access error)
DP master RUN STOP Calls OB82 with the message Module error (incoming event;
diagnostic address of the DP slave assigned to the DP slave;
tag OB82_MDL_STOP=1)
DP master STOP RUN Call of OB82 with the message Module OK. (outgoing event;
diagnostic address of the DP slave, assigned to the DP slave;
tag OB82_MDL_STOP=0)
Evaluation in the user program
The table below shows an example of you how you can evaluate RUN-STOP transitions of
the DP master in the DP slave (see also the previous table).
Table 10- 16 Evaluating RUN-STOP transitions in the DP Master/DP Slave
In the DP master In the DP slave
Diagnostics addresses: (Example)
Master diagnostic address =1023
Slave diagnostic address in the master
system=1022
(Slot 0 of slave)
(Diagnostic) address for "Slot 2"=1021
(Slot 2 of slave)
Diagnostics addresses: (Example)
Master diagnostic address = irrelevant
CPU: RUN STOP The CPU calls OB 82 with the following
information, for example:
OB82_MDL_ADDR:=422
OB82_EV_CLASS:=B#16#39 (incoming event)
OB82_MDL_DEFECT:=module malfunction
Tip: The CPU diagnostic buffer also contains this
information
ITEM 3000
10.9.3 Interrupts on the DP Master
Interrupts with S7 DP master
Process interrupts from an intelligent slave with SFC 7
In the CPU 31x-2 operating in DP slave mode, you can trigger a user-defined process
interrupt from the DP master from the user program.
A call of SFC 7 "DP_PRAL" triggers the execution of OB 40 in the user program on the DP
master. The SFC 7 allows you to forward interrupt information to the DP master in a double
word. This information can then be evaluated in the OB40_POINT_ADDR variable in the
OB40. The interrupt information can be programmed user-specific. For a detailed description
of SFC 7 "DP_PRAL", refer to the System Software for S7-300/400 - System and Standard
Functions Reference Manual.
Setting user-defined interrupts of Intelligent Slaves using SFB 75
In the CPU 31x-2 operating in DP slave mode, you can trigger user-defined interrupts from
the user program in the DP master. SFB 75 "SALRM" is used to send a process or
diagnostic interrupt from a slot in the transfer area (virtual slot) to the associated DP master
from the user program on an intelligent slave. This starts the associated OB on the DP
master.
Additional interrupt-specific information may be included. You can read this additional
information in the DP master using SFB 54 "RALRM."
Interrupts with another DP master
When CPU 31x-2 operates with another DP master, an image of these interrupts is created
in its device-specific diagnostic data. You have to post-process the relevant diagnostic
events in the DP master's user program.

Note
In order to allow the evaluation of diagnostics and process interrupts by means of device-
specific diagnostics using a different DP master, please note that:

The DP master should be able to save the diagnostics messages to its ring buffer. For
example, if the DP master can not save the diagnostic messages, only the last incoming
diagnostic message would be saved.

In your user program, you have to poll the relevant bits in the device-specific diagnostic data
in cyclic intervals. Make allowances for the PROFIBUS DP bus cycle time, for example, to be
able to poll these bits at least once and in synchronism to the bus cycle time.

With an IM 308-C operating in DP master mode, you cannot utilize process interrupts in
device-specific diagnostics, because only incoming events are reported, rather than outgoing
events.

ITEM 3000
10.9.4 Structure of the slave diagnostic data when the CPU is operated as intelligent
slave
Syntax of the diagnostics datagram for slave diagnostics

.
.
.
.
.
.
.
.
.
Station status 1 to 3
Master PROFlBUS address
High byte
Low byte
Manufacturer's lD
lD-specific diagnostics
(The length depends on the number of
configured address spaces of the transfer
memory
1
)
Module status (device-specific diagnostics)
(The length depends on the number of
configured address spaces)
lnterrupt status (device-specific diagnostics)
(The length depends on the type of interrupt)
1
exception: lf DP master is configured incorrectly, the DP slave interprets 35
configured address ranges (46
H
in Byte 6)
Byte 0
Byte 1
Byte 2
Byte 3
Byte 4
Byte 5
Byte 6
to
to
to
Byte x -1
Byte x
Byte y-1
Byte y
Byte z

Figure 10-4 Structure of slave diagnostic data
ITEM 3000
Station Status 1
Table 10- 17 Structure of station status 1 (Byte 0)
Bit Meaning Remedy
0 1: DP slave cannot be addressed by DP master. Is the correct DP address set on the DP slave?
Is the bus connector in place?
Does the DP slave have power?
Correct configuration of the RS485 Repeater?
Perform a reset on the DP slave.
1 1: DP slave is not ready for data exchange. Wait for the slave to complete start-up.
2 1: Configuration data sent by DP master to the DP slave is
inconsistent with slave configuration.
Was the software set for the correct station type or
DP slave configuration?
3 1: Diagnostic interrupt, generated by a STOP to RUN
transition on the CPU or by the SFB 75
0: Diagnostic interrupt, generated by a STOP to RUN
transition on the CPU or by the SFB 75
You can read the diagnostic data.
4 1: Function not supported; e.g. changing the DP address at
software level
Check configuration data.
5 0: The bit is always "0". -
6 1: DP slave type inconsistent with software configuration. Was the software set for the right station type?
(parameter assignment error)
7 1: DP slave was configured by a DP master other than the
master currently accessing the slave.
The bit is always 1 if, for example, you are
currently accessing the DP slave via PG or a
different DP master.
The DP address of the parameter assignment master
is in the "master PROFIBUS address" diagnostic byte.
Station Status 2
Bit Meaning
0 1: The DP slave requires new parameters and configuration.
1 1: A diagnostic message was received. The DP slave cannot resume operation until the error has been cleared
(static diagnostic message).
2 1: This bit is always "1" if a DP slave exists with this DP address.
3 1: The watchdog monitor is enabled on this DP slave.
4 1: DP slave has received control command "FREEZE".
5 1: DP slave has received control command "SYNC".
6 0:The bit is always set to "0".
7 1: DP slave is disabled, that is, it has been excluded from cyclic processing.
ITEM 3000
Station Status 3
Bit Meaning
0 to 6 0: These bits are always "0"
7 1:The incoming diagnostic messages exceed the memory capacity of the DP slave.
The DP master cannot write all diagnostic messages sent by the DP slave to its diagnostic buffer.
Master PROFIBUS address
The "Master PROFIBUS address" diagnostic byte stores the DP address of the DP master:
that has configured the DP slave and
has read and write access to the DP slave.
Table 10- 20 Structure of the Master PROFIBUS address (byte 3)
Bit Meaning
DP address of the DP master that has configured the DP slave and has read/write access to that DP slave. 0 to 7
FFH: DP slave was not configured by a DP master
Manufacturer ID
The vendor ID contains a code specifying the type of the DP slave.
Table 10- 21 Structure of the manufacturer ID (byte 4 and 5)
Byte 4 Byte 5 Vendor ID for the CPU
80H D0H 313C-2-DP
80H D1H 314C-2-DP
81H 76H 315-2 DP
81H 17H 315-2 PN/DP
80H F0H 317-2 DP
80H F1H 317-2 PN/DP
81H 1DH 319-3 PN/DP
ITEM 3000
Structure of identifier-related diagnostics of CPU 31x-2 / CPU 319-3
Module diagnostics indicate the configured address range of intermediate memory that has
received an entry.
7 6 5 4 3 2 1
1
0
7 6 5 4 3 2 1 0
7 6 5 4 3 2 1 0
7 6 5 4 3 2 1 0
7 6 5 4 3 2 1 0
7 6 5 4 3 2 1 0
0 0 0 0 0
0
Bit
Bit
Bit
Bit
Bit
Bit
Length of the identifier-related diagnostic data including byte 6
(depending on the number of configured address ranges up to 6 bytes)
Entry for 2nd configured address range
Entry for 3rd configured address range
Entry for 4th configured address range
Entry for 6th to 13th configured address range
Entry for 31st configured address range
Preset configuration Actual configuration
Code for lD-related diagnostics
Entry for 1st configured address range
Entry for 14th to 21st configured address range
Entry for 22nd to 29th configured address range
Entry for 32nd configured address range
Preset configuration Actual configuration or slave CPU in STOP
Preset configuration Actual configuration
Byte 6
Byte 7
Byte 8
Byte 9
Byte 10
Byte 11

Figure 10-5 Identifier-related diagnostic data
ITEM 3000
Structure of the module status
The module status reflects the status of the configured address ranges, and provides
detailed ID-specific diagnostics with respect to the configuration. Module status starts with
module diagnostics and consists of a maximum of 13 bytes.
2
H
=
00
B
:
01
B
:
10
B
:
11
B
:
.
.
.
..
.
.
.
0
H
0
H
7 6 5 4 3 2 1 0
7 6 5 4 3 2 1 0
7 6 5 4 3 2 1 0
7 6 5 4 3 2 1 0
7 6 5 4 3 2 1 0
7 6 5 4 3 2 1 0
0 0
0 0 0 0
1 1 0 0 0 0 0 0
0 0
Bit
Bit
Bit
Bit
Bit
Bit
1st configured address range
6th configured address range
31st configured address range
2nd configured address range
3rd configured address range
Status type: Module status
always "0"
always "0"
Length of the module status including byte x (= max. 13 bytes)
Code for device-specific diagnostics
Module status
Code for status message
CPU slot
Module ok.; valid
data
Module error; invalid data
No module; invalid data
lncorrect module; invalid
data
(Module defective)
Byte x
Byte x+1
Byte x+2
Byte x+3
Byte x+4
Byte x+5
Byte x+6
Byte y-1

Figure 10-6 Structure of the module status for CPU 31xC
ITEM 3000
Structure of the interrupt status:
The interrupt status of module diagnostics provides details on a DP slave. Device-specific
diagnostics starts at byte y and has a maximum length of 20 bytes.
The following figure describes the structure and content of the bytes for a configured address
range of transfer memory.
.
.
.
.
.
.
2
4...35
00
11
10
01
=02
H
=04
H
=05
H
7 6 5 4 3 2 1 0
7 6 5 4 3 2 1 0
0 0 0 0 0 0
0 0
Bit
Bit
Diagnostics or interrupt data
Length of the device-specific diagnostics including
byte x (= maximum 20 bytes)
Code for device-specific diagnostics
01
H
: Code for diagnostic interrupt
02
H
: Code for process interrupt
Slot no.
O
n
l
y

d
i
a
g
n
o
s
t
i
c

i
n
t
e
r
r
u
p
t
Example for Byte y+2:
etc.
2nd address range:
1st address range:
CPU:
CPU
Number of the
Transfer memory
No further information about
diagnostic state
There is outgoing diagnosis
deviating error
Going diagnosis
lncoming diagnosis (there is at
least one error)
Byte y
Byte y+1
Byte y+2
Byte y+3
Byte y+4
Byte y+7
Byte z

Figure 10-7 Device-specific diagnostics
Structure of the interrupt data for a process interrupt (from byte y+4)
When a process interrupt occurs (code 02H for process interrupt in byte y+1), 4 bytes of
interrupt information after byte y+4 are transferred. These 4 bytes are transferred to the
intelligent slave using SFC 7 "DP_PRAL" or SFC 75 "SALRM" when the process interrupt for
the master was generated.
ITEM 3000
Structure of the interrupt data when a diagnostic interrupt is generated in response to an operating
status change by the intelligent slave (after byte y+4)
Byte y+1 contains the code for a diagnostic interrupt (01H). The diagnostic data contains the
16 bytes of status information from the CPU. The figure below shows the allocation of the
first four bytes of diagnostic data. The next 12 bytes are always 0.
The data in these bytes correspond to the contents of data record 0 of diagnostic data in
STEP 7 (in this case, not all bits are used).
0:
1:
0:
1:
7 6 5 4 3 2 1 0
7 6 5 4 3 2 1 0
7 6 5 4 3 2 1 0
7 6 5 4 3 2 1 0
0 0 0 0 0 0 0
0 0 1 1 1
0 0 0 0 0
0 0 0 0 0 0 0 0
0 0
0 0 0
Bit
Bit
Bit
Bit
Byte y+4
Byte y+5
Byte y+7
Byte y+6
RUN mode
Operating mode is STOP
ldentification for address ranges of the
transfer memory (constant)
Module OK
Module problem
Note: Byte y+8 to Byte y+19 are always 0.

Figure 10-8 Bytes y+4 to y+7 for a diagnostic interrupt (operating status change by intelligent slave)
ITEM 3000
Structure of the interrupt data when a diagnostic interrupt is generated by SFB 75 on the intelligent
slave (after byte y+4)
.
.
.
0
7 6 5 4 3 2 1 0
7 6 5 4 3 2 1 0
7 6 5 4 3 2 1 0
7 6 5 4 3 2 1 0
7 6 5 4 3 2 1 0
Bit
Bit
Bit
Bit
Bit
0: module ok
Detailed information can be found in the
STEP 7 online help or in the System
Software for S7-300/400 System and
Standard Functions reference manual,
Diagnostics Data section.
Note that these diagnostics data have a
fixed meaning in the S7 context.
Note the SFB75 Operating
Manual
01: Module fault
Byte y+7
Byte y+6
Byte y+5
Byte y+4
Byte y+19

Figure 10-9 Bytes y+4 to y+19 for the diagnostics interrupt (SFB75)
ITEM 3000
10.10 Diagnostics of PROFINET CPUs
10.10.1 Diagnostics options of PROFINET IO
Diagnostics Concept
PROFINET IO supports you with an integrated diagnostics concept.
The diagnostics concept of PROFINET IO is similar to that of PROFIBUS DP.
The diagnostics functions allow you
to react to an error (event-related diagnostics, evaluation of interrupts) or
to check the current status of the AS (status-related diagnostics).
Overview of diagnostics information
You have three options of obtaining diagnostics information:
1. Diagnostics using status LEDs
Diagnostics option Benefits For detailed information refer ...
LEDs on a PROFINET interface The LED displays indicate:
whether data are being sent or received
communication error.
this manual,
chapter: Status and Error Indicators:
CPUs with PROFINET interface for the
S7-300
2. Diagnostics using the STEP 7 and NCM PC configuration and engineering tool
Online diagnostics using a
PG/PC/HMI
This allows you to evaluate the current
status of your automation system.
the System Manual: PROFINET
System Description,
chapter: Support by STEP 7/NCM PC
Reporting system errors Diagnostic information is output in plain text
format to the PC / HMI.
System Description,
chapter: Support by STEP 7/NCM PC
Network diagnostics The SNMP protocol allows you to
determine the network infrastructure
this manual,
chapter: Network infrastructure
diagnostics (SNMP)
3. Diagnostics in the STEP 7 user program
Reading system status lists (SSLs) The SSLs will help you to track down an
error.
System Description,
chapter: Evaluation of Diagnostics in
the User Program
Reference manual: System software for
S7-300/400 System and Standard
Functions
Reading diagnostics data records You can obtain detailed information about
the type and source of faults by reading the
diagnostic data records.
System Description,
the User Program
Diagnostics interrupt Can be used to evaluate diagnostics data in
the user program.
System Description,
the User Program
ITEM 3000
Evaluation of diagnostics information
PROFINET IO supports a vendor-independent structure of data records with diagnostics
information. Diagnostics information is only generated for faulty channels.
The SSLs, SFB54 and SFB52 were enhanced in order to include information about the
status of the PROFINET IO systems and the diagnostics information for an S7 user program:
Call SFC51 (read system status lists) to read module status information of the PROFINET
IO system from SSL 0x0X91.
Call SFB52 (read data record) to read status-related diagnostics data records directly
from a faulty module.
Status-related diagnostics data represent error information, for example.
Call SFB54 (read additional interrupt info) in the corresponding error OB to read event-
related diagnostics data records from a module.
Event-related diagnostics data represent interrupt information of the error OBs, for
example.
Further Information
Further information about diagnostics and diagnostics data, on the structure of diagnostics
data records and on SSLs for PROFINET is available in:
the From PROFIBUS DP to PROFINET IO Programming Manual
the PROFINET System Description System Manual
the System Software for S7-300/400, System and Standard Functions Reference Manual
10.10.2 Maintenance
Enhanced maintenance concept
PROFINET devices support the comprehensive diagnostics and maintenance concept
according to the IEC 61158-6-10 standard.
In addition to "ok" and "faulty" information, the PROFINET components can also display
information for preventive maintenance when operating with STEP 7 V5.4 Servicepack 1 or
higher.
Preventive maintenance is displayed, for example, if the attenuation of a fiber optic cable
deteriorates.
ITEM 3000
Maintenance information
Maintenance information returns maintenance priorities. The concept distinguishes between
maintenance information based on two levels:

Maintenance information Symbol in STEP 7 Example
Maintenance requirement
(maintenance required):
Maintenance recommended
green wrench The attenuation on a fiber-optic
conductor is becoming too high.
Although operation is still possible, the
transmission link may fail completely in
the near future.
Maintenance request
(maintenance demanded):
Maintenance required
yellow wrench Failure of the synchronization master in
a synchronization domain for the IRT
operation of a PNIO system.
Further Information
Further information is available in:
the From PROFIBUS DP to PROFINET IO Programming Manual
in the PROFINET System Description System Manual.
in the CPU 31xC and CPU 31x, Manual, Technical Data, chapter Webserver
See also
Diagnostics options of PROFINET IO (Page 227)
ITEM 3000
ITEM 3000

11
11.1 Standards and approvals
Introduction
Contents of general technical data:
standards and test values satisfied by modules of the S7-300 automation system
test criteria of S7-300 modules.
CE Label
The S7-300 automation system satisfies requirements and safety-related objectives
according to EC Directives listed below, and conforms with the harmonized European
standards (EN) for programmable controllers announced in the Official Journals of the
European Community:
2006/95/EC "Electrical Equipment Designed for Use within Certain Voltage Limits" (Low-
Voltage Directive)
2004/108/EC "Electromagnetic Compatibility" (EMC Directive)
94/9/EC "Equipment and protective systems intended for use in potentially explosive
atmospheres" (Explosion Protection Directive)
The EC declaration of conformity is held on file available to competent authorities at:
Bereich Automatisierungs- und Antriebstechnik
Industry Sector AS RD ST PLC
Postfach 1963
D-92209 Amberg
UL approval
Underwriters Laboratories Inc. complying with
ITEM 3000
CSA approval
Canadian Standards Association to
C22.2 No. 142 (Process Control Equipment)
or
or
UL 1604 (Hazardous Location)
CSA-213 (Hazardous Location)
APPROVED for use in
Class I, Division 2, Group A, B, C, D Tx;
Class I, Zone 2, Group IIC Tx

Note
Currently valid approvals can be found on the rating plate of the relevant module.

FM approval
Factory Mutual Research (FM) to
Approval Standard Class Number 3611, 3600, 3810
APPROVED for use in Class I, Division 2, Group A, B, C, D Tx;
Class I, Zone 2, Group IIC Tx
HAZ. LOC.
ITEM 3000
ATEX approval
to EN 60079-15:2005 (Electrical apparatus for potentially explosive atmospheres; Type of
protection "n")
ll 3 G Ex nA ll T4..T6

WARNING
Personal injury and property damage can occur.
In potentially explosive environments, there is a risk of injury or damage if you disconnect
any connectors while the S7-300 is in operation.
Always isolate the S7-300 operated in such areas before you disconnect and connectors.

WARNING
Explosion hazard
If you replace components, compliance with Class I, DIV.2 could be compromised.

WARNING
This device is only appropriate for use in Class I, Div. 2, Group A, B, C, D, or in non-
hazardous areas.

Tick-mark for Australia
The S7-300 automation system satisfies requirements of standards to
AS/NZS 2064 (Class A).
IEC 61131
The S7-300 automation system satisfies requirements and criteria to
IEC 61131-2 (Programmable Controllers, Part 2: Equipment requirements and tests).
Marine approval
Classification societies:
ABS (American Bureau of Shipping)
BV (Bureau Veritas)
DNV (Det Norske Veritas)
GL (Germanischer Lloyd)
LRS (Lloyds Register of Shipping)
Class NK (Nippon Kaiji Kyokai)

ITEM 3000
Use in industrial environments
SIMATIC products are designed for industrial applications.
Table 11- 1 Use in industrial environments
Field of
application
Noise emission requirements Noise immunity requirements
Industry EN 61000-6-4: 2001 EN 61000-6-2: 2001
Use in residential areas
To operate an S7-300 in a residential area, it's RF emission must comply with Limit Value
Class B to EN 55011.
The following measures are recommended to ensure the interference complies with limit
value class B:
S7-300 installation in grounded switch cabinets / cubicles
Use of noise filters in the supply lines

WARNING

Personal injury and damage to property may occur.
In potentially explosive environments, there is a risk of injury or damage if you
disconnect any connectors while the S7-300 is in operation.
Always isolate the S7-300 operated in such areas before you disconnect and
connectors.

ITEM 3000
Definition
Electromagnetic compatibility (EMC) is the ability of an electrical installation to function
satisfactorily in its electromagnetic environment without interfering with that environment.
The S7-300 modules also satisfy requirements of EMC legislation for the European domestic
market. Compliance of the S7-300 system with specifications and directives on electric
design is prerequisite.
Pulseshaped disturbance
The table below shows the EMC compatibility of S7 modules in areas subject to pulse-
shaped disturbance.

Pulse-shaped disturbance Test voltage corresponds with degree
of severity
to IEC 61000-4-2
Air discharge: 8 kV
Contact discharge 4 kV
3
2
Burst pulses (high-speed
transient disturbance)
to IEC 61000-4-4.
2 kV (power supply lines)
2 kV (signal lines > 3 m)
1 kV (signal lines < 3 m)
3
3
High-energy single pulse (surge) to IEC 61000-4-5
External protective circuit required
(refer to S7-300 Automation System, Hardware and Installation, Chapter
"Lightning and overvoltage protection")
asymmetric coupling 2 kV (power supply lines)
DC with protective elements
2 kV (signal/ data line only > 3 m),
symmetric coupling 1 kV (power supply lines) DC with
protective elements
1 kV (signal/ data line only > 3 m),

3
Additional measures
When connecting an S7-300 system to the public network, always ensure compliance with
Limit Value Class B to EN 55022.
ITEM 3000
Sinusoidal disturbance
The table below shows the EMC compatibility of S7-300 modules in areas subject to
sinusoidal disturbance.

Sinusoidal disturbance Test values corresponds with
degree of severity
RF radiation
(electromagnetic fields)
to IEC 61000-4-3
10 V/m, with 80% amplitude modulation of
1 kHz in the 80 MHz to 1000 MHz range
10 V/m, with 50% pulse modulation at
900 MHz

3
RF conductance on cables
and cable shielding
to IEC 61000-4-6
Test voltage 10 V, with 80% amplitude
modulation of 1 kHz in the 9 MHz to 80 MHz
range

3
Emission of radio interference
Electromagnetic interference to EN 55011: Limit Class A, Group 1 (measured at a distance
of 10 m.)

Frequency Emitted interference
30 MHz to 230 MHz < 40 dB (V/m)Q
230 MHz to 1000 MHz < 47 dB (V/m)Q

Noise emission via AC mains to EN 55011: Limit value class A, Group 1.

Frequency Emitted interference
0.15 MHz to 0.5 MHz < 79 dB (V/m)Q
< 66 dB (V/m)M
0.5 MHz to 5 MHz < 73 dB (V/m)Q
< 60 dB (V/m)M
5 MHz to 30 MHz < 73 dB (V/m)Q
< 60 dB (V/m)M
ITEM 3000
11.3 Transportation and storage conditions for modules
11.3 Transportation and storage conditions for modules
Introduction
The shipping and storage conditions of S7-300 modules surpass requirements to IEC 61131-
2. The data below apply to modules shipped or put on shelf in their original packing.
The modules are compliant with climatic conditions to IEC 60721-3-3, Class 3K7 (storage),
and with IEC 60721-3-2, Class 2K4 (shipping.)
Mechanical conditions are compliant with IEC 60721-3-2, Class 2M2.
Shipping and storage conditions for modules

Type of condition Permissible range
Free fall (in shipping package) 1 m
Temperature - 40 C to + 70 C
Barometric pressure 1080 hPa to 660 hPa (corresponds with an altitude
of -1000 m to 3500 m)
Relative humidity 10% to 95%, no condensation
Sinusoidal oscillation to
IEC 60068-2-6
5 Hz to 9 Hz: 3.5 mm
9 Hz to 150 Hz: 9.8 m/s
2

Shock to IEC 60068-2-29 250 m/s
2
, 6 ms, 1000 shocks
ITEM 3000
11.4 Mechanical and climatic environmental conditions for S7-300 operation
Operating conditions
S7-300 systems are designed for stationary use in weather-proof locations. The operating
conditions surpass requirements to DIN IEC 60721-3-3.
Class 3M3 (mechanical requirements)
Class 3K3 (climatic requirements)
Use with additional measures
The S7-300 may not be used under the conditions outlined below without taking additional
measures:
at locations with a high degree of ionizing radiation
in aggressive environments caused, for example, by
the development of dust
corrosive vapors or gases
strong electric or magnetic fields
in installations requiring special monitoring, for example
elevators
electrical plants in potentially hazardous areas
An additional measure could be an installation of the S7-300 in a cabinet or housing.
Mechanical environmental conditions
The table below shows the mechanical environmental conditions in the form of sinusoidal
oscillations.

Frequency band Continuous Infrequently
10 Hz f 58 Hz 0.0375 mm amplitude 0.75 mm amplitude
58 Hz f 150 Hz 0.5 g constant acceleration 1 g constant acceleration
Reducing vibrations
If your S7-300 modules are exposed to severe shock or vibration, take appropriate measures
to reduce acceleration or the amplitude.
We recommend the installation of the S7-300 on damping materials (for example, rubber-
bonded-to-metal mounting.)
ITEM 3000
Test of mechanical environmental conditions
The table below provides important information with respect to the type and scope of the test
of ambient mechanical conditions.

Condition tested Test Standard Comment
Vibration Vibration test to IEC
60068-2-6 (sinusoidal)
Type of oscillation: Frequency sweeps with a rate of change of 1
octave/minute.
10 Hz f 58 Hz, constant amplitude 0.075 mm
58 Hz f 150 Hz, constant acceleration 1 g
Duration of oscillation: 10 frequency sweeps per axis at each of three
vertically aligned axes
Shock Shock, tested to
IEC 60068-2-27
Type of shock: half-sine
Severity of shock: 15 g peak value, 11 ms duration
Direction of shock: 3 shocks in each direction (+/-) at each of three
Continuous shock Shock, tested to
IEC 60068-2-29
Type of shock: Half-sine
Shock intensity: 25 g peak value, 6 ms duration
Shock direction: 1000 shocks in each direction (+/-) at each of three
Climatic environmental conditions
The S7-300 may be operated on following environmental conditions:

Environmental conditions Permissible range Comments
Temperature:
horizontal mounting position:
vertical mounting position:

0C to 60C
0C to 40C
-
Relative humidity 10 % to 95 % No condensation, corresponds to relative
humidity (RH) Class 2 to IEC 61131, Part 2
Barometric pressure 1080 hPa to 795 hPa Corresponds with an altitude of -1000 m to
2000 m
SO2: < 0.5 ppm;
RH < 60 %, no condensation
H2S: < 0.1 ppm;
RH < 60 %, no condensation
Test: 10 ppm; 4 days

Test: 1 ppm; 4 days
Concentration of pollutants
ISA-S71.04 severity level G1; G2; G3 -
ITEM 3000
11.5 Specification of dielectric tests, protection class, degree of protection, and rated voltage of S7-300
11.5 Specification of dielectric tests, protection class, degree of protection,
and rated voltage of S7-300
Test voltage
Proof of dielectric strength must be provided in the type test at a test voltage to IEC 61131-2:

Circuits with rated voltage Ve to other circuits
or ground.
Test voltage
< 50 V 500 VDC
< 150 V 2500 VDC
< 250 V 4000 VDC
Protection class
Protection class I to IEC 60536, i.e., a protective conductor must be connected to the
mounting rail!
Protection against the ingress of foreign matter and water
Degree of protection IP 20 to IEC 60529, i.e., protection against contact with standard
probes.
No protection against the ingress of water.
11.6 Rated voltages of S7-300
Rated operating voltages
The S7-300 modules operate at different rated voltages. The table shows the rated voltages
and corresponding tolerances.

Rated voltages Tolerance
24 VDC 20.4 VDC to 28.8 VDC
120 VAC 93 VAC to 132 VAC
230 VAC 187 VAC to 264 VAC
ITEM 3000

Appendix
A
A.1 General rules and regulations for S7-300 operation
Introduction
Seeing that an S7-300 can be used in many different ways, we can only describe the basic
rules for the electrical installation in this document.

WARNING
Always observe these basic rules for electrical installation in order to achieve a fully
functional S7-300 system.
EMERGENCY-OFF equipment
EMERGENCY-OFF equipment to IEC 204 (corresponds to VDE 113) must remain effective
in all operating modes of the plant or system.
System startup after specific events
The table below shows what you have to observe when restarting a plant after specific
events.
Table A- 1 System startup after specific events
If there is... then ...
Restart following a voltage dip or power failure, dangerous operating states must be excluded. If
necessary, force EMERGENCY-OFF.
Startup after releasing the EMERGENCY OFF
device,
uncontrolled or undefined startup operations must
be excluded.
ITEM 3000
Appendix
A.1 General rules and regulations for S7-300 operation
Mains voltage
The table below shows what you have to watch with respect to the mains voltage.
Table A- 2 Mains voltage
In the case of ... the ...
Stationary systems or systems without all-pole
mains disconnect switch
building installation must contain a mains
disconnect switch or a fuse.
Load power supplies, power supply modules set rated voltage range must correspond to local
mains voltage.
All circuits of the S7-300 rated mains voltage fluctuation / deviation must
lie within the permitted tolerance (refer to
Technical Data of S7-300 modules).
24 VDC power supply
The table below shows what you must observe for the 24 VDC power supply.
Table A- 3 Protection against external electrical interference
In the case of ... you need to observe ...
Buildings external lightning protection
24 VDC power supply cables, signal
cables
internal lightning protection
Install lightning protection
(e.g. lightning conductors).
24 VDC power supply safe (electrical) extra-low voltage isolation
Protection against external electrical interference
The table below shows how you must protect your system against electrical interference or
faults.
Table A- 4 Protection against external electrical interference
In the case of ... Make sure that ...
All plants or system in which the S7-300 is
installed
the plant or system is connected to a protective
conductor for the discharge of electromagnetic
interference.
Supply / signal / bus cables the cable routing and installation is correct.
Signal and bus cables a cable/conductor break does not cause
undefined plant or system states.
ITEM 3000
Appendix
A.2 Protection against electromagnetic interference
A.2.1 Basic Points for EMC-compliant system installations
Definition: EMC
EMC (electromagnetic compatibility) describes the capability of electrical equipment to
operate free of errors in a given electromagnetic environment, without being subject to
external influence and without influencing external devices in any way.
Introduction
Although your S7-300 and its components are developed for an industrial environment and
high electromagnetic compatibility, you should draw up an EMC installation plan before you
install the controller taking into consideration all possible sources of interference.
Possible interferences
Electromagnetic interference can influence a PLC in various ways:
Electromagnetic fields having a direct influence on the system
Interference coupling caused by bus signals (PROFIBUS DP etc.)
Interference coupling via the system wiring
Interference influencing the system via the power supply and/or protective ground
The figure below shows the likely paths of electromagnetic interference.
PS CPU SM SM SM SM SM SM SM SM
Electromagnetic fields
Bus signal Process wiring
Protective earth
Power supply module

ITEM 3000
Appendix
Coupling mechanisms
Depending on the emitting media (line or isolated) and the distance between the interference
source and the device, four different coupling mechanisms can influence the PLC.
Table A- 5 Coupling mechanisms
Coupling
mechanisms
Cause Typical interference sources
Electrical coupling Electrical or mechanical coupling
always occurs when two circuits
use one common cable.
Clocked devices (influence on the
network due to converters and third-
party power supply modules)
Starting motors
Potential differences on component
enclosures with common power supply
Static discharge
Capacitive coupling Capacitive or electrical coupling
occurs between conductors
connected to different potentials.
The coupling effect is
proportional to voltage change
over time.
Interference coupling due to parallel
routing of signal cables
Static discharge of the operator
Contactors
Inductive coupling Inductive or magnetic coupling
occurs between two current
circuit loops. Current flow in
magnetic fields induces
interference voltages. The
coupling effect is proportional to
current change over time.
Transformers, motors, arc welding
devices
Power supply cables routed in
parallelism
Switched cable current
High-frequency signal cable
Coils without suppression circuit
Radio frequency
coupling
Radio frequency coupling occurs
when an electromagnetic wave
reaches a conductor system. This
wave coupling induces currents
and voltages.
Neighboring transmitters (e.g. radio
phones)
Sparking (spark plugs, collectors of
electrical motors, welding devices)
ITEM 3000
Appendix
A.2.2 Five basic rules for securing EMC
A.2.2.1 1. Basic rule for ensuring EMC
If you comply with theses five basic rules ...
you can ensure EMC in many cases!
Rule 1: Large area grounding contact
When you install the automation equipment, make sure that the surfaces of inactive metal
parts are properly bonded to chassis ground.
Bond all passive metal parts to chassis ground, ensuring large area and low-impedance
contact.
When using screw connections on varnished or anodized metal parts, support contact
with special contact washers or remove the protective insulating finish on the points of
contact.
Wherever possible, avoid the use of aluminum parts for ground bonding. Aluminum
oxidizes very easily and is therefore less suitable for ground bonding.
Create a central connection between chassis ground and the equipotential
grounded/protective conductor system.
Rule 2: Proper cable routing
Always ensure proper cable routing when wiring your system.
Sort your wiring system into groups (high-voltage/power supply/signal/data cables).
Always route high-voltage, signal or data cables through separated ducts or in separate
bundles.
Install the signal and data cables as close as possible to grounded surfaces (e.g.
supporting beans, metal rails, steel cabinet walls ).
See also
Cable routing inside buildings (Page 255)
Outdoor routing of cables (Page 257)
ITEM 3000
Appendix
Rule 3: Fixing the cable shielding
Ensure proper fixation of the cable shielding.
Always use shielded data cable. Always connect both ends of the shielding to ground on
a large area.
Analog cables must always be shielded. For the transmission of low-amplitude signals it
might prove to be more efficient to have only one side of the shielding connected to
ground.
Directly behind the cable entry in the cabinet or enclosure, terminate the shielding on a
large area of the shielding/protective ground bar and fasten it with the help of a cable
clamp. Then, route the cable to the module; however, do not connect the shielding once
again to ground in this place.
Connections between the shielding/protective ground conductor bar and the
cabinet/enclosure must be of a low impedance.
Always install shielded data cables in metal/metallized connector housings.
See also
Cable shielding (Page 251)
Rule 4: Special EMC measures
Take special EMC measures for particular applications.
Connect anti-surge elements to all inductive devices not controlled by S7-300 modules.
For cabinet or cubicle lighting in the immediate range of your controller, use incandescent
lamps or interference suppressed fluorescent lamps.
See also
How to protect digital output modules against overvoltages caused by inductance (Page 270)
ITEM 3000
Appendix
Rule 5: Homogeneous reference potential
Create a homogeneous reference potential and ground electrical equipment whenever
possible (refer to the section on Equipotential bonding).
Route your equipotential conductors over a wide area if potential differences exist or are
expected between your system components.
Make sure you carefully direct your grounding measures. Grounding measures protect
the controller and its functions.
Form a star circuit to connect the equipment in your system and the cabinets containing
central/expansion units to the grounding/protective conductor system. This prevents the
formation of ground loops.
See also
Equipotential Bonding (Page 253)
A.2.3 EMC-compliant installation of automation systems
Introduction
Quite often it is the case that interference suppression measures are not taken until
corruption of user signals is detected after the controller is actually in operation.
Frequently, the causes of such interference are found in inadequate reference potentials as
a result of faulty installation. This section shows you how to avoid such errors.
Inactive metal parts
Inactive parts are referred to as electrically conductive elements, separated from active
elements by a basic insulating and only subject to electrical potential if an error occurs.
Installation and ground bonding of inactive metal parts
Bond all inactive metal parts to a large-surface ground when you install the S7-300. Proper
ground bonding ensures a homogeneous reference potential for the controller and reduces
the effect of interference coupling.
The ground connection establishes an electrically conductive interconnection of all inactive
parts. The sum of all interconnected inactive parts is referred to as chassis ground.
This chassis ground must never develop a hazardous potential even if a fault occurs.
Therefore, chassis ground must be connected to the protective conductor using cables with
an adequate conductor cross-section. To avoid ground loops, physically separate chassis
ground elements (cabinets, parts of the building construction or machine) must be bonded to
the protective conductor system in a star circuit.
ITEM 3000
Appendix
Observe the following for ground connection:
In the same way as with active elements, exercise meticulous care to interconnect
inactive metal elements.
Always make sure that you have a low-impedance interconnection between metal
elements (e.g. large and highly conductive contact surface).
The protective insulating finish on varnished or anodized metal elements must be pierced
or removed. Use special contact washers or completely remove the finish on the point of
contact.
Protect your connecting elements against corrosion (e.g. with a suitable grease).
Interconnect moving chassis ground elements (e.g. cabinet doors) with flexible ground
straps. Always use short ground straps with a large surface (the surface is decisive for
the diversion of high-frequency currents).
ITEM 3000
Appendix
A.2.4 Examples of an EMC-compliant installation: Cabinet configuration
Cabinet configuration
The figure below shows a cabinet installation with the measures described above (bonding
of inactive metal parts to chassis ground and connecting the cable shielding to ground). This
sample applies only to grounded operation. Note the points in the figure when you install
your system.
1 2 3
4
5
7
8
6

Figure A-1 Example of an EMC compatible cabinet installation
ITEM 3000
Appendix
Key to installation
The numbers in the following list refer to the numbers in the figure above.
Number Identifier Explanation
Ground straps If no large-surface metal-to-metal connections are
available, you must either interconnect inactive metal parts
(e.g. cabinet doors or mounting plates) or bond them to
chassis ground using ground straps. Use short ground
straps with a large surface.
Supporting bars Interconnect the supporting bars on a large area to the
cabinet walls (metal-to-metal connection).
Mounting the rail The mounting bar and rack must be interconnected with
large-area metal-to-metal connections.
Signal cables Connect the shielding of signal cables on a large area of
the protective conductor/additional shielding conductor bar
and fasten them with cable clamps.
Cable clamp The cable clamp must cover a large area of the shielding
braid and ensure good contact.
Shielding conductor bar Interconnect the shielding conductor bar on a large
surface with the supporting bars (metal-to-metal
connection). The cable shielding is terminated on the
conductor bar.
Protective ground bar Interconnect the protective conductor bar on a large
surface with the supporting bars (metal-to-metal
connection). Interconnect the grounding busbar with the
protective ground system, using a separate cable
(minimum cross-section 10
2
).
Cable to the protective
ground system (equipotential
ground)
Interconnect the cable on a large area with the protective
ground system (equipotential ground).
A.2.5 Examples of an EMC-compliant installation: Wall mounting
Wall mounting
When operating your S7 in a low-noise environment that conform with permitted ambient
conditions (see Appendix Ambient conditions), you can also mount your S7 in frames or to
the wall.
Interference coupling must be diverted to large metal surfaces. Therefore, always mount
standard profile/shielding/protective conductor rails on metal parts of the construction. Steel
sheet panels reference potential surfaces have been found especially suitable for wall-
mounting.
Provide a shielding conductor bar for connecting your cable shielding. This shielding
conductor bar can also be used as protective ground bar.
Reference for ambient conditions
For information on ambient conditions, refer to the S7-300 Automation System, Module data
Reference Manual.
ITEM 3000
Appendix
Please note
When mounting on varnished or anodized metal parts, use special contact washers or
remove the insulating layers.
Provide a large-surface and low-impedance metal-to-metal connection for fastening the
shielding/protective protective ground bar.
Always touch-protect live mains conductors.
The figure below shows an example of EMC compatible wall-mounting of an S7.

A.2.6 Cable shielding
Purpose of the shielding
A cable is shielded to attenuate the effects of magnetic, electrical and electromagnetic
interference on the cable.
Operating principle
Interference currents on cable shielding is diverted to ground conductive interconnection
between the shielding and the cabinet. To avoid interference as a result of these currents, it
is imperative to provide a low-impedance connection to the protective conductor.
ITEM 3000
Appendix
Suitable cables
Whenever possible, use cables equipped with a shielding braid. Shielding density should be
at least 80%. Avoid cables with film shielding, because the film can be easily damaged by
tensile or pressure stress, thus reducing its shielding effect.
Handling of the shielding
Note the following points on handling the shielding:
Always use metal clamps to mount shielding braid. The clamps must contact a large area
of the shielding and provide appropriate contact force.
Directly behind the cabinet's cable entry, terminate the shielding on a shielding bus.
Then, route the cable to the module; however, do not connect the shielding once again to
ground in this place.
In installations outside of cabinets (e.g. for wall-mounting) you can also terminate the
shielding on a cable duct.
The figure below shows some options for mounting shielded cables, using cable clamps.

See also
Terminating shielded cables on the shielding contact element (Page 119)
ITEM 3000
Appendix
A.2.7 Equipotential Bonding
Potential differences
Potential differences can occur between separate system elements. This can result in high
equipotential currents, e.g. if the cable shielding is terminated at both ends and grounded to
different system components.
The cause of potential difference can be differences in the power supplies.

WARNING
Cable shielding is not suitable for equipotential bonding. Always use the prescribed cables
(e.g. with a cross-section of 16 mm
2
). When installing MPI/DP networks, provide a sufficient
conductor cross-section. Otherwise, interface hardware might get damaged or even be
destroyed.

Equipotential bonding conductor
To reduce potential differences and ensure proper functioning of your electronic equipment,
you must install equipotential bonding conductors.
Note the following points on the use of equipotential bonding conductors:
The lower the impedance of an equipotential bonding conductor, the more effective is
equipotential bonding.
When shielded signal cables interconnect two system components and the shielding is
connected on both ends to ground/protective conductors, the impedance of the additional
equipotential bonding conductor must not exceed 10% of the shielding impedance.
Determine the cross-section of your equipotential bonding conductor on the basis of the
maximum equalizing current that will flow through it. The equipotential bonding conductor
cross-section that has proven best in practice is 16 mm
2
.
ITEM 3000
Appendix
Always use equipotential bonding conductors made of copper or galvanized steel. Always
connect the cables on a large surface to the equipotential conductor bar/protective
conductor and protect it against corrosion.
Route your equipotential bonding conductor to minimize the area between the
equipotential bonding conductor and signal lines as far as possible (see the figure below).

ITEM 3000
Appendix
A.2.8 Cable routing inside buildings
Introduction
Inside buildings (inside and outside cabinets), clearances must be maintained between
groups of different cables to achieve the necessary electromagnetic compatibility (EMC).
The table contains information on the general rules governing clearances to enable you to
choose the right cables.
How to read the table
To find out how to run two cables of different types, proceed as follows:
1. Look up the type of the first cable in column 1 (Cables for ...).
2. Look up the type of the second cable in the corresponding field in column 2 (and cables
for ...).
3. Note the applicable directives in column 3 (Run ...).
Table A- 6 Cable routing inside buildings
Cables for ... and cables for ... Run ...
Bus signals, shielded (PROFIBUS)
Data signals, shielded
(programming devices, operator
panels, printers, counter inputs,
etc.)
Analog signals, shielded
DC voltage ( 60 V), unshielded
Process signals ( 25 V), shielded
AC voltage ( 25 V), unshielded
Monitors (coaxial cable)
In common bundles or cable ducts
DC voltage (> 60 V and 400 V),
unshielded
AC voltage (> 25 V and 400 V),
unshielded
In separate bundles or cable ducts (no
minimum clearance necessary)
etc.)
DC and AC voltage (> 400 V),
unshielded
Inside cabinets:
Outside cabinets:
On separate cable racks with a
clearance of at least 10 cm
ITEM 3000
Appendix
Cables for ... and cables for ... Run ...
etc.)
unshielded
unshielded
unshielded
unshielded
unshielded
Inside cabinets:
Outside cabinets:
etc.)
Inside cabinets:
Outside cabinets:
unshielded
unshielded
ETHERNET In common bundles or cable ducts ETHERNET
Others In separate bundles or cable ducts with
a clearance of at least 50 cm
ITEM 3000
Appendix
A.2.9 Outdoor routing of cables
Rules for EMC-compliant cable routing
The same EMC-compliant rules apply both to indoor and outdoor routing of cables. The
following also applies:
Running cables on metal cable trays.
Electrical connection of the joints of cable trays/ducts.
Ground the cable carriers.
If necessary, provide adequate equipotential bonding between connected devices.
Take the necessary (internal and external) lightning protection and grounding measures
in as far as they are applicable to your particular application.
Rules for lightning protection outside buildings
Run your cables either:
in metal conduits grounded at both ends, or
in concrete cable ducts with continuous end-to-end armoring.
Overvoltage protection equipment
An individual appraisal of the entire plant is necessary before any lightning protection
measures are taken.
ITEM 3000
Appendix
A.3 Lightning and surge voltage protection
A.3.1 Overview
Introduction
One of the most common causes of failure is overvoltage caused by:
Atmospheric discharges
Electrostatic discharges
Switching overvoltages
The concepts or measures for protection from overvoltages is based on the lightning
protection zone concept.
The rules to be complied with for the transitions between the individual lightning protection
zones are presented here.

Note
This section can only provide you with the general guide on protecting the S7-300 from
overvoltage.
Complete protection from overvoltage is only guaranteed if the entire system design is based
on the lightning protection zone concept. Comprehensive consideration must be given to this
when planning construction of facilities.
We therefore recommend that you contact your Siemens representative or a company
specialized in lightning and overvoltage protection if you require more detailed information
about overvoltage.
In the following we refer to the overvoltage protection device using the normative
terminology, i.e., according to the degree of hazard expected, overvoltage suppressor for
pulse shape 8/20 s and lightning current suppressor for pulse shape 10/350 s.

Further references
The following information is based on the lightning protection zone concept described in IEC
IEC 62305-4 - "Protection against LEMP".
ITEM 3000
Appendix
A.3.2 Lightning protection zone concept
Principle of the lightning protection zone concept according to IEC 62305-4, DIN EN 62305-4, VDE
0185-305-4
The principle behind the lightning protection zone concept is the division of the volume to be
protected from overvoltages (e.g. a control room) into lightning protection zones based on
EMC considerations (see figure A-2).
The various lightning protection zones (LPZ: Lightning Protection Zone) are delimited
spatially as follows and not necessarily by physical boundaries, such as walls, floors, etc.

Lightning protection zones (LPZ: Lightning Protection Zone)
Outside areas of a building with risk of a direct strike Lightning protection zone LPZ 0A
Outside areas of a building that are not at risk of a direct strike Lightning protection zone LPZ 0B
Inside areas of a building that follow lightning protection zone
0B
Lightning protection zone LPZ 1
Inside areas of a building that normally represent separate
EMC-reducing rooms and are in lightning protection zone 1
Electrical equipment (with shielding properties) in lightning
protection zone 2
Effects of the Lightning Strike
Direct lightning strikes occur in lightning protection zone 0A. Effects of the lightning strike are
high-energy lightning currents and strong electromagnetic fields. Effects must be reduced
from one lightning protection zone to the next through suitable lightning current or surge
arresters/shielding measures.
Overvoltage
Electromagnetic fields of the lightning channel can be reduced with appropriate shielding
measures. Overvoltages due to inductions can be reduced to an non-dangerous level
starting in lightning protection zone 0B using surge arresters.
ITEM 3000
Appendix
Diagram of the lightning protection zones
The following schematic diagram shows the implementation of the lightning protection zone
concept for a building with outside lightning protection.
LEMP
LEMP
M
LEMP
LPZ 0
A
LPZ 0
B
LPZ 0
B
LPZ 1
LPZ 3
LPZ 2
LPZ 2
LPZ 1 SEMP
SEMP
LEMP LPZ
DEHN + SHNE
Lightning conducting
equipment
Ventilation
Suppression
Room shield
Terminal device
Foundation ground electrode
Steel armor
Low voltage
supply system
lnformation system
Lightning protection equipotential bonding
Lightning arrester (SPD type 1)
Local equipotential bonding of overvoltage
suppressor (SPD type 2, SPD type 3)
Lightning protection equipotential
bonding Lightning arrester
Local equipotential bonding
Surge arrester
Electromagnetic
lightning pulse
Electromagnetic
switching pulse
Lightning
protection zone
Source:

Figure A-2 Lightning protection zones of a building with outside lightning protection
Principle of interfaces between the lighting protection zones
Measures must be taken to reduce the peak current load and the magnetic fields at the
interfaces between the lightning protection zones.
Each zone-penetrating metallic/electrical system must be incorporated into the equipotential
bonding at the zone transition.

Note
Metal systems include channels, structural parts, pipelines (water, gas and heat), etc.
Electrical systems include power and IT cables and wires (e.g. line voltage, bus cable).

ITEM 3000
Appendix
A.3.3 Rules for the interface between the lightning protection zones 0 and 1
Rules for the interface 0
A
to 1 (lightning protection equipotential bonding)
For lightning protection equipotential bonding at the interface of lightning protection zone 0A
to 1, the following applies:
Use of surge arresters prevents introduction of lightning partial currents into buildings.
Creation of a local equipotential bonding at the transition of lightning protection zones,
with incorporation of metal supply systems (pipes, air ducts, cable ducts, cable channels
etc.) and electrical wire and cable systems.
Components for the lightning protection equipotential bonding
Table A- 7 Components for the lightning protection equipotential bonding
Seq.
No.
Cables for ... Connection at the
interface 0A to 1 with:
Item number
1 3-phase TN-C system DEHNventil
DV M TNC 255
DEHNventil
DV M TNC 255 FM *
951 300
951 305 *
2 3-phase TN-S system DEHNventil
DV M TNS 255
DEHNventil
DV M TNS 255 FM *
951 400
951 405 *
3 3-phase TT system DEHNventil
DV M TT 255
DEHNventil
DV M TT 255 FM *
951 310
951 315 *
4 AC TN-S system DEHNventil
DV M TN 255
DEHNventil
DV M TN 255 FM *
951 200
951 205 *
5 AC TT system DEHNventil
DV M TT 2P 255
DEHNventil
DV M TT 2P 255 FM *
951 110
951 115 *
6 Supply UN = 24 VDC: BLITZDUCTOR
XT, basic unit BXT BAS

BLITZDUCTOR
XT, Module BXT ML2 B 180

(IL = 1.2A) (2-wire)
920 300
920 211
7 Supply UN = 24 VDC: DEHNbloc
M, DB M 1 150
DEHNbloc
M, DB M 1 150 FM *
(2 ea. required)
961 110
961 115 *
8 MPI bus cable, RS485, RS
232 (V.24)
BLITZDUCTOR

BLITZDUCTOR

(2-wire)
920 300
920 211
ITEM 3000
Appendix
Seq.
No.
interface 0A to 1 with:
Item number
9
Inputs/outputs of digital
modules UN = 24 VDC:
BLITZDUCTOR

BLITZDUCTOR

(IL = 1.2A) (4-wire)
920 300
920 310
10 Inputs/outputs of digital
modules UN = 230 VAC:
DEHNbloc
M, DB M 1 255
DEHNbloc
M, DB M 1 255 *
(2 ea. required)
961 120
961 125 *
11 Inputs/outputs of analog
modules (e.g. 4-20 mA, 1-
10V)
BLITZDUCTOR

BLITZDUCTOR

(IL = 1.2A) (4-wire)
920 300
920 310
* Version: With remote indication contact
Components of the series BLITZDUCTOR
XT can be remotely monitored with the appropriate accessories. For further

information, refer to http://www.dehn.de
Direct order of components via:
DEHN+SHNE GMBH+CO.KG.
Hans-Dehn-Str. 1
D-92318 Neumarkt
Tel. +49 (0)9181-906-730
Rules for the interface 0
B
to 1 (strong electromagnetic coupling)
For overvoltage protection at the interface of lightning protection zone 0B to 1, the following
applies:
Use of power cables with peak current-capable cable shields (e.g., NYCWY) or twisted-
pair IT cables (e.g. A2Y(K)Y).
Laying cables and lines
In continuous, peak current-capable metal pipes that are grounded at both ends
In reinforced concrete channels in which the reinforcement is grounded at both ends
On closed metal cable racks that are grounded at the beginning and end.
Use of fiber optic cables without a metal shield if such a transmission is intended.
Additional measures
If the actions listed above cannot be performed, protection by means of surge arresters must
be provided. The following table A-8 contains surge arrestors that may be used to protect the
system.
Overvoltage protection of 24 VDC power supply
Always use the BLITZDUCTOR VT, type AD 24 V for the 24 VDC power supply module of
the S7-300. All other surge arrestors do not meet the tolerance range (20.4-28.8 V) of the
S7-300
ITEM 3000
Appendix
General information on use of surge arresters
If, taking into account the tolerance range, the voltages that occur in the system exceed the
specified maximum limits of the surge arresters used, surge arrestors of the next highest
rated voltage series are to be used.
Components for the overvoltage protection
Table A- 8 Components for the overvoltage protection
Seq.
No.
interface 0B to 1 with:
Item number
1 3-phase TN-C system DEHNguard
DG M TNC 275
DEHNguard
DG M TNC 275 FM *
952 300
952 305 *
2 3-phase TN-S system DEHNguard
DG M TNS 275
DEHNguard
DG M TNS 275 FM *
952 400
952 405 *
3 3-phase TT system DEHNguard
DG M TT 275
DEHNguard
DG M TT 275 FM *
952 310
952 315 *
4 AC TN-S system DEHNguard
DG M TN 275
DEHNguard
DG M TN 275 FM *
952 200
952 205 *
5 AC TT system DEHNguard
DG M TT 2P 275
DEHNguard
DG M TT 2P 275 FM *
952 110
952 115 *
VT, BVT AD 24 918 402

7 MPI/DP RS485 bus cable BLITZDUCTOR

BLITZDUCTOR
XT, Module BXT ML2 BD HFS 5

920 300
920 271
8 RS 232 (V.24) bus cable BLITZDUCTOR

BLITZDUCTOR
XT, Module BXT ML2 BE S 12

920 300
920 222
9 Industrial Ethernet DEHNpatch DPA M CLE RJ45B 48 929 121
DEHNconnect RK, DCO RK ME 24
(IL = 0.5 A)
919 921
11 Outputs of digital modules UN
= 24 VDC:
DEHNconnect RK, DCO RK D 5 24
(IL = 10.0 A)
919 986
DEHNguard
DG S 275
DEHNguard
DG S 275 FM *
N-PE arrester in the TT system
DEHNgap C S, DGP C S
DEHNgap C S, DGP C S FM *
952 070
952 090 *

952 030
952 035 *
10V)
(IL = 0.5 A)
919 921

Hans-Dehn-Str. 1
D-92318 Neumarkt
Tel. +49 (0)9181-906-730
ITEM 3000
Appendix
Rules for the interface 1 to 2 (strong electromagnetic coupling)
For overvoltage protection at the interface 1 to 2, the following applies:
In continuous, peak current-capable metal pipes that are grounded at both ends, or
In reinforced concrete channels in which the reinforcement is grounded at both ends,
or
Additional measures
be provided. The following table A-9 contains surge arrestors that may be used to protect the
system.
S7-300
ITEM 3000
Appendix
Seq.
No.
interface 1 to 2 with:
Item number
1 3-phase TN-C system DEHNguard
DG M TNC 275
DEHNguard
DG M TNC 275 FM *
952 300
952 305 *
2 3-phase TN-S system DEHNguard
DG M TNS 275
DEHNguard
DG M TNS 275 FM *
952 400
952 405 *
3 3-phase TT system DEHNguard
DG M TT 275
DEHNguard
DG M TT 275 FM *
952 310
952 315 *
4 AC TN-S system DEHNguard
DG M TN 275
DEHNguard
DG M TN 275 FM *
952 200
952 205 *
5 AC TT system DEHNguard
DG M TT 2P 275
DEHNguard
DG M TT 2P 275 FM *
952 110
952 115 *
VT, BVT AD 24 918 402

7 MPI/DP RS485 bus cable BLITZDUCTOR

BLITZDUCTOR

920 300
920 271

BLITZDUCTOR

920 300
920 222
(IL = 0.5 A)
919 921
= 24 VDC:
(IL = 10.0 A)
919 986
DEHNguard
DG S 275
DEHNguard
DG S 275 FM *
DEHNgap DGP C S
DEHNgap DGP C S FM *
952 070
952 090 *

952 030
952 035 *
10V)
(IL = 0.5 A)
919 921

Hans-Dehn-Str. 1
D-92318 Neumarkt
Tel. +49 (0)9181-906-730
ITEM 3000
Appendix
Rules for the interface 2 to 3 (electromagnetic coupling)
For overvoltage protection at the interface 2 to 3, the following applies:
In continuous, peak current-capable metal pipes that are grounded at both ends, or
In reinforced concrete channels in which the reinforcement is grounded at both ends,
or
Additional measures
be provided. The following table A-10 contains surge arrestors that may be used to protect
the system.
S7-300
ITEM 3000
Appendix
Seq.
no.
interface 2 to 3 with:
Item number
1 3-phase TN-S system, TT
system
DEHNrail
DR M 4P 255
DEHNrail
DR M 4P 255 FM *
(IL = 25.0 A)
953 400
953 405 *
2 3-phase TN-S system, TT
system
DEHNrail
DR M 2P 255
DEHNrail
DR M 2P 255 FM *
(IL = 25.0 A)
953 200
953 205 *
VT, BVT AD 24 918 402

4 MPI/DP RS 485 bus cable BLITZDUCTOR

BLITZDUCTOR

920 300
920 271

BLITZDUCTOR

920 300
920 222
(IL = 0.5 A)
919 921
= 24 VDC:
(IL = 10.0 A)
919 986
DEHNguard
DG S 275
DEHNguard
DG S 275 FM *
DEHNgap C S, DGP C S
DEHNgap C S, DGP C S FM *
952070
952 090 *

952 030
952 035 *
10V)
(IL = 0.5 A)
919 921

Hans-Dehn-Str. 1
D-92318 Neumarkt
Tel. +49 (0)9181-906-730
ITEM 3000
Appendix
A.3.6 Example: Surge protection circuit for networked S7-300 CPUs
The figure shows the required measures for the protection of two networked S7-300 against
lightning strikes and overvoltage.
2
1
9
4
3 5
10
7 6 3
5 5 6 7
10
9 9
8
9 9
9 9
8
4
lnputs and
outputs
Control cabinet Control cabinet
lnputs and
outputs
230/400VAC
230 VAC
SV CPU
MPl
SM
LPZ 0
A
LPZ 0
B
LPZ 3 LPZ 3 LPZ 3 LPZ 3
LPZ 2
LPZ 1
LPZ 3 LPZ 3
LPZ 2
SV
MPl
SM CPU
HV
UV
ITEM 3000
Appendix
Components of the application example
The following table explains the components of the application example:

Seq. No. Component Meaning
Combination arrester 230/400 VAC supply,
DEHNventil
DV M TNC 255
Part. no. 951 300
DEHNventil
DV M TNC 255 FM *
Part no. 951 305 *
DEHNventil
DV M TNS 255
Part no. 951 400
DEHNventil
DV M TNS 255 FM *
Part no. 951 405 *
Protection against indirect lighting strikes and
overvoltages at zone transition 0A-> 1 and 0A ->
2
Combination arrester, 230/400 VAC supply,
DEHNguard
DG M TNC 275
Part no. 952 300
DEHNguard
DG M TNC 275 FM *
Part no. 952 305 *
DEHNguard
DG M TNS 275
Part no. 952 400
DEHNguard
DG M TNS 275 FM *
Part No. 952 405 *
Protection against indirect lightning strikes and
overvoltages at the zone transition 1 -> 2
Surge arrester, 230 VAC supply,
DEHNrail DR M 2P 255
Art. Nr. 953 200
DEHNrail DR M 2P 255 FM *
Part no. 953 205 *
(IL = 25.0 A)
Surge arrester, BLITZDUCTOR
VT, BVT AD 24, 24 VDC

supply
Part no. 918 402
Surge arrester, RS 485 interface
BLITZDUCTOR
XT Basic unit BXT BAS,

Part no. 920 300
BLITZDUCTOR
XT Module BXT ML2 BD HFS 5,

Part no. 920 271
(2-wire)
Surge arrester, digital inputs of modules
Part no. 919 921
(IL = 0.5 A)
(2-wire)
Surge arrester, digital outputs of modules
Part no. 919 986
(IL = 10.0 A)
(2-wire)
ITEM 3000
Appendix
Seq. No. Component Meaning
Surge arrester, inputs/outputs of the modules
BLITZDUCTOR
XT Basic unit BXT BAS,

Part no. 920 300
BLITZDUCTOR
XT, Module BXT ML2 B 180,

Part no. 920 211
(IL = 1.2 A)
(2-wire)
Protection against indirect lighting strikes and
overvoltages at the zone transition 0A -> 1
2 EMC spring terminals for the basic unit of the
BLITZDUCTOR
XT
Part no. 920 395
Direct or indirect shield grounding
Protective equipotential bonding line 6 mm
2
Cu Protective equipotential bonding

Hans-Dehn-Str. 1
D-92318 Neumarkt
Tel. +49 (0)9181-906-730
A.3.7 How to protect digital output modules against overvoltages caused by inductance
Inductive overvoltage
Overvoltage occurs, for example, when inductance is deactivated. Examples are relay coils
and contactors.
Integrated surge arrester
S7-300 digital output modules are equipped with an integrated surge arrester.
Additional overvoltage protection
Inductive devices require additional surge arresters only in following cases:
If these can be switched off by additional contacts (e.g. relay contacts).
If the inductance cannot be controlled by SIMATIC modules, but the overvoltages that
occur can nevertheless have a negative effect on SIMATIC.

Note: Request information on relevant surge protection rating from the supplier of inductive
devices.
ITEM 3000
Appendix
Example: EMERGENCY-OFF relay contact in the output circuit
The figures illustrates an output circuit requiring additional overvoltage protectors.
CPU PS SM SM SM SM SM SM
Contact in output current circuit
lnductive reactance
needs a protective
circuit

Refer also to the rest of the information in this section.
Circuit for coils operated with DC voltage
The figure below shows DC-operated coils equipped with diode or Zener diode circuit.
+
-
+
-
with diode with Z diode

Diode/Zener diode circuits have the following characteristics:
Switching overvoltages can be avoided.
The Zener diode has a higher switch-off voltage capacity.
High switch-off delay (6 to 9 times higher than without protective circuit).
The Zener diode switches off faster than a diode circuit.
ITEM 3000
Appendix
A.4 Functional safety of electronic control equipment
Circuit for coils operated with AC voltage
The figure shows coils operated with AC voltage and varistor or RC circuit.
~
~
~
~
with varistor
with RC element

Properties of a protective circuit with varistor:
The amplitude of the opening surge is limited rather than attenuated.
The surge rise-ratio remains the same.
Short off-delay.

Properties of a protective circuit with RC elements:
Amplitude and steepness of the opening surge are reduced.
Short off-delay.
Reliability through basic measures
SIMATIC devices and components are extremely reliable thanks to extensive measures in
development and production.
The basic measures include:
Selection of high-quality components and strategic cooperation with high-performance
suppliers
Measures to prevent static discharge when handling MOS circuits
Checks and monitoring of the production processes using statistical methods and visual
inspections at various production stages
Heat endurance run at higher ambient temperature as monitoring run-in
Thorough computer-controlled final inspection and testing of all modules.
Statistical evaluation of all returned systems and components and analysis of service
requests to enable the immediate initiation of suitable corrective measures
Comprehensive computer-aided acquisition of the quality data in the production in order
to ensure all the adopted measures
ITEM 3000
Appendix
Increased safety measures
In all cases where the occurrence of failures can result in material damage or injury to
persons, special measures must be taken to enhance the safety of the entire installation. For
these there exist special plant-specific regulations that also have to be taken into
consideration by the owner-operator when structuring the control system.
For electronic control equipment with a safety function, the measures that have to be taken
to prevent or rectify faults are based on the risks involved in the installation. As of a certain
degree of hazard the basic measures mentioned above are no longer sufficient. The owner-
operator has to ensure that additional measures are realized for the plant, for example by
using SIMATIC S7-F fail-safe control systems.
Important note
The instructions in the operating manual must be followed exactly. Incorrect handling can
render measures intended to prevent dangerous faults ineffective, or generate additional
sources of danger.
Fail-safe systems in SIMATIC S7
Two fail-safe systems are available for the integration of the safety technology in the
SIMATIC S7 automation systems:
The fail-safe S7 Distributed Safety automation system
For the implementation of safety concepts in the field of machine and person
protection, for example EMERGENCY-OFF facilities for the operation of machine
tools/processing machines.
In the process industry, for example for carrying out protection functions for
instrumentation-and-control protective systems and burners.
The fail-safe and optionally fault-tolerant S7 F/FH Systems automation system for plants
for example in process technology and the oil industry.
Fail-safe and redundant system S7 F/FH system
To increase the availability of the automation system and thereby avoid process interruption
in the case of errors, it is possible to build in fail-safe systems as optionally redundant S7
F/FH systems. The increased availability is achieved through the redundancy of the following
components: Power supply, CPU module, communications and IO devices.
Attainable safety requirements
S7 Distributed Safety F systems and S7 F/FH systems can meet the following safety
requirements:
Safety Integrity Level SIL1 to SIL3 to IEC 61508
Categories 2 to 4 according to EN 954-1.
Reference
You can find further information in the Safety Engineering in SIMATIC S7 system description
(A5E00109528-05).
ITEM 3000
Appendix
ITEM 3000

Glossary
Accumulator
Accumulators represent CPU register and are used as buffer memory for download, transfer,
comparison, calculation and conversion operations.
Address
An address is the identifier of a specific address or address area. Examples: Input I 12.1;
Flag Word MW 25; Data Block DB 3.
Analog module
Analog modules convert process values (e.g. temperature) into digital values which can be
processing in the CPU, or they convert digital values into analog manipulated variables.
Application
User program
Application
An application is a program that runs directly on the MS-DOS / Windows operating system.
Applications on the programming device are for example STEP 7.
ASIC
ASIC is the acronym for Application Specific Integrated Circuits.
PROFINET ASICs are components with a wide range of functions for the development of
your own devices. They implement the requirements of the PROFINET standard in a circuit
and allow extremely high packing densities and performance.
Because PROFINET is an open standard, SIMATIC NET offers PROFINET ASICs for the
development of your old devices under the name ERTEC .
Backplane bus
The backplane bus is a serial data bus. It supplies power to the modules and is also used by
the modules to communicate with each other. Bus connectors interconnect the modules.
Backup memory
Backup memory ensures buffering of the memory areas of a CPU without backup battery. It
backs up a configurable number of timers, counters, flag bits, data bytes and retentive
timers, counters, flag bits and data bytes).
ITEM 3000
Glossary

Bit memory
Flag bits are part of the CPU's system memory. They store intermediate results of
calculations. They can be accessed in bit, word or dword operations.
See System memory
Bus
A bus is a communication medium connecting several nodes. Data can be transferred via
serial or parallel circuits, that is, via electrical conductors or fiber optic.
Bus segment
A bus segment is a self-contained section of a serial bus system. Bus segments are
interconnected by way of repeaters, for example, in PROFIBUS DP.
Central module
CPU
Changing IO devices during operation (changing partner ports)
Functionality of a PROFINET device. A PROFINET device that supports this function can
communicate during operation with changing communication partners at the same port.
Clock flag bits
flag bit which can be used to generate clock pulses in the user program (1 byte per flag bit).

Note
When operating with S7-300 CPUs, make sure that the byte of the clock memory bit is not
overwritten in the user program!

Coaxial cable
A coaxial cable, also known as "coax", is a metal conductor system used in HF transmission
circuits, for example, as radio and TV antenna cable, and in modern networks demanding
high data transmission rates. The inner conductor of a coaxial cable is sheathed by a tube-
like outer conductor. These conductors are separated by plastic insulation. In contrast to
other cables, this type of cable provides a high degree of immunity to interference and EMC
compatibility.
Code block
A SIMATIC S7 code block contains part of the STEP 7 user program. (in contrast to a DB:
this contains only data.)
ITEM 3000
Glossary

Code block
Global data
Code block
Nesting depth
Communication processor
Communication processors are modules used for point-to-point and bus topologies.
PROFINET CBA
Compress
The PG online function "Compress" is used to rearrange all valid blocks in CPU RAM in a
contiguous area of load memory, starting at the lowest address. This eliminates
fragmentation which occurs when blocks are deleted or edited.
Configuration
Assignment of modules to module racks/slots and (e.g. for signal modules) addresses.
Consistent data
Data which belongs together in terms of content and must not be separated is known as
consistent data.
For example, the values of analog modules must always be handled as a whole, that is, the
value of an analog module must not be corrupted as a result of read access at two different
points of time.
Counter
Counters are part of CPU system memory. The content of "Counter cells" can be modified by
STEP 7 instructions (for example, up/down count.)
See also System memory
CP
Communication processor
CPU
Central processing unit = CPU of the S7 automation system with a control and arithmetic
unit, memory, operating system, and interface for programming device.
ITEM 3000
Glossary

Cycle time
The cycle time represents the time a CPU requires for one execution of the user program.
Cyclic interrupt
Interrupt, cyclic interrupt
Data block
Data blocks (DB) are data areas in the user program which contain user data. There are
global data blocks which can be accessed by all code blocks, and instance data blocks
which are assigned to a specific FB call.
Data exchange broadcast
Direct data exchange
Data exchange traffic
Data set routing
Functionality of a module with several network connections. Modules that support this
function are able to pass on data of an engineering system (for example parameter data
generated by SIMATIC PDM) from a subnetwork such as Ethernet to a field device at the
PROFIBUS DP.
Data, static
Static data can only be used within a function block. These data are saved in an instance
data block that belongs to a function block. Data stored in an instance data block are
retained until the next function block call.
Data, temporary
Temporary data represent local data of a block. They are stored in the L-stack when the
block is executed. After the block has been processed, these data are no longer available.
Default Router
The default router is the router that is used when data must be forwarded to a partner
located within the same subnet.
In STEP 7, the default router is named Router. STEP 7 assigns the local IP address to the
default router.
ITEM 3000
Glossary

Detecting the network topology
topology.
Determinism
Real Time
Device Name
Before an IO device can be addressed by an IO controller, it must have a device name. In
PROFINET, this method was selected because it is simpler to work with names than with
complex IP addresses.
The assignment of a device name for a concrete IO device can be compared with setting the
PROFIBUS address of a DP slave.
When it ships, an IO device does not have a device name. An IO device can only be
addressed by an IO controller, for example for the transfer of project engineering data
(including the IP address) during startup or for user data exchange in cyclic operation, after it
has been assigned a device name with the PG/PC .
Device replacement without medium change
IO devices having this function can be replaced simply:
A removable medium (such as Micro Memory Card) with the stored device name is not
required.
The device name does not have to be assigned using the programming device.
The replaced IO device obtains the device name from the IO controller, not from the
removable medium or from the programming device. The IO controller uses the
configured topology and the neighboring relationships determined by the IO devices to
this purpose. The configured setpoint topology must agree with the actual topology.
In case of a part being replaced, an IO device already in operation has to be reset to the
state of delivery using "Reset to factory setting".
Modules capable of diagnostics operations report detected system errors to the CPU by
means of diagnostic interrupts.
Diagnostics
System diagnostics
ITEM 3000
Glossary

Diagnostics buffer
The diagnostics buffer represents a buffered memory area in the CPU. It stores diagnostic
events in the order of their occurrence.
Direct data exchange is a special communication relationship between PROFIBUS DP
nodes. Direct data exchange is characterized by PROFIBUS DP nodes that "listen" on the
bus and know which data a DP slave returns to its DP master.
DP master
A master which behaves in accordance with EN 50170, Part 3 is known as a DP master.
DP slave
A slave operated on PROFIBUS with PROFIBUS DP protocol and in accordance with EN
50170, Part 3 is referred to as DP slave.
DPV1
The designation DPV1 means extension of the functionality of the acyclical services (to
include new interrupts, for example) provided by the DP protocol. The DPV1 functionality has
been incorporated into IEC 61158/EN 50170, volume 2, PROFIBUS.
Electrically isolated
The reference potential of the control and on-load power circuits of isolated I/O modules is
electrically isolated; for example, by optocouplers, relay contact or transformer. Input/output
circuits may be grouped.
Electrical connection (equipotential bonding conductor) which eliminates potential difference
between electrical equipment and external conductive bodies by drawing potential to the
same or near the same level, in order to prevent disturbing or dangerous voltages between
these bodies.
Error display
One of the possible reactions of the operating system to a runtime error is to output an error
message. Further reactions: Error reaction in the user program, CPU in STOP.
Error handling via OB
After the operating system has detected a specific error (e.g. access error with STEP 7), it
calls a dedicated block (Error OB) that determines further CPU actions.
ITEM 3000
Glossary

Error response
Reaction to a runtime error. Reactions of the operating system: It sets the automation
system to STOP, indicates the error, or calls an OB in which the user can program a
reaction.
ERTEC
ASIC
Fast Ethernet
Fast Ethernet describes the standard with which data is transmitted at 100 Mbps. Fast
Ethernet uses the 100 Base-T standard.
FB
Function block
FC
Function
FEPROM
Memory Card (MC)
Flash EPROM
FEPROMs can retain data in the event of power loss, same as electrically erasable
EEPROMs. However, they can be erased within a considerably shorter time (FEPROM =
Flash Erasable Programmable Read Only Memory). They are used on Memory Cards.
Force
The Force function can be used to assign the variables of a user program or CPU (also:
inputs and outputs) constant values.
In this context, please note the limitations listed in the Overview of the test functions section
in the chapter entitled Test functions, Diagnostics and Troubleshooting in the S7-300
Installation manual.
Function
According to IEC 1131-3, a function (FC) is a code block without static data. A function
allows parameters to be passed in the user program. Functions are therefore suitable for
programming frequently occurring complex functions, e.g. calculations.
ITEM 3000
Glossary

Function block
According to IEC 1131-3, a function block (FB) is a code block with static data. A function
block allows parameters to be transferred to the user program. Function blocks are therefore
suitable for programming frequently recurring, complex functions, e.g., closed-loop controls,
mode selection.
Functional ground
Grounding which has the sole purpose of safeguarding the intended function of electrical
equipment. With functional grounding you short-circuit interference voltage which would
otherwise have an unacceptable impact on equipment.
GD circuit
A GD circuit comprises a number of CPUs sharing data by means of global data
communication, and is used as follows:
A CPU broadcasts a GD packet to the other CPUs.
A CPU sends and receives a GD packet from another CPU.
A GD circuit is identified by a GD circuit number.
GD element
A GD element is generated by assigning shared global data. It is identified by a unique
global data ID in the global data table.
GD packet
A GD packet can consist of one or several GD elements transmitted in a single message
frame.
Global data
Global data can be addressed from any code block (FC, FB, OB). In particular, this refers to
flag bits M, inputs I, outputs Q, timers, counters and data blocks DB. Global data can be
accessed via absolute or symbolic addressing.
Global data communication
Global data communication is a method of transferring global data between CPUs (without
CFBs).
Ground
The conductive earth whose electrical potential can be set equal to zero at any point.
Ground potential can be different from zero in the area of grounding electrodes. The term
reference ground is frequently used to describe this situation.
ITEM 3000
Glossary

Grounding means, to connect an electrically conductive component via an equipotential
grounding system to a grounding electrode (one or more conductive components with highly
conductive contact to earth).
Chassis ground is the totality of all the interconnected passive parts of a piece of equipment
on which dangerous fault-voltage cannot occur.
Ground
Ground
GSD file
The properties of a PROFINET device are described in a GSD file (General Station
Description) that contains all the information required for configuration.
As with PROFIBUS, you can link a PROFINET device in STEP 7 by means of a GSD file.
In PROFINET IO, the GSD file is in XML format. The structure of the GSD file conforms to
ISO 15734, which is the world-wide standard for device descriptions.
In PROFIBUS, the GSD file is in ASCII format.
HART
English: Highway Adressable Remote Transducer
Hub
Switch
ITEM 3000
Glossary

Industrial Ethernet
Fast Ethernet
Industrial Ethernet
Industrial Ethernet (formerly SINEC H1) is a technology that allows data to be transmitted
free of interference in an industrial environment.
Due to the openness of PROFINET, you can use standard Ethernet components. We
recommend, however, that you install PROFINET as Industrial Ethernet.
Instance data block
The STEP 7 user program assigns an automatically generated DB to every call of a function
block. The instance data block stores the values of input, output and in/out parameters, as
well as local block data.
Interface, MPI-compatible
MPI
Interrupt
The CPU's operating system distinguishes between different priority classes for user
program execution. These priority classes include interrupts, e.g. process interrupts. When
an interrupt is triggered, the operating system automatically calls an assigned OB. In this OB
the user can program the desired response (e.g. in an FB).
Interrupt, cyclic interrupt
A cyclic interrupt is generated periodically by the CPU in a configurable time pattern. A
corresponding OB will be processed.
Interrupt, delay
The delay interrupt belongs to one of the priority classes in SIMATIC S7 program
processing. It is generated on expiration of a time started in the user program. A
corresponding OB will be processed.
Interrupt, delay
Interrupt, delay
Interrupt, diagnostic
ITEM 3000
Glossary

Interrupt, process
Process interrupt
Interrupt, status
A status interrupt can be generated by a DPV1 slave or a PNIO device respectively. At the
DPV1 master or the PNIO controller respectively the receipt of the interrupt causes the OB
55 to be called up.
For detailed information on OB 56, refer to the Reference Manual System Software for S7-
300/400: System and Standard Functions.
Interrupt, time-of-day
The time-of-day interrupt belongs to one of the priority classes in
SIMATIC S7 program processing. It is generated at a specific date (or daily) and time-of-day
(e.g. 9:50 or hourly, or every minute). A corresponding OB will be processed.
Interrupt, update
An update interrupt can be generated by a DPV1 slave or a PNIO device respectively. At the
DPV1 master or the PNIO controller respectively the receipt of the interrupt causes the OB
56 to be called up.
Interrupt, vendor-specific
A vendor-specific interrupt can be generated by a DPV1 slave or a PNIO device respectively.
At the DPV1 master or the PNIO controller respectively the receipt of the interrupt causes
the OB 57 to be called up.
IP address
To allow a PROFINET device to be addressed as a node on Industrial Ethernet, this device
also requires an IP address that is unique within the network. The IP address is made up of
4 decimal numbers with a range of values from 0 through 255. The decimal numbers are
separated by a period.
The IP address is made up of
The address of the (subnet) network and
The address of the node (generally called the host or network node).
IRT
Isochronous Real Time communications
ITEM 3000
Glossary

Isochronous Real Time communications
Synchronized transmission procedure for the cyclic exchange of IO data between
PROFINET devices.
A reserved bandwidth within the send clock is available for the IRT / IO data. The reserved
bandwidth guarantees that the IRT data can also be transferred even during another high
network load (for example TCP/IP communication or additional real time communication) at
reserved, synchronized intervals.
LAN
Local Area Network; interconnects multiple computers within a company. The geographical
topology of a LAN is limited to the local premises and is only available to the operating
company or institution.
LLDP
topology.
Load memory
This memory contains objects generated by the programming device. Load memory is
implemented by means of a plug-in Micro Memory Card of different memory capacities. The
SIMATIC Micro Memory Card must be inserted to allow CPU operation.
Load power supply
Power supply to the signal / function modules and the process I/O connected to them.
Local data
Data, temporary
MAC address
Each PROFINET device is assigned a worldwide unique device identifier in the factory. This
6-byte long device identifier is the MAC address.
The MAC address is divided up as follows:
3 bytes vendor identifier and
3 bytes device identifier (consecutive number).
The MAC address is normally printed on the front of the device.
Example: 08-00-06-6B-80-C0
ITEM 3000
Glossary

Master
When a master has the token, it can send data to other nodes and request data from other
nodes (= active node).
Memory Card (MC)
Memory Cards are memory media for CPUs and CPs. They are implemented in the form of
RAM or FEPROM. An MC differs from a Micro Memory Card only in its dimensions (MC is
approximately the size of a credit card).
MIB
An MIB (Management Information Base) is a data base of a device. SNMP clients access
this data base in the device. The S7 device family supports, among others, the following
standard MIBs:
MIB
An MIB (Management Information Base) is a database of a device. SNMP clients access this
database in the device. The S7 device family supports, among others, the following standard
MIBs:
Micro Memory Card (MMC)
Micro Memory Cards are memory media for CPUs and CPs. Their only difference to the
Memory Card is the smaller size.
Module parameters
Module parameters are values which can be used to configure module behavior. A
distinction is made between static and dynamic module parameters.
MPI
The multipoint interface (MPI) represents the programming device interface of SIMATIC S7.
It enables multiple nodes (PGs, text-based displays, OPs) to be operated simultaneously by
one or more CPUs. Each node is identified by its unique (MPI) address.
MPI address
MPI
ITEM 3000
Glossary

NCM PC
SIMATIC NCM PC
Nesting depth
A block can be called from another by means of a block call. Nesting depth is referred to as
the number of simultaneously called code blocks.
Network
A network consists of one or more interconnected subnets with any number of nodes.
Several networks can exist alongside each other.
Network
A network is a larger communication system that allows data exchange between a large
number of nodes.
All the subnets together form a network.
Non-isolated
The reference potential of the control and on-load power circuits of non-isolated I/O modules
is electrically interconnected.
NTP
The Network Time Protocol (NTP) is a standard for synchronizing clocks in automation
systems via Industrial Ethernet. NTP uses the UDP wireless network protocol.
OB
Organization blocks
OB priority
The CPU operating system distinguishes between different priority classes, for example,
cyclic program execution, process interrupt controlled program processing. Each priority
class is assigned organization blocks (OBs) in which the S7 user can program a response.
The OBs are assigned different default priority classes. These determine the order in which
OBs are executed or interrupt each other when they appear simultaneously.
Operating state
SIMATIC S7 automation systems know the following operating states: STOP, START, RUN.
ITEM 3000
Glossary

Operating system
The CPU operating system organizes all the CPU functions and processes which are not
associated with a specific control task.
Organization blocks
Organization blocks (OBs) form the interface between the CPU operating system and the
user program. The order in which the user program is executed is defined in the organization
blocks.
Parameters
1. Variable of a STEP 7 code block
2. Variable for declaring module response (one or several per module). All modules have a
suitable basic factory setting which can be customized in STEP 7.
There are static and dynamic parameters.
Parameters, dynamic
Unlike static parameters, you can change dynamic module parameters during runtime by
calling an SFC in the user program, e.g. limit values of an analog signal input module.
Parameters, static
Unlike dynamic parameters, static parameters of modules cannot be changed by the user
program. You can only modify these parameters by editing your configuration in STEP 7, for
example, modification of the input delay parameters of a digital signal input module.
PC station
SIMATIC PC Station
PG
Programming device
PLC
Programmable logic controller
PLC
A PLC in the context of SIMATIC S7 --> is a programmable logic controller.
PNO
Technical committee that defines and further develops the PROFIBUS and PROFINET
standards with the following homepage: http://www.profinet.com.
ITEM 3000
Glossary

Prioritized startup
The term "prioritized startup" is used for the PROFINET functionality for accelerating the
startup of IO devices in a PROFINET IO system with RT and IRT communications.
The function reduces the time that the correspondingly configured IO devices require in
order to return to the cyclic user data exchange in the following cases:
After the power supply has returned
After a station has come back online
After IO devices have been activated
Priority class
The S7 CPU operating system provides up to 26 priority classes (or "Program execution
levels"). Specific OBs are assigned to these classes. The priority classes determine which
OBs interrupt other OBs. Multiple OBs of the same priority class do not interrupt each other.
In this case, they are executed sequentially.
Process image
The process image is part of CPU system memory. At the start of cyclic program execution,
the signal states at the input modules are written to the process image of the inputs. At the
end of cyclic program execution, the signal status of the process image of the outputs is
transferred to the output modules.
Process interrupt
A process interrupt is triggered by interrupt-triggering modules as a result of a specific event
in the process. The process interrupt is reported to the CPU. The assigned organization
block will be processed according to interrupt priority.
Process-Related Function
PROFINET Component
Product version
The product version identifies differences between products which have the same order
number. The product version is incremented when forward-compatible functions are
enhanced, after production-related modifications (use of new parts/components) and for bug
fixes.
PROFIBUS
Process Field Bus - European field bus standard.
PROFIBUS devicePROFIBUS device
ITEM 3000
Glossary

PROFINET devices
PROFIBUS devices
PROFIBUS devicePROFIBUS device
PROFINET devices
PROFIBUS devices
PROFIBUS DP
A PROFIBUS with the DP protocol that complies with EN 50170. DP stands for distributed
peripheral (IO) = fast, real-time, cyclic data exchange. From the perspective of the user
program, the distributed IOs are addressed in exactly the same way as the central IOs.
PROFINET
Within the framework of Totally Integrated Automation (TIA), PROFINET is the consistent
further development of:
ITEM 3000
Glossary

PROFIBUS DP, the established fieldbus and
Industrial Ethernet, the communication bus for the cell level.
The experience gained from both systems was and is being integrated in PROFINET.
PROFINET as an Ethernet-based automation standard from PROFIBUS International
(previously PROFIBUS Users Organization) defines a vendor-independent communication,
automation, and engineering model.
PROFINET ASIC
ASIC
PROFINET CBA
As part of PROFINET, PROFINET CBA (Component Based Automation) is an automation
concept that focuses on the following:
Implementation of modular applications
Machine - machine communication
PROFINET CBA lets you create distributed automation solutions, based on default
components and partial solutions. This concept meets the demand for a greater modularity in
the field of mechanical and systems engineering by extensive distribution of intelligent
processes.
With Component Based Automation you can implement complete technological modules as
standardized components that can be used in large systems.
You create the modular, intelligent components of the PROFINET CBA in an engineering
tool (which may differ according to the device manufacturer). Components that are formed
from SIMATIC devices are created with STEP 7, and are interconnected using the SIMATIC
iMAP tool.
PROFINET Component
A PROFINET component includes the entire data of the hardware configuration, the
parameters of the modules, and the corresponding user program. The PROFINET
component is made up as follows:
Technological Function
The (optional) technological (software) function includes the interface to other PROFINET
components in the form of interconnectable inputs and outputs.
Device
The device is the representation of the physical programmable controller or field device
including the I/O, sensors and actuators, mechanical parts, and the device firmware.
PROFINET device
PROFIBUS device
ITEM 3000
Glossary

PROFINET device
A PROFINET device always has at least one Industrial Ethernet port. A PROFINET device
can also have a PROFIBUS port, that is, as master with proxy functionality.
PROFINET IO
As part of PROFINET, PROFINET IO is a communication concept that is used to implement
modular, distributed applications.
PROFINET IO allows you to create automation solutions, which are familiar to you from
PROFIBUS.
PROFINET IO is implemented using the PROFINET standard for programmable controllers.
The STEP 7 engineering tool helps you to structure and configure an automation solution.
In STEP 7 you have the same application view, regardless of whether you are configuring
PROFINET devices or PROFIBUS devices. You will program your user program in the same
way for both PROFINET IO and PROFIBUS DP since you will use the extended blocks and
system status lists for PROFINET IO.
PROFINET IO controller
Device used to address the connected IO devices. This means that the IO controller
exchanges input and output signals with assigned field devices. The IO controller is often the
controller on which the automation program runs.
PROFINET IO device
A decentralized field device that is assigned to one of the IO controllers (e.g. remote IO,
valve terminals, frequency converters, switches)
PROFINET IO Supervisor
Programming device, PC or HMI device used for commissioning and diagnostics.
PROFINET IO system
PROFINET IO controller with assigned PROFINET IO devices.
Programmable logic controller
Programmable controllers (PLCs) are electronic controllers whose function is stored as a
program in the control unit. The structure and wiring of the device does not therefore depend
on the controller's function. A programmable logic controller is structured like a computer. It
consists of a CPU with memory, input/output modules and an internal bus system. The IOs
and the programming language are oriented to control engineering needs.
ITEM 3000
Glossary

Programming device
Programming devices are essentially compact and portable PCs which are suitable for
industrial applications. They are identified by a special hardware and software for
programmable logic controllers.
Proxy
PROFINET device
Proxy
The PROFINET device with proxy functionality is the substitute for a PROFIBUS device on
Ethernet. The proxy functionality allows a PROFIBUS device to communicate not only with
its master but also with all nodes on PROFINET.
With PROFINET, existing PROFIBUS systems can be integrated into the PROFINET
communication with the aid of an IE/PB link, for example. The IE/PB link then handles
communication via PROFINET on behalf of the PROFIBUS components.
In this way, you can link both DPV0 and DPV1 slaves to PROFINET.
Proxy
Proxy
Proxy functionality
Proxy
RAM
Memory Card (MC)
RAM
RAM (Random Access Memory) is a semiconductor read/write memory.
Real Time
Real time means that a system processes external events within a defined time.
Determinism means that a system reacts in a predictable (deterministic) manner.
In industrial networks, both these requirements are important. PROFINET meets these
requirements. PROFINET is implemented as a deterministic real-time network as follows:
ITEM 3000
Glossary

The transfer of time-critical data between different stations over a network within a
defined interval is guaranteed.
To this end, PROFINET has an optimized communication channel for real-time
communication: real time (RT): Real Time (RT).
An exact prediction of the time at which the data transfer takes place is possible.
It is guaranteed that problem-free communication using other standard protocols, for
example industrial communication for a programming device / PC, can take place within
the same network.
Real Time
Real Time
Reduction factor
The reduction rate determines the send/receive frequency for GD packets on the basis of the
CPU cycle.
Reference ground
Ground
Reference potential
Voltages of participating circuits are referenced to this potential when they are viewed and/or
measured.
Restart
On CPU start-up (e.g. after is switched from STOP to RUN mode via selector switch or with
POWER ON), OB100 (restart) is initially executed, prior to cyclic program execution (OB1).
On restart, the input process image is read in and the STEP 7 user program is executed,
starting at the first instruction in OB1.
Retentive memory
A memory area is considered retentive if its contents are retained even after a power loss
and transitions from STOP to RUN. The non-retentive area of memory flag bits, timers and
counters is reset following a power failure and a transition from the STOP mode to the RUN
mode.
Retentive can be the:
Bit memory
S7 timers
S7 counters
Data areas
ITEM 3000
Glossary

Router
A router interconnects two subnets. A router works in a similar way to a switch. You can also
enable/disable nodes for communication at the router. The communication nodes on various
sides of a router can only communicate with one another if you have explicitly enabled
communication between these nodes via the router. Real-time data cannot be exchanged
beyond subnet boundaries.
Router
Default Router
Router
Switch
RT
Real Time
Runtime error
Errors occurred in the PLC (that is, not in the process itself) during user program execution.
Scan cycle check point
The cycle control point is the section of the CPU program processing in which the process
image is updated.
Segment
Bus segment
Send clock
Period between two successive intervals for IRT or RT communication. The send clock is the
shortest possible transmit interval for exchanging data. The calculated update times are
multiples of the send clock.
The minimum possible update time thus depends on the minimum send clock of the IO
controller that can be set.
If both the IO controller and the IO device support a send clock of 250 s, you can achieve a
minimum update time of 250 s.
It is also possible to operate IO devices that only support a send clock of 1 ms on an IO
controller that works with a send clock of 250 s. The minimum update time for the IO
devices concerned is then at least 1 ms, however.
SFB
System function block
ITEM 3000
Glossary

SFC
System function
Signal module
Signal modules (SM) form the interface between the process and the PLC. There are digital
input and output modules (input/output module, digital) and analog input and output
modules. (Input/output module, analog)
SIMATIC
The term denotes Siemens AG products and systems for industrial automation.
SIMATIC NCM PC
SIMATIC NCM PC is a version of STEP 7 tailored to PC configuration. For PC stations, it
offers the full range of functions of STEP 7.
SIMATIC NCM PC is the central tool with which you configure the communication services
for your PC station. The configuration data generated with this tool must be downloaded to
the PC station or exported. This makes the PC station ready for communication.
SIMATIC NET
Siemens Industrial Communication division for Networks and Network Components.
SIMATIC PC Station
A "PC station" is a PC with communication modules and software components within a
SIMATIC automation solution.
Slave
A slave can only exchange data after being requested to do so by the master.
SNMP
SNMP (Simple Network Management Protocol) makes use of the connectionless UDP
transport protocol. It consists of two network components, similar to the client/server model.
The SNMP manager monitors the network nodes and the SNMP agents collect the various
network-specific information in the individual network nodes and stores it in a structured form
in the MIB (Management Information Base). This information allows a network management
system to run detailed network diagnostics.
STARTUP
A START-UP routine is executed at the transition from STOP to RUN mode. Can be
triggered by means of the mode selector switch, or after power on, or by an operator action
on the programming device. An S7-300 performs a restart.
ITEM 3000
Glossary

STEP 7
STEP 7 is an engineering system and contains programming software for the creation of
user programs for SIMATIC S7 controllers.
Subnet mask
The bits set in the subnet mask decides the part of the IP address that contains the address
of the subnet/network.
In general:
The network address is obtained by an AND operation on the IP address and subnet
mask.
The node address is obtained by an AND NOT operation on the IP address and subnet
mask.
Subnetwork
All the devices connected by switches are located in the same network - a subnet. All the
devices in a subnet can communicate directly with each other.
All devices in the same subnet have the same subnet mask.
A subnet is physically restricted by a router.
Substitute value
Substitute values are configurable values which output modules transfer to the process when
the CPU switches to STOP mode.
In the event of an I/O access error, a substitute value can be written to the accumulator
instead of the input value which could not be read (SFC 44).
Switch
PROFIBUS is based on a bus topology. Communication nodes are connected by a passive
cable - the bus.
In contrast, Industrial Ethernet is made up of point-to-point links: Each communication node
is connected directly to one other communication node.
If a communication node needs to be connected to several other communication nodes, this
communication node is connected to the port of an active network component- a switch.
Other communications nodes (including switches) can then be connected to the other ports
of the switch. The connection between a communication node and the switch remains a
point-to-point link.
The task of a switch is therefore to regenerate and distribute received signals. The switch
"learns" the Ethernet address(es) of a connected PROFINET device or other switches and
forwards only the signals intended for the connected PROFINET device or connected switch.
A switch has a certain number of ports). At each port, connect a maximum of one
PROFINET device or a further switch.
ITEM 3000
Glossary

System diagnostics
System diagnostics refers to the detection, evaluation, and signaling of errors that occur
within the PLC, for example programming errors or module failures. System errors can be
indicated by LEDs or in STEP 7.
System function
A system function (SFC) is a function that is integrated in the operating system of the CPU
and can be called in the STEP 7 user program, when necessary.
System function block
A system function block (SFB) is a function block integrated in the CPU operating system
that can be called in the STEP 7 user program when required.
System memory
System memory is an integrated RAM memory in the CPU. System memory contains the
address areas (e.g. timers, counters, flag bits) and data areas that are required internally by
the operating system (for example, communication buffers).
System memory
Counter
System memory
Timers
System status list
The system status list contains data that describes the current status of a SIMATIC S7. You
can always use this list to obtain an overview of the following points:
Status of the SIMATIC S7 extension.
The current CPU configuration and configurable signal modules.
The current states and processes in the CPU and in configurable signal modules.
Terminating resistor
The terminating resistor is used to avoid reflections on data links.
Timer
Timers
ITEM 3000
Glossary

Timers
Timers are part of CPU system memory. The content of timer cells is automatically updated
by the operating system, asynchronously to the user program. STEP 7 instructions are used
to define the precise function of the timer cell (for example, on-delay) and to initiate their
execution (for example, start).
TOD interrupt
Interrupt, time-of-day
Token
Allows access to the bus for a limited time.
Tool changer
Changing IO devices during operation (changing partner ports)
Topology
Network structure. Commonly used structures:
Bus topology
Ring topology
Star topology
Tree topology
Transmission rate
Data transfer rate (in bps)
Twisted-pair
Fast Ethernet over twisted-pair cables is based on the IEEE 802.3u standard (100 base TX).
The transmission medium is a shielded 2x2 twisted-pair cable with an impedance of 100
Ohm (AWG 22). The transmission characteristics of this cable must meet the requirements
of category 5 (see glossary).
The maximum length of the connection between the terminal and the network component
must not exceed 100 m. The cables are wired according to the 100 base TX standard using
the RJ45 connector system.
Ungrounded
Having no direct electrical connection to ground
ITEM 3000
Glossary

Update time
Within this time interval an IO device/IO controller in the PROFINET IO system is supplied
with new data by the IO controller/IO device. The send cycle can be configured separately
for each IO device and determines the interval at which data are sent from the IO controller
to the IO device (outputs) as well as data from the IO device to the IO controller (inputs).
User program
In SIMATIC, we distinguish between the operating systems of the CPU and user programs.
The user program contains all instructions, declarations and data for signal processing
required to control a plant or a process. It is assigned to a programmable module (for
example CPU, FM) and can be structured in smaller units (blocks).
Varistor
Voltage-dependent resistor
WAN
Wide Area Network. Network beyond LAN boundaries which allows, for example,
intercontinental communication. Legal rights do not belong to the user but to the provider of
the communication network.
Work memory
The working memory is integrated in the CPU and cannot be extended. It is used to run the
code and process user program data. Programs only run in the working memory and system
memory.
ITEM 3000
Glossary

ITEM 3000

Index
(
(PtP, 53
A
Accessories, 92
for wiring, 101
Actuator/Sensor Interface, 53, 90
Addresses
Analog module, 128
Digital module, 126
Technological functions, 129
Addressing
Addressing PROFINET IO, 132
On PROFIBUS DP, 131
slotspecific, 123
Analog module
Addresses, 128
Application
in industrial environments, 232
in residential areas, 232
Application View, 76, 81
Approval
CE, 229
CSA, 230
FM, 230
Marine, 231
UL, 229
Approvals
Standards, 229
Arrangement
of the modules, 31
ASI, 53
Assembly dimensions
of the modules, 28
Asynchronous error, 194
Automation concept, 53, 76
B
Back up
Basic knowledge required, 3
Burst pulses, 233
Bus cables
Installation rules, 64
Bus connector, 65
Connecting the bus cable, 120
removing, 121
Setting the terminating resistor, 121
Bus connector
Connecting to module, 121
Bus connectors
plugging, 97
Bus termination, 69
Bus topology
Detection, 197
C
Cabinet
Dimensions, 36
power loss dissipated, 38
Selecting and dimensioning, 35
Types, 37
Cable lengths
longer, 62
maximum, 66
MPI subnet, 62
PROFIBUS subnet, 62
Stub cables, 63
Cable routing inside buildings, 253
Cable shielding, 249
Ground, 46
Cables
Preparing, 108
shield, 249
Category, 271
CE
Approval, 229
Central unit, 26
DP interface, 60, 61
MPI interface, 58
PROFIBUS DP Interface, 60
ITEM 3000
Index

Commissioning
Check list, 136
CPU 31x-2 DP as a DP master, 157
CPU 31x-2 DP as a DP slave, 161, 212
CPU 31xC-2 DP as a DP master, 157
CPU 31xC-2 DP as a DP slave, 161
Hardware Requirements, 133
Procedure with the hardware, 134
Procedure with the software, 135
PROFINET IO, 168
Reaction to errors, 136
Software requirement, 135
Commissioning the CPU as DP master
Constant Bus Cycle Time, 159
Isochronous Updating of Process Image
Partitions, 159
Sync/Freeze, 160
Communications concept, 53, 76
Component based Automation, 53
Component Based Automation, 76
Connecting
PG, 145, 146, 147, 148, 150
Sensors and actuators, 107
Spring terminals, 107
Connecting actuators, 107
Connecting cables
for interface modules, 32
Connecting sensors, 107
Consistency, 131, 132
Continuous shock, 237
Controlling
of tags, 192
CP 343-1, 79
CP 443-1 Advanced, 79
CPU
CPU memory reset, 141, 144
Wiring, 105
CPU 313C-2 DP
commissioning as a DP master, 158
commissioning as DP-Slave, 162
CPU 314C-2 DP
CPU 315-2 DP
CPU 317-2 DP
CPU memory reset, 141
CPU activities, 143
MPI parameters, 143
CSA
Approval, 230
D
Data consistency, 131, 132
Default addressing, 123
Definition
Electromagnetic compatibility, 233
Degree of protection IP 20, 238
Delivery state of the CPU
Lamp images during reset, 183
Properties, delivery state, 182
Restore delivery state, 182
Device-specific diagnostics, 222
Diagnostic address, 209, 214
with direct data exchange, 211
Diagnostic buffer, 196
Diagnostics
configured address range, 220
device-specific, 222
in DP Master mode, 208
with Diagnosing Hardware, 198
with LEDs, 201
with system functions, 197
Digital module
Addresses, 126
Digital output module
Replacement fuse, 187
Replacing fuses, 188
Direct data exchange, 166
DP interface
Clock synchronization, 60, 61
DP master, 73
Class 2, 73
Interrupts, 216
DP master system, 73
DP slave, 73
E
Electrostatic discharge, 233
EMC, 233
Definition, 241
Fault-free installation, 245
Emission of radio interference, 234
Engineering tool, 76
Equipotential bonding - lightning protection, 259, 260
Equipotential bonding conductor, 46
Error
Asynchronous, 194
Synchronous, 194
Error-free operation of the S7-300, 239
Event detection, 210, 215
Expansion module, 26
ITEM 3000
Index

F
F system, 271
Fail-safe system, 271
Fieldbus integration, 75
FM
Approval, 230
Forcing, 193
Front connector coding
Removing from front connector, 186
Removing from module, 185
Front connectors
encoding, 110
plugging, 110
Preparing, 108
Wiring, 102, 109
Full assembly, 34
G
General technical data, 229
Ground bonding for EMC-compliant installation, 245
Grounding
Grounding, 48
Grounding concept, 43
GSD file, 79
H
Highest MPI address, 55
Highest PROFIBUS DP address, 55
HMI, 73
I
I&M data, 190
Identification, 207
Identification and maintenance data, 190
Identification code for Australia, 231
Identification data, 190
Identifier-related diagnostic data, 220
IE/PB link, 76
IEC 61131, 231
Industrial Ethernet, 53, 73
Inscription labels, 92
installation
arranging modules, 31
horizontal, 27
vertical, 27
Installation
in cabinets, 35
of the modules, 97
ungrounded reference potential, 42
Installation
grounded reference potential, 41
Installing
of the modules, 185
Installing EMC plants, 241
Insulation test, 238
Interconnection, 75
Interface module
Connecting cables, 32, 172
Interfaces
MPI interface, 57
MPI interface:Connectable devices, 57
PROFIBUS DP interface, 59
PROFIBUS DP interface:Operating modes with two
DP interfaces, 59
PtP interface, 90
Interfaces PROFIBUS DP interface
Connectable devices, 60
Interferences
electromagnetic, 241
Interrupt
on the DP master, 216
IO controller, 73
IO device, 73
IO supervisor, 73
IO system, 73
L
Labeling strips
Assignment to modules, 116
inserting, 116
Lightning protection
S7-300, 256
Lightning protection equipotential bonding, 259, 260
Lightning protection zone concept, 257
Lightning protector, 262, 264
Load circuit
Ground, 46
Load current
determining, 50
Load power supply
from PS 307, 51
Load voltage
Connecting the reference potential, 47
Local equipotential bonding, 262, 264
ITEM 3000
Index

M
Mains
grounded, 39
Mains voltage
Selecting the mains voltage, 104
Mains voltage selector switch, 104
Maintenance data, 190
Manufacturer ID, 219
Marine
Approval, 231
Material
Structure, 92
Mechanical environmental conditions, 236
MIB, 199
Micro Memory Card, 138
Formatting, 144
Inserting and removing when power is switched
off, 139
Inserting/removing, 139
Module
Arrangement, 31, 33
Assembly dimensions, 28
installing, 185
Installing, 97
isolated, 43
labeling, 116
non-isolated, 43
removing, 184
replacing, 183
Replacing, 96
Start addresses, 123
Module replacement
Reaction of the S7-300, 186
Rules, 96, 183
Monitoring
of tags, 192
Monitoring and modifying tags
Creating a tag table, 152
establishing a connection to the CPU, 154
Modifying outputs in CPU STOP mode, 155
modifying tags, 153
Monitor tag, 152
opening the VAT, 154
Saving the variable table, 154
setting the trigger points, 153
Mounting rail
connecting the protective conductor, 103
Fixing screws, 94
Ground conductor, 93
Length, 28
mounting holes, 94
Preparing, 93
MPI, 52
Maximum number of nodes, 55
Maximum transmission rate, 54
MPI address
default, 55
highest, 55
Recommendation, 56
Rules, 55
MPI and PROFIBUS subnet, 71
MPI interface, 57
Clock synchronization, 58
MPI subnet
Example, 67
maximum distances, 68
Segment, 62
Terminating resistor, 69
Multi-Point Interface, 52
O
Open components, 91
Operating system
Back up, 176
Outdoor routing of cables, 255
Overvoltage protection
S7-300, 256
P
PC, 79
PG
Access to remote networks, 88
Connecting, 145, 146, 147, 148, 150
ungrounded configuration, 150
Point-to-point connection, 53
Potential differences, 46
Power on
initial, 140
Requirements, 140
Power supply module
Selecting the mains voltage, 104
PROFIBUS, 52, 73, 76
PROFIBUS address
Recommendation, 56
PROFIBUS cable
Properties, 64
PROFIBUS device, 72
ITEM 3000
Index

PROFIBUS DP
Commissioning, 156
Direct data exchange, 166
DP address ranges, 156
DP diagnostics addresses, 157
Maximum number of nodes, 55
Maximum transmission rate, 54
PROFIBUS DP address
default, 55
highest, 55
Rules, 55
PROFIBUS DP Interface, 59
PROFIBUS DP Interface
Clock synchronization, 60
PROFIBUS subnet
Cable lengths, 62
Example, 70
PROFIBUS terminator, 69
PROFINET, 53, 73, 76
CBA, 53
Commissioning, 168, 196
Commissioning via MPI/DP, 169
Commissioning via PN interface, 169
Configuring, 170
Environment, 72
Implementation, 76
IO, 53
Send clock, 81
Standard, 76
Update times, 80
Update times of CPU 319-3 PN/DP, 81
PROFINET CBA, 53, 76
PROFINET devices, 72
PROFINET diagnostics
Evaluation, 226
Information, 225
Maintenance, 226
Maintenance information, 227
PROFINET IO, 53, 78
Commissioning, 168
Programming, 76
Protect digital output modules from inductive
surge, 268
Protection class, 238
Protective conductor
Connecting to the mounting rail, 93
Connecting to the rail, 103
Protective grounding
measures, 45
Protective measures
for the overall system, 40
Proxy, 76
Proxy functionality, 76
PtP interface, 90
Pulse-shaped disturbance, 233
Purpose of this documentation, 3
R
Redundancy, 271
Redundant system, 271
Reference potential
grounded, 41
ungrounded, 42
Removing
of the modules, 184
Replacing
Fuses, 188
Module, 96, 183
Replacing fuses
Digital output module, 188
Routing, 88
Routing an equipotential bonding conductor, 251
RS 485
Bus connector, 65
RS 485 repeater, 65
Rules and regulations for error-free operation, 239
S
S7 Distributed Safety, 271
S7 F/FH Systems, 271
S7-300
initial power on, 140
Lightning protection, 256
Overvoltage protection, 256
S7-300 configuration
Components, 22
Example, 21
Safety integrity level, 271
Scope of the manual, 3
Scope of this documentation, 11
Segment, 54
in the MPI subnet, 62
on the PROFIBUS subnet, 62
Service data
Application, 189
Procedure, 189
SF
LED, evaluation, 202
SFB52, 197
SFC 103, 65, 197
SFC 13, 197
SFC 51, 197
SFC 6, 197
ITEM 3000
Index

SFC14, 131, 132
SFC15, 131, 132
Shielding contact element, 29, 117
installing, 118
Terminating cables, 119
Shielding terminals, 29
Shipping conditions, 235
Shock, 237
SIL, 271
SIMATIC iMap, 76
SIMATIC Manager, 151
start, 151
SIMOTION, 79
Sinusoidal disturbance, 234
Slave diagnostics
installation, 217
Reading, example, 212
Slot number label, 92
Slot numbers
Assigning, 98
Mounting, 99
SNMP, 200
MIB, 199
Network diagnostics, 199
SOFTNET PROFINET, 79
Standards and certifications, 229
Startup
CPU 31x-2 DP as a DP slave, 162
CPU 31xC-2 DP as a DP master, 158, 173
CPU 31xC-2 DP as a DP slave, 162
Station status, 218
stepping mode, 192
Strain relief, 109
Stub cables
Length, 63
Subnet, 52
SYNC/FREEZE, 160
Synchronous error, 194
T
Tags
Controlling, 192
Forcing, 193
Monitoring, 192
Technical data
Shipping and storage conditions, 235
Temperature, 235
Terminating resistor
MPI subnet, 69
Setting the bus connector, 121
Test voltage, 238
Tools
Structure, 92
Transfer memory, 163
Troubleshooting, 194
U
UL
Approval, 229
Ungrounded configuration
connecting a PG, 150
Update
Requirements, 177
Via network, 179
Update using a network
Requirements, 179
Update via Micro Memory Card, 178
V
Vibration, 237
W
WinLC, 79
Wiring
Accessories required, 101
Front connectors, 109
Front Connectors, 102
PS and CPU, 105
Tools and materials required, 101

ITEM 3000
DESCRIPTION

The Model 278 AC Current Transducer is designed to
accept an AC current input, and provide a proportional DC
current output. A linear transformer input is coupled to a
solid-state output amplifier. The Model 278 is powered by
a 115 VAC source, and is socket-mounted for ease of use.

Model 278 Current Transducers can be used with
computer and programmable controls to provide:

- Motor and power control
- Supervisory data acquisition
- Load monitoring
- Feedback control
- Energy management

The Model 278 is available in three standard input/output
configurations.
l l High accuracy, low cost
l l Isolated input and output
l l Socket-mounted, solid-state design
l l Five year unconditional warranty
DIMENSIONS
3.25"
1.95"
1.95"
MODEL 278
AC Current
Transducer
MODEL A278 B278 C278
Supply voltage 115VAC @ 50/60 Hz
Input current 0-5 amps 1-5 amps 0-5 amps
Input frequencies 25-400 Hz
Input burden 0.5VA at 120VAC 60 Hz
Output @ rated input 0-1ma 4-20ma 4-20ma
Maximum load 10k ohms 500 ohms 500 ohms
Output accuracy 2% at 77F
Output ripple 1% max at nominal frequency
Response time 800 msec from 0-99%
Overload withstand 2 times rated output-continuous
10 times rated input-1 second
Dielectric withstand
voltage (isolation)
1500 VRMS input, output, case
Operating temperature -40 to +131F
Humidity tolerance 0-97% w/o condensation
Enclosure material ABS plastic
Mounting 8-pin socket (*order separately)
Weight 6 oz.
*Order 8-pin socket number 51X120
SPECIFICATIONS
Access Control Sales
6110 Ordan Drive, Unit 9
Mississauga, Ontario
Canada L5T 2B4
Tel: 905 564-1472
Fax: 905 564-3349
Toll Free: 1-800-567-1041
E-Mail: sales@accesscontrolsales.com Web Site: www.accesscontrolsales.com
ITEM 4510
INSTALLATION

The Model 278 AC Current Transducer requires an 8-
pin mounting socket, such as the Time Mark Model
51X120.

The base connecting diagram on the unit shows the pin
connection numbers for the 115 volt power, the AC
Current input, and the DC Current Out.

Connect the appropriate wiring to the socket as required
(See the Typical Application diagram).

PIN DRAWING

NOTE: When installing the Model 278 Transducer in
areas of high humidity or contamination, it is
recommended that the base area and all exposed metal
parts of the socket be coated liberally with a good
quality silicon grease, such as Dow Corning DC-4 or
DC-4X. Insert the unit into the socket and wipe off
excess grease around the base. This will prevent the
entrance of moisture and other contaminates into the
base and socket areas.
TROUBLESHOOTING

Should the Model 278 AC Current Transducer fail to
operate properly, check that all voltage is present, and
is of the correct voltage level. Check all fuses and
verify that all wiring connections are correct. If
problems persist, contact your local Time Mark
Distributor, or the factory for assistance, Monday-
Friday, 8 a.m. to 5 p.m. CST.

WARRANTY

The Model 278 AC Current Transducer is warranted
to be free from defects in materials and workmanship,
and is covered by our exclusive 5-year Unconditional
Warranty. If this device fails to operate, for any
reason, we will repair or replace it free, for five years
from the date of purchase. Contact the Time Mark
Sales department, Monday through Friday; 8 a.m. to 5
p.m., CST, for further details.
AC
CURRENT
DC
CURRENT
OUT
115
VAC
1
2 3
4
5
6 7
8
CT-Model 276-xxx
Model 278
2 3
115
VAC
DC
Current Out
1
8
6
7
TYPICAL APPLICATION
MODEL 278 AC Current Transducer
READ ALL INSTRUCTIONS BEFORE INSTALLING, OPERATING OR SERVICING THIS DEVICE.
KEEP THIS DATA SHEET FOR FUTURE REFERENCE.
GENERAL SAFETY

POTENTIALLY HAZARDOUS VOLTAGES ARE PRESENT AT THE TERMINALS OF THE MODEL 278.
ALL ELECTRICAL POWER SHOULD BE REMOVED WHEN CONNECTING OR DISCONNECTING WIRING.
THIS DEVICE SHOULD BE INSTALLED AND SERVICED BY QUALIFIED PERSONNEL.
Installation Instructions
6110 Ordan Drive, Unit 9
Mississauga, Ontario
Canada L5T 2B4
Tel: 905 564-1472
Fax: 905 564-3349
Toll Free: 1-800-567-1041
E-Mail: sales@accesscontrolsales.com Web Site: www.accesscontrolsales.com
ITEM 4510
DESCRIPTION

Model 276A Current Transformer - A low cost, open-
frame type current transformer (CT). For use with up to 8
gauge wire, and up to 40 amps on the primary. 2500
VRMS insulation is standard. Frequency range is 25-400
Hz. The Model 276A CT is CSA Certified.

Model 276B Current Transformer - A ring-type current
transformer for currents from 50 to 1200 amps. The Model
276B has an accuracy rating of 2% for 50-100 amp CTs
and 1% over 100 amps at 60 Hz.

This CT also features a 25-400 Hz frequency range, #8-32
secondary terminals and mounting brackets. Polarity
markings are stamped on the CT. The Model 276B is UL
Recognized and CSA Certified.
276A APPLICATION DIAGRAM
276B APPLICATION DIAGRAM
Model 276B
One primary turn
Model 276A
One primary turn
Loop one leg of AC
line thru transformer
2.00"
B
0.44"
3.90"
1.25"
3.88"
4.50"
C
L
276B DIMENSIONS
SPECIFICATIONS

Ratio Part No. Ratio Part No. Burden Ratio Part No. Burden
50:5 276B-50 1.0 300:5 276B-300 12.5
10:5 276A-10 60:5 276B-60 1.0 400:5 276B-400 12.5
15:5 276A-15 75:5 276B-75 1.5 500:5 276B-500 25.0
20:5 276A-20 80:5 276B-80 1.5 600:5 276B-600 15.0
25:5 276A-25 100:5 276B-100 2.0 750:5 276B-750 7.0
30:5 276A-30 150:5 276B-150 5.0 800:5 276B-800 8.0
35:5 276A-35 200:5 276B-200 5.0 1000:5 276B-1000 10.0
40:5 276A-40 250:5 276B-250 12.5 1200:5 276B-1200 12.5
Burden VA @ 60 Hz
1.25"
.43" 1.95"
2.38"
.19" dia. typ.
Secondary
Space for primary
turn :0 .25" x 0.38"
1.63"
276A DIMENSIONS
l l 25 to 400 HZ
l l 0 to 5 Amp Secondary
l l Wide Application Range
l l Agency Approved
MODEL 276 SERIES
Current Transformers
TIME MARK is a division of
Telephone: Main - (918) 438-1220
Sales - (800) 862-2875
Fax: (918) 437-7584

E-mail: sal es@ti me-mark.com
Internet: http://www.time-mark.com
Doc No. 87A013 12/00
2000 TIME MARK CORPORATION
11440 East Pi ne St r eet
Tul sa, Okl ahoma 74116
ITEM 4510
PRIMARY TURN RATIO MODIFICATION

The nameplate ratio of the current transformer is based on the
condition that the primary conductor will be passed once
through the transformer window. This rating can be reduced in
even multiples by looping the conductor two or more times
through the window. A transformer having a rating of 200 to 5
amps will be changed to 50 to 5 amps if four loops or turns are
made with the primary cable as illustrated.

S ECO N D A R Y T U R N R A T I O
MODIFICATION

Formula:

Where: Ip - Primary amperage
Is - Secondary amperage
Np - Number of primary turns
Ns - Number of secondary turns

Example: A 300:5 current transformer

(in practicality, one turn is dropped from the secondary as a
ratio correction factor).
The ratio of the current transformer can be modified by altering
the number of secondary turns by forward or back-winding the
secondary lead through the window of the CT.

By adding secondary turns the same primary amperage will
result in a decrease in secondary output. By subtracting
secondary turns the same primary amperage will result in
greater secondary output.

Again using the 300:5 example, adding 5 secondary turns will
require 325 amps on the primary to maintain the 5 amp
secondary output, or

Deducting 5 secondary turns will only require 275 amps on the
primary to maintain the 5 amp secondary output, or

The above ratio modifications are achieved in the following
manner.

To add secondary turns, the
white lead should be wound
through the CT from the side
opposite the polarity mark.

To subtract secondary turns,
the white lead should be wound
through the CT from the same
side as the polarity mark.

WARRANTY

The Model 276 Series Current Transformers are
warranted to be free from defects in materials and
workmanship for one year. Should the device fail to
operate, we will repair or replace it for one year from the
date of purchase. For complete warranty details, see
the Terms and Conditions of Sales page in the front
section of the Time Mark catalog.
Ip Ns
Is Np
300p
60s
5s 1p
Nameplate
Ratio
Actual
Ratio
Nameplate
Ratio
Actual
Ratio
100:5 25:5 400:5 100:5
150:5 37.5:5 500:5 125:5
200:5 50:5 600:5 150:5
300:5 75:5 800:5 200:5
4 Primary Turns
Nameplate
Ratio
Actual
Ratio
Nameplate
Ratio
Actual
Ratio
100:5 50:5 400:5 200:5
150:5 75:5 500:5 250:5
200:5 100:5 600:5 300:5
300:5 150:5 800:5 400:5
2 Primary Turns
Nameplate
Ratio
Actual
Ratio
Nameplate
Ratio
Actual
Ratio
100:5 100:5 400:5 400:5
150:5 150:5 500:5 500:5
200:5 200:5 600:5 600:5
300:5 300:5 800:5 800:5
1 Primary Turn
325p
65s
5s 1p
275p
55s
5s 1p
TURNS ARE
COUNTED IN
THIS WINDOW
X2 BLACK LEAD
X1 WHITE LEAD
INCOMING
POWER
POLARITY
MARKING
TURNS ARE
COUNTED IN
THIS WINDOW
X2 BLACK LEAD
X2 WHITE LEAD
INCOMING
POWER
POLARITY
MARKING
MODEL 276 Current Transformers
READ ALL INSTRUCTIONS BEFORE INSTALLING, OPERATING OR SERVICING THIS DEVICE.
KEEP THIS DATA SHEET FOR FUTURE REFERENCE.
GENERAL SAFETY

POTENTIALLY HAZARDOUS VOLTAGES ARE PRESENT AT THE TERMINALS OF THE MODEL 276.
ALL ELECTRICAL POWER SHOULD BE REMOVED WHEN CONNECTING OR DISCONNECTING WIRING.
THIS DEVICE SHOULD BE INSTALLED AND SERVICED BY QUALIFIED PERSONNEL.
Instal l ati on Instr ucti ons
TIME MARK is a division of
Telephone: Main - (918) 438-1220
Sales - (800) 862-2875
Fax: (918) 437-7584

E-mail: sal es@ti me-mark.com
Internet: http://www.time-mark.com
Doc No. 87A013 12/00
2000 TIME MARK CORPORATION
11440 East Pi ne St r eet
Tul sa, Okl ahoma 74116
ITEM 4510
1150 mm
1480mm
Total Weight TURBLEX P/N:
C.G. X' RATED LOAD/UNIT
C.G. Y' LOAD/ISO
C.G. Z' COMPRESSIVE STRESS/ISO
Base length
Motor Horsepower
Motor RPM
Isolator Model/Size
QTY of ISO's USED
QTY of ISO's/SIDE
ISOLATOR LOCATIONS:
LAST ISOLATOR
1st ISOLATOR
2nd ISOLATOR
3rd ISOLATOR
4th ISOLATOR
5th ISOLATOR
6th ISOLATOR
7th ISOLATOR

85%
7
ACTUAL LOAD
PERCENTAGE PER
VIBRATION ISOLATOR
84%
14
4607T
PAUL WURTH
KA66S-GL400
JOB NUMBER:
J0B NAME:
BLOWER MODEL:
2,983 kw
TARGET LOAD
PERCENTAGE PER
VIBRATION ISOLATOR
INPUTS: OUTPUTS:
15,914 kg.
-8 mm
556 mm
Note: Load percentage per Vibration Isolator is
acceptable.
3,600 RPM
71188
1,361 kg.
1,137 kg.
288.20 kPa
1102 mm
-1611 mm
3962 mm
XLW-3000
CENTER OF GRAVITY CALCULATIONS (SI UNITS)
0 mm
1009 mm
1463 mm
1917 mm
2371 mm
3861 mm
102 mm
Z
Y
X
ITEM J
Document Name: 4607T-FOUND Rev A
DOCUMENT NAME: 4607T INST LIST REV D
VENDOR
TURBLEX
TID
TURBLEX P&ID
UNIT 1 CUSTOMER TAG
NUMBER
UNIT 2 CUSTOMER TAG
NUMBER
UNIT 3 CUSTOMER TAG
NUMBER
INSTRUMENT TYPE TAG DESCRIPTION MANUFACTURER MODEL FLUID TYPE
WET MATERIAL
TYPE
ELEMENT LENGTH
ENCLOSURE
CLASSIFICATION
Alarm
(LL)
Alarm
(L)
Alarm
(H)
Alarm
(HH)
RANGE ZERO VALUE SPAN
ENGINEERING
UNITS
MAX TEMP AMBIENT CONNECTION SIZE REV REV DATE REMARKS
TURBLEX 0010
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-ZI-3101 AF2-SOP-ZI-3201 AFC-SOP-ZI-3301 TRANSMITTER VARIABLE DIFFUSERS FRAMO FOR COMPRESSOR KA66 NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE
FULL CLOSED TO FULL
OPEN
TBD FOLLOWING DENMARK
PERFORMANCE TESTING
TBD FOLLOWING
DENMARK PERFORMANCE
TESTING
SCALE NOT APPLICABLE NOT APPLICABLE A 24-Jun-09 -
TURBLEX 0520
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-VV-BOFF1 AF2-SOP-VV-BOFF1 AFC-SOP-VV-BOFF1 VALVE ACTUATOR BLOWOFF VALVE ACTUATOR AUMA
SAR07.5-54B/GS63.3
NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE
FULL CLOSED TO FULL
OPEN
4mA = CLOSED 100% NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE A 24-Jun-09 -
TURBLEX 0530 4607T- PD02B04 AF1-SOP-VV-BRBA-01 VALVE ACTUATOR DISCHARGE VALVE ACTUATOR AUMA SA10.1-26B/GS100.3 NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE
FULL CLOSED TO FULL
OPEN
TURBLEX 0530 4607T- PD02B04 AF2-SOP-VV-BRBA-02 VALVE ACTUATOR DISCHARGE VALVE ACTUATOR AUMA SA10.1-26B/GS100.3 NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE
FULL CLOSED TO FULL
OPEN
4mA = CLOSED 100% NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE A 24-Jun-09
TURBLEX 0530 4607T- PD02B04 AFC-SOP-VV-BRBA-03 VALVE ACTUATOR CROSS OVER DISCHARGE VALVE ACTUATOR AUMA SA10.1-26B/GS100.3 NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE
FULL CLOSED TO FULL
OPEN
TURBLEX 0530 4607T- PD02B04 AFC-SOP-VV-BRBA-04 VALVE ACTUATOR CROSS OVER DISCHARGE VALVE ACTUATOR AUMA SA10.1-26B/GS100.3 NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE
FULL CLOSED TO FULL
OPEN
TURBLEX 0740
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-FILT-02 AF2-SOP-FILT-02 AFC-SOP-FILT-02 SWITCH/GAUGE OIL FILTER, DUPLEX WITH VISUAL & ELECTRICAL INDICATOR PARKER DIL2210QMD35Y9Y91 OIL NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 2.41 bar G NOT APPLICABLE 0 - 2.41 bar G NOT APPLICABLE NOT APPLICABLE bar G NOT APPLICABLE NOT APPLICABLE A 24-Jun-09 -
TURBLEX 0740
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-FILT-02 AF2-SOP-FILT-02 AFC-SOP-FILT-02 SWITCH/GAUGE OIL FILTER, DUPLEX WITH VISUAL & ELECTRICAL INDICATOR PARKER DIL2110QMD35Y9Y91 OIL NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 2.41 bar G NOT APPLICABLE 0 - 2.41 bar G NOT APPLICABLE NOT APPLICABLE bar G NOT APPLICABLE NOT APPLICABLE A 24-Jun-09 -
TURBLEX 0770
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-LI-3101 AF2-SOP-LI-3201 AFC-SOP-LI-3301 LEVEL INDICATOR OIL LEVEL INDICATOR FLOWEZY FILTERS AB-1010-13-G-DS-13-CH OIL NOT APPLICABLE 13" NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 148 C NOT APPLICABLE A 24-Jun-09
TURBLEX 0775
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-SVO-3101 AF2-SOP-SVO-3201 AFC-SOP-SVO-3301 SOLENOID VALVE WATER COOLER SOLENOID VALVE ASCO 8210B59 WATER BRASS NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 52 C NOT APPLICABLE A 24-Jun-09 -
TURBLEX 1110
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-TT-3101 AF2-SOP-TT-3201 AFC-SOP-TT-3301 TRANSMITTER INLET TEMPERATURE #1 SIEMENS 7NG3211-0NN00-Z+C11+Y01 AIR 316 SS NOT APPLICABLE NEMA 4X NOT APPLICABLE NOT APPLICABLE 49 C 54 C 0 to 54C 4mA = 0 C 54 C 85 C 1/2" NPT C 20-Jul-09 -
TURBLEX 1110
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-TT-3119 AF2-SOP-TT-3119 AFC-SOP-TT-3119 TRANSMITTER INLET TEMPERATURE #2 SIEMENS 7NG3211-0NN00-Z+C11+Y01 AIR 316 SS NOT APPLICABLE NEMA 4X NOT APPLICABLE NOT APPLICABLE 49 C 54 C 0 to 54C 4mA = 0 C 54 C 85 C 1/2" NPT C 20-Jul-09 -
TURBLEX 1110
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-TE-3101 AF2-SOP-TE-3201 AFC-SOP-TE-3301 RTD INLET TEMPERATURE #1 SMART SENSORS CA-NUN-3-SS-6-R.1.75-PO14SR AIR 316 SS 6" NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 260 C NOT APPLICABLE A 24-Jun-09 -
TURBLEX 1110
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-TE-3119 AF2-SOP-TE-3119 AFC-SOP-TE-3119 RTD INLET TEMPERATURE #2 SMART SENSORS CA-NUN-3-SS-6-R.1.75-PO14SR AIR 316 SS 6" NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 260 C NOT APPLICABLE A 24-Jun-09 -
TURBLEX 1120
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-PDT-3103 AF2-SOP-PDT-3203 AFC-SOP-PDT-3303 TRANSMITTER COMPRESSOR DIFFERENTIAL PRESSURE SIEMENS 7MF4433-1GA22-1AC1-Z+B11+C11+Y01 AIR 316 SS NOT APPLICABLE IP65 NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 0-2.00 bar D 4mA = 0 bar 2 bar D 85 C 1/2-14"FNPT C 1-Jul-09 -
TURBLEX 1140
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-TT-3108 AF2-SOP-TT-3208 AFC-SOP-TT-3308 TRANSMITTER OIL RESERVOIR TEMPERATURE SIEMENS 7NG3211-0NN00-Z+C11+Y01 OIL 316 SS NOT APPLICABLE NEMA 4X 10 C 16 C 66 C 71 C 0 - 93 C 4mA = 0 C 93 C 85 C 3/4" NPT B 1-Jul-09 -
TURBLEX 1140
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-TE-3108 AF2-SOP-TE-3208 AFC-SOP-TE-3308 RTD OIL RESERVOIR TEMPERATURE SMART SENSORS CA-NUN-3-SSO-9-R.1.75-PO14SR AIR 316 SS 9" NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE A 24-Jun-09 -
TURBLEX 1190
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-TT-3102 AF2-SOP-TT-3202 AFC-SOP-TT-3302 TRANSMITTER ACOUSTICAL ENCLOSURE TRANSMITTER ROSEMOUNT 7NG3211-0NN00-Z+C11+Y01 AIR 316 SS NOT APPLICABLE NEMA 4X NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 0 - 93 C 4mA = 0 c 93 C 85 C NOT APPLICABLE B 1-Jul-09
TURBLEX 1190
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-TE-3102 AF2-SOP-TE-3202 AFC-SOP-TE-3302 TRANSMITTER ACOUSTICAL ENCLOSURE RTD MINCO S454PD AIR NOT APPLICABLE 5.6" NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE A 24-Jun-09
TURBLEX 1270
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-TT-3103 AF2-SOP-TT-3203 AFC-SOP-TT-3303 TRANSMITTER COMPRESSOR BEARING RTD SIEMENS 7NG3211-0NN00-Z+C11+Y01 EMBEDDED 100 OHM Pt NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 90 C 95 C 0 - 148 C 4mA = 0 C 148 C 85 C NOT APPLICABLE B 1-Jul-09 -
TURBLEX 1270
4607T- PD02B01,
PD02B02, PD02B03
TURBLEX 1270
4607T- PD02B01,
PD02B02, PD02B03
TURBLEX 1270
4607T- PD02B01,
PD02B02, PD02B03
TURBLEX 1270
4607T- PD02B01,
PD02B02, PD02B03
TURBLEX 1280
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-TT-3109 AF2-SOP-TT-3209 AFC-SOP-TT-3309 TRANSMITTER DRIVE END MOTOR BEARING RTD SIEMENS 7NG3211-0NN00-Z+C11+Y01 EMBEDDED 100 OHM Pt NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 90 C 95 C 0 - 148 C 4mA = 0 C 148 C 85 C NOT APPLICABLE B 1-Jul-09 -
TURBLEX 1280
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-TT-3117 AF2-SOP-TT-3217 AFC-SOP-TT-3317 TRANSMITTER NON DRIVE END MOTOR BEARING RTD SIEMENS 7NG3211-0NN00-Z+C11+Y01 EMBEDDED 100 OHM Pt NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 90 C 95 C 0 - 148 C 4mA = 0 C 148 C 85 C NOT APPLICABLE B 1-Jul-09 -
TURBLEX 1290
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-TT-3111 AF2-SOP-TT-3211 AFC-SOP-TT-3311 TRANSMITTER MOTOR WINDING RTD SIEMENS 7NG3211-0NN00-Z+C11+Y01 EMBEDDED 100 OHM Pt NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 160 C 165 C 0 - 204 C 4mA = 0 C 204 C 85 C NOT APPLICABLE C 6-Jul-09 -
TURBLEX 1290
4607T- PD02B01,
PD02B02, PD02B03
TURBLEX 1290
4607T- PD02B01,
PD02B02, PD02B03
TURBLEX 1340
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-PDT-3101 AF2-SOP-PDT-3201 AFC-SOP-PDT-3301 TRANSMITTER INLET FILTER 1ST STAGE DIFFERENTIAL PRESSURE SIEMENS 7MF4433-1BA22-1AC6-Z+B11+C11+Y01 VACUUM 316 SS NOT APPLICABLE NEMA 4X NOT APPLICABLE NOT APPLICABLE .0025 bar D NOT APPLICABLE .001 - .02 bar D 4mA = .001 bar D 0.019 bar D 85 C 1/2-14" FNPT D 20-Jul-09 -
TURBLEX 1340
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-PDT-3102 AF2-SOP-PDT-3202 AFC-SOP-PDT-3302 TRANSMITTER INLET FILTER 2ND STAGE DIFFERENTIAL PRESSURE SIEMENS 7MF4433-1BA22-1AC6-Z+B11+C11+Y01 VACUUM 316 SS NOT APPLICABLE NEMA 4X NOT APPLICABLE NOT APPLICABLE .0037 bar D NOT APPLICABLE .001 - .02 bar D 4mA = .001 bar D 0.019 bar D 85 C 1/2-14" NPT D 20-Jul-09 -
TURBLEX 1350
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-PSL-3101 AF2-SOP-PSL-3201 AFC-SOP-PSL-3301 SWITCH OIL (LL) PRESSURE UE H100-702, M540, M201 OIL 316 SS NOT APPLICABLE NEMA 4X 1.03 bar G NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 0 - 6.89 bar G NOT APPLICABLE NOT APPLICABLE bar G 71 C 1/4 " NPTF A 24-Jun-09 -
TURBLEX 1355
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-PT-3101 AF2-SOP-PT-3201 AFC-SOP-PT-3301 TRANSMITTER OIL (L) PRESSURE SIEMENS MF4033-1DA10-1AC6-Z+B11+A02+C11+Y0 OIL 316 SS NOT APPLICABLE NEMA 4X NOT APPLICABLE 2 bar G NOT APPLICABLE NOT APPLICABLE 0 - 11 bar G 4mA = 0 bar G 11 bar G 71 C 1/2 " NPTF C 20-Jul-09 -
TURBLEX 1370
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-PSH-3101 AF2-SOP-PSH-3201 AFC-SOP-PSH-3301 SWITCH SURGE TURBLEX SUC III VACUUM 316 SS NOT APPLICABLE NEMA 4X NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 70 C 1/2" NPT A 24-Jun-09 -
TURBLEX 1375
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-LSL-3101 AF2-SOP-LSL-3201 AFC-SOP-LSL-3301 SWITCH OIL RESERVOIR LEVEL THOMAS PROD. 4000-4084SPST OIL BRASS, SS NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 148 C 2" NPT A 24-Jun-09 -
TURBLEX 1395
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-XS-3101 AF2-SOP-XS-3201 AFC-SOP-XS-3301 SWITCH ZERO SPEED TELEMACANIQUE XS1M18MA250 NOT APPLICABLE 316 SS N/A IP 65 NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 70 C NOT APPLICABLE A 24-Jun-09 -
TURBLEX 1410
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-TI-3101 AF2-SOP-TI-3201 AFC-SOP-TI-3301 GAUGE INLET TEMPERATURE ASHCROFT 50EI-60E060XCS AIR BRASS 6" IP 65 NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 0- 93 C NOT APPLICABLE 93 C 93 C 1/2" NPT B 19-Aug-09 -
TURBLEX 1420
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-TI-3102 AF2-SOP-TI-3202 AFC-SOP-TI-3302 GAUGE OIL TEMPERATURE ASHCROFT 50EI-60E025XCS OIL BRASS 2 1/2" IP 65 NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 0 - 93 C NOT APPLICABLE 93 C 93 C 1/2" NPT A 24-Jun-09 -
TURBLEX 1430
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-TI-3109 AF2-SOP-TI-3209 AFC-SOP-TI-3309 GAUGE COOLING WATER INLET TEMPERATURE ASHCROFT 50EI-60E025XCS WATER BRASS 2 1/2" IP 65 NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 0 - 93 C NOT APPLICABLE 93 C 93 C 1/2" NPT A 24-Jun-09 -
TURBLEX 1435
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-TI-3103 AF2-SOP-TI-3203 AFC-SOP-TI-3303 GAUGE COOLING WATER OUTLET TEMPERATURE ASHCROFT 50EI-60E025XCS WATER BRASS 2 1/2" IP 65 NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 0 - 93 C NOT APPLICABLE 93 C 93 C 1/2" NPT A 24-Jun-09 -
TURBLEX 1520
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-PI-3101 AF2-SOP-PI-3201 AFC-SOP-PI-3301 GAUGE DISCHARGE PRESSURE ASHCROFT 451279RS04LXXL30 psi and bar AIR 316L SS NOT APPLICABLE IP 65 NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 0 - 2.07 bar G NOT APPLICABLE 2.07 bar G 121 C 1/2" NPT C 19-Aug-09 -
TURBLEX 1540
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-PI-3102 AF2-SOP-PI-3202 AFC-SOP-PI-3302 GAUGE LUBE OIL PRESSURE ASHCROFT 451279RS04LXXL160 psi and bar OIL 316L SS NOT APPLICABLE IP 65 NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 0 - 11.03 bar G NOT APPLICABLE 11.03 bar G 121 C 1/2" NPT C 19-Aug-09 -
TURBLEX 1540
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-PI-3103 AF2-SOP-PI-3203 AFC-SOP-PI-3303 GAUGE MOTOR LUBE OIL PRESSURE ASHCROFT 25-1009-SW-02L-XLL 30psi and bar OIL 316L SS NOT APPLICABLE IP65 NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 0 - 2.07 bar G NOT APPLICABLE 2.07 bar G 66 C 1/4"NPT C 19-Aug-09 -
TURBLEX 1830
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-FI3102 AF2-SOP-FI3102 AFC-SOP-FI3102 FLOWINDICATOR MOTOR LUBE OIL JOHN C. ERNST E-540-S1 1/4 OIL 316 SS NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 93 C NOT APPLICABLE B 19-Aug-09 -
TURBLEX 1830
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-FI3103 AF2-SOP-FI3103 AFC-SOP-FI3103 FLOWINDICATOR MOTOR LUBE OIL JOHN C. ERNST E-540-S1 1/4 OIL 316 SS NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 93 C NOT APPLICABLE B 19-Aug-09 -
TURBLEX 1820
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-FI-3101 AF2-SOP-FI-3201 AFC-SOP-FI-3301 FLOWINDICATOR COMPRESSOR LUBE OIL WE ANDERSON SFI550SS-1/2 OIL 316 SS NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 93 C NOT APPLICABLE B 19-Aug-09 -
TURBLEX 1910
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-FT-3101 AF2-SOP-FT-3201 AFC-SOP-FT-3301 TRANSMITTER DISCHARGE FLOW SAGE SRL AIR 316 SS 18" NEMA 4X NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 0-97000 nm3/h 4mA = 0 nm
3
/h 97000 nm3/h 85 c 1"ANSI 150# FLNG A 24-Jun-09 -
TURBLEX 2000
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-VTX-3101 AF2-SOP-VTX-3201 AFC-SOP-VTX-3301 TRANSMITTER COMPRESSOR X VIBRATION BENTLY NEVADA 990-05-50-01-00 NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NEMA 4X NOT APPLICABLE NOT APPLICABLE .08 mm-pp .13 mm-pp 0 - .13 mm-pp 4mA = 0 mm-pp 0.13 mm-pp 48 C NOT APPLICABLE A 24-Jun-09 -
TURBLEX 2000
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-VEX-3101 AF2-SOP-VEX-3201 AFC-SOP-VEX-3301 PROBE COMPRESSOR RADIAL "X" VIBRATION BENTLY NEVADA 330909-65-90-10-02-00 NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NEMA 4X NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 3/8" UFN - 24 A 19-Aug-09 -
TURBLEX 2000
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-VTY-3101 AF2-SOP-VTY-3201 AFC-SOP-VTY-3301 TRANSMITTER COMPRESSOR Y VIBRATION BENTLY NEVADA 990-05-50-01-00 NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NEMA 4X NOT APPLICABLE NOT APPLICABLE .08 mm-pp .13 mm-pp 0 - .13 mm-pp 4mA = 0 mm-pp 0.13 mm-pp 48 C NOT APPLICABLE A 24-Jun-09 -
TURBLEX 2000
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-VEY-3101 AF2-SOP-VEY-3201 AFC-SOP-VEY-3301 PROBE COMPRESSOR RADIAL "Y" VIBRATION BENTLY NEVADA 330909-65-90-10-02-00 NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NEMA 4X NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 3/8" UFN - 24 A 19-Aug-09 -
TURBLEX 2000
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-VTZ-3101 AF2-SOP-VTZ-3201 AFC-SOP-VTZ-3301 TRANSMITTER COMPRESSOR "Z" THRUST VIBRATION BENTLY NEVADA 991-25-50-01-00 NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NEMA 4X NOT APPLICABLE NOT APPLICABLE +/- .64 mm-pp +/- .76 mm-pp -.51 TO .51 mm-pp 4mA = -.51 mm-pp 0.13 mm-pp 48 C NOT APPLICABLE B 6-Jul-09 -
TURBLEX 2000
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-VEZ-3101 AF2-SOP-VEZ-3201 AFC-SOP-VEZ-3301 PROBE COMPRESSOR THRUST "Z" VIBRATION BENTLY NEVADA 330909-15-40-10-02-00 NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NEMA 4X NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 3/8" UFN - 24 A 19-Aug-09 -
TURBLEX 2000
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-VTX-3101 AF2-SOP-VTX-3201 AFC-SOP-VTX-3301 TRANSMITTER DRIVE END MOTOR "X" VIBRATION BENTLY NEVADA 990-05-50-01-00 NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NEMA 4X NOT APPLICABLE NOT APPLICABLE .08 mm-pp .13 mm-pp 0 - .13 mm-pp 4mA = 0 mm-pp 0.13 mm-pp 48 C NOT APPLICABLE A 24-Jun-09 -
TURBLEX 2000
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-VEX-3101 AF2-SOP-VEX-3201 AFC-SOP-VEX-3301 PROBE DRIVE END MOTOR "X" VIBRATION BENTLY NEVADA 330909-05-40-10-02-00 NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NEMA 4X NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 3/8" UFN - 24 A 19-Aug-09 -
TURBLEX 2000
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-VTY-3102 AF2-SOP-VTY-3202 AFC-SOP-VTY-3302 TRANSMITTER DRIVE END MOTOR "Y" VIBRATION BENTLY NEVADA 990-05-50-01-00 NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NEMA 4X NOT APPLICABLE NOT APPLICABLE .08 mm-pp .13 mm-pp 0 - .13 mm-pp 4mA = 0 mm-pp 0.13 mm-pp 48 C NOT APPLICABLE A 24-Jun-09 -
TURBLEX 2000
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-VEY-3102 AF2-SOP-VEY-3202 AFC-SOP-VEY-3302 PROBE DRIVE END MOTOR "Y" VIBRATION BENTLY NEVADA 330909-05-40-10-02-00 NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NEMA 4X NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 3/8" UFN - 24 A 19-Aug-09 -
TURBLEX 2000
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-VTX-3103 AF2-SOP-VTX-3203 AFC-SOP-VTX-3303 TRANSMITTER NON DRIVE END MOTOR "X" VIBRATION BENTLY NEVADA 990-05-50-01-00 NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NEMA 4X NOT APPLICABLE NOT APPLICABLE .08 mm-pp .13 mm-pp 0 - .13 mm-pp 4mA = 0 mm-pp 0.13 mm-pp 48 C NOT APPLICABLE A 24-Jun-09 -
TURBLEX 2000
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-VEX-3103 AF2-SOP-VEX-3203 AFC-SOP-VEX-3303 PROBE NON DRIVE END MOTOR "X" VIBRATION BENTLY NEVADA 330909-05-40-10-02-00 NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NEMA 4X NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 3/8" UFN - 24 A 19-Aug-09 -
TURBLEX 2000
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-VTY-3104 AF2-SOP-VTY-3204 AFC-SOP-VTY-3304 TRANSMITTER NON DRIVE END MOTOR "Y" VIBRATION BENTLY NEVADA 990-05-50-01-00 NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NEMA 4X NOT APPLICABLE NOT APPLICABLE .08 mm-pp .13 mm-pp 0 - .13 mm-pp 4mA = 0 mm-pp 0.13 mm-pp 48 C NOT APPLICABLE A 24-Jun-09 -
TURBLEX 2000
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-VEY-3104 AF2-SOP-VEY-3204 AFC-SOP-VEY-3304 PROBE NON DRIVE END MOTOR "Y" VIBRATION BENTLY NEVADA 330909-05-40-10-02-00 NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NEMA 4X NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 3/8" UFN - 24 A 19-Aug-09 -
TURBLEX 4510
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-IE-3101 AF2-SOP-IE-3201 AFC-SOP-IE-3301 TRANSFORMER CURRENT TRANSFORMER TIME MARK MODEL 276B-400 NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NEMA 4X NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE 400 AMPS NOT APPLICABLE NOT APPLICABLE AMPS 48 C NOT APPLICABLE A 24-Jun-09 -
TURBLEX 4510
4607T- PD02B01,
PD02B02, PD02B03
AF1-SOP-IT-3101 AF2-SOP-IT-3201 AFC-SOP-IT-3301 TRANSMITTER CURRENT TRANSMITTER TIME MARK C278 NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE NEMA 4X NOT APPLICABLE NOT APPLICABLE 294 Amps 303 Amps 0 AMPS - 400 AMPS 4mA = 0 AMPS 400 AMPS 48 C NOT APPLICABLE A 24-Jun-09 -
INSTRUMENTATION

www.turblex.com

Quality Assurance Plan and Documents Revision 0 June 25, 2009
VALLOUREC & SUMITOMO
TUBOS DO BRASIL LTDS BRAZIL

Foreword

Dear valued customer,

Turblex recognizes its responsibility as a provider of quality products and services. Our
quality policy is to exceed customer expectations. To this end, Turblex has developed a
Quality Assurance Plan to document internal business practices to better satisfy the
needs of its customers and improve management of the company. The Turblex Quality
Assurance Plan complies with ISO 9001:2000 requirements.
The Turblex Quality Assurance Plan defines the quality system, establishes the
responsibilities of the personnel affected by the system, and provides general procedures
for all activities comprising the quality system. This manual is used internally by Turblex
employees for guidance and training on the Turblex quality system, and externally to
inform our customers of the quality system and what specific controls are implemented in
each stage of the project to ensure quality.
We hope you find this manual to be useful in understanding the quality procedures used in
the design and manufacture of your product. In addition to information about Turblex
quality assurance procedures, you will find details of inspections made on individual
components used in the manufacture of your product. From initial design through
completion of the project, we are committed to providing a quality experience.
Best regards,

Your Management Team

Contents

Item Description
Page

- Title Page

- Table of Contents

A ISO Certificate 1-2

B Turblex, Inc. Organization Chart 3
1. Company - June 17, 2008 4
2. Industrial Project Engineering December 18, 2008 5

C Turblex, Inc. Quality Manual 6
1. Revisions List 7
2. Circulation List 8
3. Introduction 9
4. Quality Management System 10-12
5. Management Responsibility 13-15
6. Resource Management 16
7. Product Realization 17-22
8. Measurement, Analysis, and Improvement 23-26

D Procedures 27
1. Project Design Change (QAP # 4.4-02) 28-29
2. Inspection/Testing (QAP # 4.10-01) 30-32
3. Control of Inspection Equipment (QAP # 4.11-01) 33-34
4. Non-Conforming Product (QAP # 4.13-01) 35-36
5. Corrective/Preventive Action (QAP # 4.14-01) 37-38
6. Statistical Techniques (QAP # 4.20-01) 39-40
7. Quality Management Process Flow Chart 41
8. Servicing

E Production Traveler Quality Assurance 42-69

Plant name, plant location
Quality Assurance Plan and Documents
www.turblex.com

Item A
ISO Certificate
www.turblex.com
@
CERTIFICATEOF APPROVAL
Thisis to certifythat the Quality Management System of:
TURBLEX, Inc.
Springfield, Missouri, USA
has been approved by Lloyd'sRegisterQuality Assurance
to the following Quality Management SystemStandards:
ISO 9001 :2000
The Quality Management Systemisapplicableto:
Design and Manufacturing of Single Stage
Compressorsfor the Waste Water Treatment Industry
and other Industrial Applicationswhere large Volumes
of low Pressure Regulated Air is Needed.
Approval
CertificateNo: UQA 4000762
Original Approval: October 29, 2008
Current Certificate: October 29, 2008
Certificate Expiry: July 16, 2011
Issued by: L
This document is subject to the provision on the reverse
1401 EnclaveParkway, Suite200, Houston, Texas 77077, USA
Thisapproval iscarried out in accordance with the lRQA assessment and certification procedures and monitored by LRQA.
Maaolllwislon1J
- -

Item B
Organization Chart
www.turblex.com
Industrial Project Engineering Organization Chart
April 23, 2009
INDUSTRIAL
PROJECT ENG. MGR.
Gerardo Serralde
Project Engineer Project Manager Quality Engineer
Fernando Blanco Mark Deckard John Platz Barry Bougher Carlos Callender Amber Bridges Brian Beaty
Nikki Westmoreland
April Cole Audrey Johnson Jeanne Seals

Item C
Quality Manual
www.turblex.com

Revisions List
CHANGE
REV.
DATE BRIEF DESCRIPTION OF CHANGE SECTION(S) INVOLVED PAGE
NOS.
000 03/16/95 Original issue of all sections of the Quality Manual All Sections All
Pages
001 09/12/95 Various Minor Revisions 2.0, 4.2, 4.8, 4.9, 4.15, 4.16
002 11/30/95 Changed Policy Manual to Quality. Defined Manage-
ment Review Board
4.1, 4.2
003 03/26/96 Various Minor Revisions 2.0, 4.1, 4.4, 4.8, 4.15
004 09/24/96 Minor Revisions to Circulation List 2.0
005 01/23/97 Minor Revision to Management Responsibility 4.1
008 12/16/98 Added Quality Planning Statement 4.2
009

12/22/98 Changed Semblex to Mace Industries

All sections All
Pages
010 01/21/99 Date corrected on the introduction. 3.0
011 07/28/99 Various Minor Revisions 2.0, 4.1, 4.8
012 10/05/99 Placed Job Descriptions in separate book 4.1
013 11/12/99 Management Review Board topics discussed 4.1
014 01/21/00 Circulation List 2.0
015 02/04/00 Revisions made to Introduction and Mgmt. Resp. 3.0, 4.1
018 09/07/01 Introduction 3.0
019 03/18/03 Issue all sections of the Quality Management System
(SO 9001:2000 E.)
All Sections All
Pages
020 4/15/03 Add scope to QMS 4, include Quality Objectives in the
MRB meeting requirements
QMS 4, QMS 5
Turblex, Inc.
Quality Manual
Section 1.0
Revision: 021
Date: 4/24/09
Revisions List

This manual is a controlled and maintained document. The only controlled copies are the elec-
tronic files located in L:\Turblex\ISO9001_2000\ISO_REQUIREMENTS and the master copy main-
tained by the Asst. ISO Coordinator:

Note: Electronic or master copies may be printed or photocopied by anyone and are not
considered controlled documents, they are not allowed on the premises unless used for
training purposes...at the end of which they are collected and destroyed.

Circulation List
Turblex, Inc.
Quality Manual
Section 2.0
Revision: 014
Date: 4/24/09
Circulation List

3.1 Place of the Quality Manual in the Quality Assurance Documentation
This manual is part of Turblex, Inc. controlled Quality Assurance documentation. De-
scribed in this document is the Quality Policy, the responsibilities, authorities and inter
relationships of personnel who manage, perform, verify or review work affecting quality.

The Quality Manual is controlled by circulation and revision. Only the latest revision
number is valid. The ISO Coordinator controls all revisions, issues and circulation.

The Quality Manual has been approved by management of Turblex, Inc. and expresses
the policies and philosophy of the Quality Assurance System.

3.2 Quality Policy Statement
Turblex pledges total commitment to provide products and services to the Cus-
tomer that always meet or exceed the requirements. Management will provide
the environment and resources where every employee contributes toward the
never-ending process of improvement and innovation in all aspects of our busi-
ness.

3.3 Turblex, Inc. Brief History
Turblex, Inc. was incorporated in 1988. Turblex has experience dynamic growth since its
inception and has turned into a multi-million dollar corporation that is continuing to
grow.

Turblex designs and assembles a wide range of the most efficient single stage compres-
sors available today. Sales are generated through a network of manufacturers' represen-
tatives located throughout the United States and overseas. Approximately 20 percent of
sales are shipped outside of the United States.

Introduction
Turblex, Inc.
Quality Manual
Section 3.0
Revision: 005
Date: 4/24/09
Introduction

QMS 4 Quality Management System
Turblex, Inc.
Quality Management System
Revision: 005
Date: 4/24/09
4.0 Scope/Exclusions
Turblex, Inc.'s Quality Management System covers design and manufacturing of single-
stage compressors for the wastewater treatment industry and other industrial applica-
tions where large volumes of low pressure regulated air are needed.

Turblexs Quality Management System covers the manufacture of aerators, positive dis-
placement blowers, constant pressure water supply systems; polymer feed equipment
and other related products for the wastewater treatment industry.

Turblex, Inc. claims no exclusions from the Quality Management System.

4.1 General Requirements
Turblex, Inc. has established documented, implemented and maintained a quality man-
agement system and continually improves its effectiveness in accordance with the re-
quirements of ISO 9001: 2000 E.

Turblex, Inc. has
a) identified the processes needed for the quality management system and their appli-
cation throughout the organization
b) determined the sequence and interaction of these processes,
c) determined criteria and methods needed to ensure that both the operation and con-
trol of these processes are effective,
d) ensured the availability of resources and information necessary to support the op-
eration and monitoring of these processes,
e) monitored, measured and analyzed these processes, and
f) implemented actions necessary to achieve planned results and continual improve-
ment of these processes.

These processes are managed by Turblex, Inc. in accordance with the requirements of
ISO 9001: 2000 E.

Where Turblex, Inc. chooses to outsource any process that affects product conformity
with requirements, Turblex, Inc. shall ensure control over such processes. Control of
such outsourced processes is identified within the quality management system.

QMS 4 Quality Management Sys-
tem

Turblex, Inc.
Revision: 05
Date: 4/24/09
4.2 Documentation Requirements

4.2.1 General

The quality management system documentation includes
a) documented statements of a quality policy and quality objectives,
b) a quality manual,
c) documented procedures required by ISO 9001: 2000 E,
d) documents need by Turblex, Inc. to ensure the effective planning, operation and control of its
processes, and records required by ISO 9001: 2000 E (see 4.2.4).

4.2.2 Quality Manual

Turblex, Inc. has established and maintained a quality manual that includes:
a) the scope of the quality management system, including details of and justification for any exclu-
sions,
b) the documented procedures established for the quality management system, or reference to
them, and
c) a description of the interaction between the processes of the quality management system.

The following is a table referencing QMS requirements to procedures or work instructions that ad-
dress those requirements:

QMS PROCEDURE / WORK INSTRUCTION
4.2.3 4.5-01 QAP
4.2.4 4.16-01 QAP
5.4.2 4.5-01 QAP
6.2 4.18-01QAP
7.2 4.3-01QAP
7.2.3 4.3-01QAP
7.3 4.4-01 / 4.4-02 / 4.4-03QAP
7.4 4.6-01 & 4.10-01QAP
7.5.2 4.9-01 & 4.19-01, 4.7-01QAP
7.5.4 4.7-01QAP
7.5.5 4.10-01QAP
7.6 4.11-01QAP
8.2.1 4.20-02QAP
8.2.2 4.17-01QAP
8.2.3 4.20-01QAP
8.2.4 4.10-01QAP
8.3 4.13-01QAP
8.4 4.20-01QAP
8.5.2 4.14-01QAP
8.5.3 4.14-01QAP

Turblex, Inc.
Revision: 05
Date: 4/24/09
4.2.3 Control of documents

Documents required by the quality management system are controlled. Records are a special type of
document and are controlled according to the requirements given in 4.2.4.

A documented procedure has been established to define the controls needed
a) to approve documents for adequacy prior to issue,
b) to review and update as necessary and re-approve documents,
c) to ensure that changes and the current revision status of documents are identified,
d) to ensure that relevant versions of applicable documents are available at points of use,
e) to ensure that documents remain legible and readily identifiable,
f) to ensure that documents of external origin are identified and their distribution controlled, and
g) to prevent the unintended use of obsolete documents, and to apply suitable identification to
them if they are retained for any purpose.

4.2.4 Control of records

Records have been established and maintained to provide evidence of conformity to requirements
and of the effective operation of the quality management system. Records are legible, readily iden-
tifiable and retrievable. A documented procedure has been established to define the controls
needed for the identification, storage, protection, retrieval time and disposition of records.

QMS 5 Management Responsibility
Turblex, Inc.
Revision: 03
Date: 4/24/09
5.1 Management Commitment

Top management has provided evidence of its commitment to the development and im-
plementation of the quality management system and continually improves its effective-
ness by:
a) communicating to the organization the importance of meeting customer as well as
statutory and regulatory requirements,
b) establishing the quality policy,
c) ensuring that quality objectives are established,
d) conducting management reviews, and ensuring the availability of resources.

5.2 Customer Focus
Top management has ensured that customer requirements are determined and are met
with the aim of enhancing customer satisfaction (see 7.2.1 and 8.2.1).

5.3 Quality policy

Top management has ensured that the quality policy:
a) is appropriate to the purpose of the organization,
b) includes a commitment to comply with requirements and continually improve the
effectiveness of the quality management system,
c) provides a framework for establishing and reviewing quality objectives,
d) is communicated and understood within the organization, and
e) is reviewed for continuing suitability.

The following Quality Policy is the guideline by which employees perform their work.

Quality Policy

Turblex, Inc. pledges to:

EXCEED CUSTOMER EXPECTATIONS


Turblex, Inc.
Revision: 03
Date: 4/24/09
5.4 Planning

5.4.1 Quality Objectives

Top management has ensured that quality objectives, including those needed to meet requirements
for product (see 7.1 a) are established at relevant functions and levels within the organization. The
quality objectives are measurable and consistent with the quality policy. Quality Objectives are es-
tablished for the coming year in the final Management Review Board Meeting each year. The
Quality Objectives are then issued in a memo from the President.

5.4.2 Quality management system planning

Top management has ensured that
a) the planning of the quality management system is carried out in order to meet the requirements
given in 4.1, as well as the quality objectives, and
b) the integrity of the quality management system is maintained when changes to the quality
management system are planned and implemented.

5.5 Responsibility, Authority, and Communication

5.5.1 Responsibility and Authority

Turblex, Inc. has ensured that responsibilities and authorities are defined and communicated within
the organization by maintaining a current organization chart that lists the position titles and direct
reporting relationships of each position. There will also be a current job description for each posi-
tion that defines the title, scope, responsibility, and authority of that position. The job description
will also include the direct and indirect reporting relationships for the position. The job descriptions
will be kept in a separate book with the Master ISO documentation. Furthermore, when the Organ-
izational Chart is revised, the Assistant ISO Coordinator will compare it to the current job descrip-
tions ensuring that a current job description always exists for each position reflected on the Organ-
izational Chart.

5.5.2 Management Representative

Turblex, Inc. has appointed a member of management as the ISO Coordinator who, irrespective of
other responsibilities, has responsibility and authority that includes:
a) ensuring that processes needed for the quality management system are established, imple-
mented and maintained,
b) reporting to top management on the performance of the quality management system and any
need for improvement, and
c) ensuring the promotion of awareness of customer requirements throughout the organization.

5.5.3 Internal Communication

Top management has ensured that appropriate communication processes are established within the
organization and that communication takes place regarding the effectiveness of the quality man-
agement system (see 5.6.1).

Turblex, Inc.
Revision: 03
Date: 4/24/09
5.6 Management Review

5.6.1 General

Top management consisting of the President, Controller, Chief Engineer, and Manufacturing Man-
ager, or the President and two of the three mentioned, review the organizations quality manage-
ment system semi-annually to ensure its continuing suitability, adequacy and effectiveness. This re-
view includes assessing opportunities for improvement and the need for changes to the quality
management system, including the quality policy and quality objectives. Records from management
reviews are made available to all personnel within the organization and maintained in accordance
with ISO requirements (see 4.2.4).

5.6.2 Review Input

The input to management review includes information on
a) results of audits,
b) customer feedback,
c) process performance and product conformity,
d) status of preventive and corrective actions,
e) follow-up actions from previous management reviews,
f) changes that could affect the quality management system, and recommendations for improve-
ment.

5.6.3 Review Output

The output from the management review includes any decisions and actions related to
a) improvement of the effectiveness of the quality management system and its processes,
b) improvement of product related to customer requirements, and
c) resource needs

Review status of quality objectives and as necessary establish quality objectives for the coming year.

QMS 6 Resource Management
Turblex, Inc.
Revision: 01
Date: 3/18/03
6.1 Provisions of Resources

Turblex, Inc. has determined and provided the resources needed
a) to implement and maintain the quality management system and continually improve
its effectiveness, and
b) to enhance customer satisfaction by meeting customer requirements.

6.2 Human Resources
6.2.1 General

Personnel performing work affecting product quality are competent on the basis
of appropriate education, training, skills and experience.

6.2.2 Competence, Awareness, and Training

Turblex, Inc. has
a) determined the necessary competence for personnel performing work af-
fecting product quality,
b) provided training or take other actions to satisfy these needs,
c) evaluated the effectiveness of the actions taken,
d) ensured that its personnel are aware of the relevance and importance of
their activities and how they contribute to the achievement of the quality
objectives, and maintained appropriate records of education, training, skills
and experience (see 4.2.4).

6.3 Infrastructure

Turblex, Inc. shall determine, provide and maintain the infrastructure needed to achieve
conformity to product requirements. Infrastructure includes, as applicable
a) buildings, workspace and associated utilities,
b) process equipment (both hardware and software), and
c) supporting services (such as transport or communication)

6.4 Work Environment

Turblex, Inc. has determined and managed the work environment needed to achieve
conformity to product requirements.
QMS 6 Resource Management

QMS 7 Product Realization
Turblex, Inc.
Revision: 02
Date: 4/24/09
7.1 Planning of Product Realization

Turblex, Inc. has planned and developed the processes needed for product realization.
Planning of product realization has been consistent with the requirements of the other
processes of the quality management system (see 4.1).

In planning product realization, the organization has determined the following, as ap-
propriate:
a) quality objectives and requirements for the product;
b) the need to establish processes, documents, and provide resources specific to the
product;
c) required verification, validation, monitoring, inspection and test activities specific to
the product and the criteria of the product acceptance;
d) records needed to provide evidence that the realization processes and resulting
product meet requirements (see 4.2.4).

The output of the planning is in a form suitable for the organizations method of opera-
tions.

7.2 Customer-Related Processes
7.2.1 Determination of Requirements Related to the Product

Turblex, Inc. determines
a) Requirements specified by the customer, including the requirements for de-
livery and post-delivery activities,
b) Requirements not stated by the customer but necessary for specified or in-
tended use, where known,
c) Statutory and regulatory requirements related to the product, and
d) Any additional requirements determined by the organization.


Turblex, Inc.
Revision: 02
Date: 4/24/09
7.2.2 Review of Requirements Related to the Product

Turblex, Inc. reviews the requirements related to the product. This review is conducted prior to the
organizations commitment to supply a product to the customer (e.g. submission of tenders, accep-
tance of contracts or orders, acceptance of changes to contracts or orders) and ensures that
a) product requirements are defined,
b) contract or order requirements differing from those previously expressed are resolved, and
c) Turblex, Inc. has the ability to meet the defined requirements.

Records of the results of the review and actions arising from the review are maintained (see 4.2.4).

Where the customer provides no documented statement of requirement, the customer requirements
are confirmed by the organization before acceptance.

Where product requirements are changed, the organization ensures that relevant documents are
amended and that relevant personnel are made aware of the changed requirements.

7.2.3 Customer Communication

Turblex, Inc. has determined and implemented effective arrangements for communicating with cus-
tomers in relation to
a) product information,
b) inquiries, contracts or order handling, including amendments, and
c) customer feedback, including customer complaints.

7.3 Design and Development

7.3.1 Design and Development Planning

Turblex, Inc. plans and controls the design and development of product.

During the design and development planning, the organization determines:
a) the design and development stages,
b) the review, verification and validation that are appropriate to each design and development
stage, and
c) the responsibilities and authorities for design and development.

Turblex, Inc. manages the interface between different groups involved in design and development to
ensure effective communication and clear assignment of responsibility.

Planning output is updated, as appropriate, as the design and development progresses.

Turblex, Inc.
Revision: 02
Date: 4/24/09

7.3.2 Design and Development Inputs

Inputs relating to product requirements have been determined and records are maintained (see
4.2.4). These inputs include:
a) functional and performance requirements,
b) applicable statutory and regulatory requirements,
c) where applicable, information derived from previous similar designs, and
d) other requirements essential for design and development.

These inputs are reviewed for adequacy. Requirements are complete, unambiguous and not in con-
flict with each other.

7.3.3 Design and Development Outputs

The outputs of design and development are provided in a form that enables verification against the
design and development input and is approved prior to release.

Design and development outputs:
a) meet the input requirements for design and development,
b) provide appropriate information for purchasing, production and for service provision,
c) contain or reference product acceptance criteria, and specify the characteristics of the product
that are essential for its safe and proper use.

7.3.4 Design and Development Review

At suitable stages, systematic reviews of design and development are performed in accordance with
planned arrangements (see 7.3.1)
a) to evaluate the ability of the results of design and development to meet requirements, and
b) to identify any problems and propose necessary actions.

Participants in such reviews include representatives of functions concerned with the design and de-
velopment stage(s) being reviewed. Records of the results of the reviews and any necessary actions
are maintained (see 4.2.4).

7.3.5 Design and Development Verification

Verification is performed in accordance with planned arrangement (see 7.3.1) to ensure that the de-
sign and development outputs have met the design and development input requirements. Records
of the results of the verification and any necessary actions are maintained (see 4.2.4).

7.3.6 Design and Development Validation

Design and development validation is performed in accordance with planned arrangements (see
7.3.1) to ensure that the resulting product is capable of meeting the requirements for the specified
application or intended use, where known. Wherever practicable, validation is completed prior to
the delivery or implementation of the product. Records of the results of validation and any neces-
sary actions are maintained (see 4.2.4).

Turblex, Inc.
Revision: 02
Date: 4/24/09
7.3.7 Control of Design and Development Changes

Design and development changes are identified and records maintained. The changes are reviewed,
verified and validated, as appropriate, and approved before implementation. The reviews of design
and development changes include evaluation of the effect of the changes on constituent parts and
product already delivered.

Records of the results of the review of changes and any necessary actions are maintained (see
4.2.4).

7.4 Purchasing

7.4.1 Purchasing Process

Turblex, Inc. ensures that purchased product conforms to specified purchase requirements. The type
and extent of control applied to the supplier and the purchased product is dependent upon the ef-
fect of the purchased product on subsequent product realization or the final product.

Turblex, Inc. has evaluated and selected suppliers based on their ability to supply product in accor-
dance with the organizations requirements. Criteria for selection, evaluation and re-evaluation
have been established. Records of the results of evaluations and any necessary actions arising from
the evaluation are maintained (see 4.2.4).

7.4.2 Purchasing Information

Purchasing information describes the product to be purchased, including where appropriate
a) requirements for approval of product, procedures, processes and equipment,
b) requirements for qualification of personnel, and
c) quality management system requirements.

Turblex, Inc. ensures the adequacy of specified purchase requirements prior to their communication
to the supplier.

7.4.3 Verification of Purchased Product

Turblex, Inc. has established and implemented inspections or other activities necessary for ensuring
that purchased product meets specified purchase requirements.

Where Turblex, Inc. or its customer intends to perform verification at the suppliers premises, Tur-
blex, Inc. shall state the intended verification arrangements and method of product release in the
purchasing information.

Turblex, Inc.
Revision: 02
Date: 4/24/09

7.5 Product and Service Provision

7.5.1 Control of Production and Service Provision

Turblex, Inc. plans and carries out production and service provisions under controlled conditions.
Controlled conditions include, as applicable
a) the availability of information that describes the characteristics of the product,
b) the availability of work instruction, as necessary,
c) the use of suitable equipment,
d) the availability and use of monitoring and measuring devices,
e) the implementation of monitoring and measurement, and
f) the implementation of release, delivery and post-delivery activities

7.5.2 Validation of Processes for Production and Service Provision

Turblex, Inc. validates any processes for production and service provision where the resulting output
cannot be verified by subsequent monitoring or measurement. This includes any processes where
deficiencies become apparent only after the product is in use or the service has been delivered.

Validation demonstrates the ability of these processes to achieve planned results.

Turblex, Inc. has established arrangements for these processes including, as applicable
a) defined criteria for review and approval of the processes,
b) approval of equipment and qualification of personnel,
c) use of specific methods and procedures,
d) requirements for records (see 4.2.4), and
e) revalidation

7.5.3 Identification and Traceability

Turblex, Inc. identifies product from receipt and during all stages of production through a combina-
tion of our part number, vendors part number, description of the product, and/or placed in a job
specific material-handling item.

Turblex, Inc. assigns and records a unique serial number and attaches a Turblex, Inc. nameplate to
each machine or job for product identification.

Turblex, Inc. has established a quality plan for identifying the product by suitable means from re-
ceipt and during all stages of production, delivery and installation where and to the extent that
traceability is a specified requirement.

7.5.4 Customer Property

Turblex, Inc. exercises care with customer property while it is under the organizations control or be-
ing used by the organization. Turblex, Inc. identifies, verifies, protects and safeguards customer
property provided for use or incorporation into the product. If any customer property is lost, dam-
aged or otherwise found to be unsuitable for use, this is reported to the customer and records main-
tained (see 4.2.4).

Turblex, Inc.
Revision: 02
Date: 4/24/09
7.5.5 Preservation of Product

Turblex, Inc. preserves the conformity of product during internal processing and delivery to the in-
tended destination. This preservation includes identification, handling, packaging, storage and pro-
tection. Preservation also applies to the constituent parts of a product.

7.6 Control of Monitoring and Measuring Devices

Turblex, Inc. has determined the monitoring and measurement to be undertaken and the monitoring and
measuring devices needed to provide evidence of conformity of product to determined requirements (see
7.2.1).

Turblex, Inc. has established processes to ensure that monitoring and measurement can be carried out and
are carried out in a manner that is consistent with the monitoring and measurement requirements.

Where necessary to ensure valid results, measuring equipment is:
a) calibrated or verified at specified intervals, or prior to use, against measurement standards traceable to
international or national measurement standards; where no such standards exist, the basis used for
calibration or verification is recorded;
b) adjusted or re-adjusted as necessary;
c) identified to enable the calibration status to be determined;
d) safeguarded from adjustments that would invalidate the measurement result;
e) protected from damage and deterioration during handling, maintenance and storage

In addition, Turblex, Inc. assesses and records the validity of the previous measuring results when the equip-
ment is found not to conform to requirements. Turblex, Inc. takes appropriate action on the equipment and
any product affected. Records of the results of calibration and verification are maintained (see 4.2.4).

When used in the monitoring and measurement of specified requirements, the ability of computer software
to satisfy the intended application is confirmed. This is undertaken prior to initial use and reconfirmed as
necessary.

QMS 8 Measurement, Analysis, and Improvement
Turblex, Inc.
Revision: 02
Date: 4/24/09
8.1 General

Turblex, Inc. plans and implements the monitoring, measurement, analysis and im-
provement processes needed:
a) to demonstrate conformity of the product,
b) to ensure conformity of the quality management system, and
c) to continually improve the effectiveness of the quality management system

This includes determination of applicable methods, including statistical techniques, and
the extent of their use.

8.2 Monitoring and Measurement
8.2.1 Customer Satisfaction

As one of the measurements of the performance of the quality management
system, Turblex, Inc. monitors information relating to customer perception as to
whether the organization has met customer requirements. The methods for ob-
taining and using this information have been determined.

8.2.2 Internal Audit

Turblex, Inc. conducts internal audits at planned intervals to determine whether
the quality management system:
a) conforms to the planned arrangements (see 7.1), to the requirements of ISO
9001: 2000 E and to the quality management system requirements estab-
lished by Turblex, Inc. and
b) is effectively implemented and maintained

An audit program was planned, taking into consideration the status and impor-
tance of the processes and areas to be audited, as well as the results of previous
audits. The audit criteria, scope, frequency and methods are defined. Selection
of auditors and conduct of audits ensures objectivity and impartiality of the au-
dit process. Auditors do not audit their own work.

QMS 8 Measurement, Analysis, and
Improvement

Turblex, Inc.
Revision: 02
Date: 4/24/09
The responsibilities and requirements for planning and conducting audits, and for reporting results
and maintaining records (see 4.2.4) are defined in a documented procedure.

The management responsible for the area being audited ensures that actions are taken without un-
due delay to eliminate detected nonconformities and their causes. Follow-up activities include the
verification of the actions taken and the reporting of verification results (see 8.5.2).

8.2.3 Monitoring and Measurement of Processes

Turblex, Inc. applies suitable methods for monitoring and, where applicable, measurement of the
quality management system processes. These methods demonstrate the ability of the processes to
achieve planned results. When planned results are not achieved, correction and corrective action is
taken, as appropriate, to ensure conformity of the product.

8.2.4 Monitoring and Measurement of Product

Turblex, Inc. monitors and measures the characteristics of the product to verify that product re-
quirements have been met. This is carried out at appropriate stages of the product realization proc-
ess in accordance with the planned arrangements (see 7.1).

Evidence of conformity with the acceptance criteria is maintained. Records indicate the person(s)
authorizing release of product (see 4.2.4).

Product release and service delivery do not proceed until the planned arrangements (see 7.1) have
been satisfactorily completed, unless otherwise approved by a relevant authority and, where appli-
cable, by the customer.

8.3 Control of Nonconforming Product

Turblex, Inc. ensures that product which does not conform to product requirements is identified and con-
trolled to prevent its unintended use or delivery. The controls and related responsibilities and authorities for
dealing with nonconforming product are defined in a documented procedure.

Turblex, Inc. deals with nonconforming product by one or more of the following ways:
a) by taking action to eliminate the detected nonconformity
b) by authorizing its use, release or acceptance under concession by a relevant authority and, where appli-
cable, by the customer
c) by taking action to preclude its original intended use or application

Records of the nature of nonconformities and any subsequent actions taken, including concessions ob-
tained, are maintained (see 4.2.4).

When nonconforming product is corrected it is subject to re-verification to demonstrate conformity to the
requirements.

When nonconforming product is detected after delivery or use has started, the organization takes action ap-
propriate to the effects, or potential effects of the nonconformity.

Turblex, Inc.
Revision: 02
Date: 4/24/09
8.4 Analysis of Data

Turblex, Inc. determines, collects and analyzes appropriate data to demonstrate the suitability and effective-
ness of the quality management system and to evaluate where continual improvement of the effectiveness
of the quality management system can be made. This includes data generated as a result of monitoring and
measurement and from other relevant sources.

The analysis of data provides information relating to:
a) customer satisfaction (see 8.2.1),
b) conformity to product requirements (see 7.2.1),
c) characteristics and trends of processes and products including opportunities for preventative action, and
suppliers

8.5 Improvement

8.5.1 Continual Improvement

Turblex, Inc. continually improves the effectiveness of the quality management system through the
use of the quality policy, quality objectives, audit results, analysis of data, corrective and preventive
actions and management review.

8.5.2 Corrective Action

Turblex, Inc. takes action to eliminate the cause of nonconformities in order to prevent recurrence.
Corrective actions are appropriate to the effects of the nonconformities encountered.

A documented procedure has been established to define requirements for:
a) reviewing nonconformities (including customer complaints),
b) determining the causes on nonconformities,
c) evaluating the need for action to ensure that nonconformities do not recur,
d) determining and implementing action needed,
e) records of the results of action taken (see 4.2.4), and
f) reviewing corrective action taken

8.5.3 Preventative Action

Turblex, Inc. determines action to eliminate the causes of potential nonconformities in order to pre-
vent their occurrence. Preventive actions are appropriate to the effects of the potential problems.

A documented procedure has been established to define requirements for:
a) determining potential nonconformities and their causes,
b) evaluating the need for action to prevent occurrence of nonconformities,
c) determining and implementing action needed,
d) records of results of action taken (see 4.2.4), and
e) reviewing preventative action taken

Item D
Procedures
www.turblex.com

Project Design Change Control Procedure
Turblex, Inc.
Design Change Control Procedure (QAP# 4.4-02)
Revision: 009
Date: 4/27/09
1.0 Purpose

1.1 To establish and maintain documented procedures to insure that all design
changes and modifications will be identified, documented, reviewed and ap-
proved by authorized personnel before their realization.

2.0 Scope
2.1 This procedure covers all changes to standards, drawings or bills of material that
have been released from Engineering.

3.0 Key Words

3.1 Red Line - An approved change to a drawing.

4.0 Reference

4.1 Please reference Flow Chart - Design Change Control Procedure.
4.2 Please reference Engineering Work Instruction titled Change Order.

5.0 Procedure

General:

The two general ways to approve changes to information that has been released from
Engineering are an ECO form or a Red Line that is followed up with an As Built drawing.
As stated in QAP# 4.6-01: The use of a component shall be approved by Engineering.
This means that any additions, deletions, or changes in type or quantity of material must
be done through an Engineering Change Order (ECO), except as stated below.

The Assembly Shop must follow the information released by Engineering or receive ap-
proval before any deviations are made, except for the following areas: 1. The Shop has
authority to make clerical corrections to Electrical schematics such as wire labeling.
These corrections will be made to the As Built. 2. The Process and Instrumentation
Diagram (P&ID) is the guideline for skid electrical. Engineering and Shop personnel
should meet to have a discussion for each specific jobs skid electrical layout. The shop
has authority to add or delete quantity of components in the estimated Bill of Material to
complete skid electrical. The shop cannot change type of material. 3. The Shop will be
Project Design Change Control
Procedure

Project Design Change Control Procedure
Turblex, Inc.
Design Change Control Procedure (QAP# 4.4-02)
Revision: 009
Date: 4/27/09
given an oil/water piping layout to follow. As long as field connection points listed on
the General Arrangement drawing are met, the Shop has authority to adjust length di-
mensions, and add or delete fittings as needed. The Shop does not have authority to
change the sequence of components such as gauges, valves, filters, etc.

5.1 A potential change to a drawing or bill of material may be found at any time, or by anyone,
after it has been released by Engineering.

5.2 The person identifying a potential change(s) should initiate an ECO (Form #95032401,
printed on goldenrod paper). The Project Manager reviews the ECO changes and assesses
the effect of the changes on parts or products that have already been approved, creating
additional ECOs, if necessary. The Project Manager assigns an ECO number and records the
ECO on the ECO log. The Project Manager will make a copy of the ECO on white paper, and
place the copy in the job file. All of these steps must be completed prior to releasing the
ECO.

5.3 The original ECO with any revised drawings will be released to the Materials department for
processing. To process the ECO, the Materials department will create the proper paperwork
in accordance with the ECO. This paperwork may include, among other things, an inventory
activity sheet, return goods form, purchase order, purchase order cancellation, or change.
Materials will make the appropriate changes to the BOM in the computer.

5.4 Materials will issue the original ECO to either the Electrical or Mechanical Shop department
to implement the change into the product.

5.5 After the change is completed, the Team Leader will inspect the product, sign-off on the
original ECO, and place it in the production traveler.

5.6 Prior to the functional testing, the Project Manager will verify that all ECO's have been proc-
essed, and all changes have been made to the product. File all original ECOs in the job file,
complete the ECO log, and discard all ECO copies. The product cannot pass final inspection,
and therefore is not shipped, until the above has been completed.

5.7 Prior to the completion of a product or process, minor changes to drawings can be docu-
mented by the Project Manager approving a red line correction without an ECO. The Project
Manager is responsible for making the red line correction on the master drawing and all re-
leased copies in the Production Managers office, Buyers office, Shop and Warehouse. The
Project Manager will initial and date all red line corrections.

5.8 During quality inspection, the Production Manager will verify that all red line corrections are
implemented, initial and date each red lined drawing (shop copy only) next to the Project
Managers initial.

5.9 Prior to the functional testing, the Project Manager will collect all the shop drawings and in-
corporate all red lines into As Built drawings.

6.0 Records, Reports, and Forms

6.1 ECO Form 95032401.QAS
ECO Log Form 95041201.QAS

Project Design Control:
Non-Standard Material Selection Process
Review
Customers
Specifications
Review
Customers
Approved
Suppliers
Review Quotes
Against Specs
and Budget
Select
Conforming
Quote
Project Engineering
Technical
Review With
Project
Engineering
Manager
Business Review
With Material
Selection
Committee
Material
Requisition to
Purchasing
RFQs to 3-5
Suppliers
Submittal To
Customer For
Approval
Approved
Submittal From
Customer

Inspection and Testing Procedure
Turblex, Inc.
Inspection and Testing Procedure (QAP# 4.10-01)
Revision: 07
Date: 4/27/09
1.0 Purpose

1.1 To establish and maintain documented procedures for inspection and testing
and for the coordination of these activities.

2.0 Scope
2.1 This procedure will cover the inspection, testing, and verification functions for
all products produced by Turblex at the following points in production; incoming
product, in-process, functional, and final visual inspection.

3.0 Key Words

3.1 Specified Requirements - The requirements by which a product or service must
conform that have been contractually agreed upon between the customer and
supplier which includes any exceptions taken and agreed upon modifications.

4.0 Reference

4.1 Please reference Procedure 4.13-01 Control of Nonconforming Product.
4.2 Please reference Procedure 4.4-02 Design Change Control.
4.3 Please reference the ASME PTC-10 test procedure performed on Turblex com-
pressors by HV-Turbo.
4.4 Please reference Procedure 4.20-01 Statistical Techniques.
4.5 Please reference Flow Chart 4.10 Inspection and Testing Procedure.

5.0 Procedure

General:

A production traveler, which lists the inspection and test hold points, will be attached to
a quality board as the product is being assembled and tested. The status of any inspec-
tion and test should be recorded on this traveler.

5.1 Turblex has determined that all incoming product to be used in production or as
service parts will be inspected and verified. No incoming product will be issued
to manufacturing until the incoming inspection has been performed.


Turblex, Inc.
Revision: 07
Date: 4/27/09
A determination will be made on product that is shipped directly from the vendor to the customer
on whether it will be inspected on a case by case basis that takes into consideration the value added
work being done by the vendor and the quality reliability of the vendor.

5.2 Turblex has identified four categories of incoming product for the purpose of inspection and verifi-
cation and shipments directly from the vendor to the customer. These categories and the associated
inspection and verification procedures are as follows:

A. Raw Material for fabrication. The initial inspection will be done by receiving according to the
Non-fabricated parts procedure. (See category C.) Final inspection of raw material is done by
the fabrication department as raw material is pulled into fabrication.

Raw material will be compared to drawings and any applicable standards for all relevant data
such as dimensions and correct material. Relevant data will be recorded and records main-
tained.

B. Fabricated. This inspection will generally be done by receiving unless there is an inspection data
sheet in the Traveler or the item is unusual, then the Project Manager or the CADD Manager will
be involved.

Fabricated parts will be compared to the following documents based on the sampling methods
described in QAP# 4.20-01:

1. Drawing for all relevant data such as dimensions, welds, correct materials, tolerances, paint
specifications, etc.

2. Packing list to determine if what was received is the same as the items listed as shipped.
The inspector shall initial the packing list to verify that the appropriate review has been
completed.

3. Purchase Order to determine if what was received is the same as the items listed as pur-
chased.

C. Non-fabricated. This inspection will generally be done by receiving unless the item is unusual,
then the Project Manager will be involved.

All non-fabricated parts will be compared to the following documents where appropriate:

1. Packing list to determine if what was received is the same as the items listed as shipped.
The inspector shall initial the packing list to verify that the appropriate review has been
completed.

chased.

3. Bill of Material to determine if what was received is the same as the items called for on the
Bill of Material.

Turblex, Inc.
Revision: 07
Date: 4/27/09
D. Main drive motor, compressor, main motor starter, valves, and other special specified items.

1. Packing list to determine if what was received is the same as the items listed as shipped

chased.

3. Inspection data sheets will be completed as applicable.

E. Shipments directly from the vendor to the customer. If this inspection will be performed during
start-up, then this will be listed on the Job Start-up Log form 99021802.

1. If a fabricated item, drawing for all relevant data such as dimensions, welds, correct materi-
als, tolerances, paint specifications, etc.

2. Purchase Order to determine if what is to be shipped is the same as the items listed as pur-
chased.

All incoming product and product shipped directly from the vendor to the customer that is in-
spected will be visually inspected for damage.

5.3 If there is a nonconformance, a completed red tag should be attached to the product and the prod-
uct placed in a segregated nonconformance area if possible. Please see Procedure 4.13 Control of
Non-Conforming Product if there are any non-conformances. If no discrepancies, proceed to Step
5.4.

5.4 After all discrepancies have been resolved; the incoming product will be issued to the appropriate
job or put into stock.

5.5 The in-process inspection and test procedures will be performed according to work instructions de-
veloped for each product line. The work instructions will identify at what stage each inspection or
test should be performed, what each inspection or test will cover, and who has authority to perform
and approve each inspection or test. The person having the authority to approve the inspection and
test will record the inspection and test results on the production traveler.

5.6 If there is a non-conformance, a completed red tag should be attached to the product and the prod-
5.7.

5.7 The functional test procedures will be performed according to work instructions developed for each
product line. The work instructions will identify what the operational test will cover and who has
authority to perform and approve each test. The person having the authority to approve the inspec-
tion and test will record the inspection and test results on the production traveler.

Records of applicable vendor test reports shall be evaluated for conformance to specified require-
ments before check off of functional inspection and testing.

Turblex, Inc.
Revision: 07
Date: 4/27/09
5.9.

5.9 Before shipment of the completed product, a final visual inspection will be performed according to
work instructions developed for each product line. The work instructions will identify what the final
visual inspection will cover and who has authority to perform and approve the final visual inspec-
tion. The person having the authority to approve the inspection and test will record the inspection
and test results on the production traveler.

5.11.

5.11 The product will be shipped after it has passed all inspections, tests, and verifications performed at
incoming, in process, operational, and final inspection.


6.1 Production Traveler
6.2 Inspection and Test Checklists

Control of Inspection, Measuring, and Test Equipment Procedure
Turblex, Inc.
Control of Inspection, Measuring, and Test Equipment Procedure (QAP# 4.11-01)
Revision: 009
Date: 4/27/09
1.0 Purpose

1.1 To provide a system to assure that all measurement and test equipment used for
activities affecting quality is controlled, calibrated, and adjusted to maintain
necessary accuracy.

2.0 Scope
2.1 This procedure covers all inspection, measuring and test equipment affecting
quality that is used for the purpose of final inspection, measurement, or test
during inspection, production, quality control, testing, startup, and service.

3.0 Key Words

3.1 Calibration: Comparison of a measurement standard or instrument of known
accuracy with another standard or instrument to detect, correlate, report, or
eliminate by adjustment any variation in the accuracy of the item being com-
pared.

3.2 Measuring and Test Equipment: All equipment used to measure, gauge, test, in-
spect, or otherwise examine items to determine compliance with specifications.

4.0 Reference

4.1 Please reference Procedure 4.10-01 Inspection and Testing.
4.2 Please reference Flow Chart 4.11 Control of Inspection, Measuring and Test
Equipment.

5.0 Procedure

5.1 Engineering, in accordance with the specifications, will define on the drawing
what measurements are to be made and the accuracy required; and, on the Pro-
duction Traveler, what tests will be required.

5.2 Engineering and Manufacturing will identify the type of equipment needed to
perform the necessary inspections, measurements and test equipment.
Control of Inspection, Measuring,
and Test Equipment Procedure

Turblex, Inc.
Revision: 009
Date: 4/27/09
5.3 Receive all newly purchased or repaired inspection, measuring, and test equipment in accordance
with Procedure 4.10-01. Send all equipment to the ISO department to be recorded in test equip-
ment calibration certificate log.

5.4 Log the following information on the inspection, measuring and test equipment log sheet:

A. Description of instrument
B. Serial number, if available
C. Location to be used
D. The unique number assigned to that instrument
E. Frequency the instrument should be recalled to check calibration and re-calibrate if needed.

When size permits, place a calibration label on the instrument indicating the unique instrument
number, date of calibration, and date next calibration is due.

5.5 The Chief Engineer or designee will determine if calibration certification has been issued with in-
strument. If certification has been issued, then file the certification and proceed to Step 5.6. If cer-
tification has not been issued, then proceed to Step 5.8.

5.6 The instrument can be placed in use. The person using an instrument has the responsibility of re-
turning to the Chief Engineer or designee any instrument suspected of being damaged or out of
calibration, has an expired label, or if the calibration label has been removed.

5.7 On a monthly basis, all equipment to be calibrated by the end of that month will be recalled from
use by the Chief Engineer or designee.

5.8 All recalled equipment, new equipment without calibration evidence, and any equipment suspected
of being damaged or out of calibration will be calibrated in accordance with approved work instruc-
tions. Detailed results of the calibration, along with date calibrated and by who will be recorded on
the approved calibration form (see Quality Control including Calibration Work Instructions and
Forms). If during re-calibration, the instrument is found to be outside the required calibration limits,
corrective action will be taken. Evaluation will be made to determine the effects the instrument that
is out of calibration may have had on completed or in-process work and to what extent reprocessing
or retesting needs to be done.

5.9 The Chief Engineer or designee will verify that the instrument was calibrated. If the instrument is
unable to be properly calibrated, go to Step 5.10. If it has been properly calibrated, go to Step 5.11.

5.10 All instruments in need of repair because of damage or inability to be calibrated will be sent for re-
pairs or removed from service.

5.11 The results of the calibration or repair or disposal of the instrument should be recorded on the in-
spection, measuring and test equipment log sheet. Any calibration certificate will be filed by the
Chief Engineer or designee.

5.12 Calibration may be extended or delayed on an emergency as needed basis if an instrument is in the
field or is required to satisfy production.

Turblex, Inc.
Revision: 009
Date: 4/27/09

6.1 Test Equipment Calibration Certificate Log, #95120502
6.2 Calibration Label

Control of Non-Conforming Product Procedure
Turblex, Inc.
Control of Non-Conforming Product Procedure (QAP# 4.13-01)
Revision: 009
Date: 4/27/09
1.0 Purpose

1.1 To establish and maintain documented procedures for control and proper dispo-
sition of nonconforming product.

2.0 Scope
2.1 This procedure covers all components and completed units. This includes ven-
dor and customer supplied items, as well as items that are assembled or fabri-
cated by Turblex.

3.0 Key Words

3.1 Non-conforming Product - Product that does not meet the specified require-
ments.


3.3 Corrective/Preventive Action Report - Report filed due to major or recurring non-
conforming product or procedure.

4.0 Reference

4.1 Please reference Procedure 4.10-01 Inspection and Testing.
4.2 Please reference Procedure 4.18-01 Training.
4.3 Please reference Flow Chart 4.13 Control of Non-Conforming Product.
4.4 Please reference Procedure 4.14-01 Corrective and Preventive Action.

5.0 Procedure

5.1 Every employee has the inherent responsibility to look for and identify possible
non-conforming product.

Control of Non-Conforming Prod-
uct Procedure

Turblex, Inc.
Revision: 009
Date: 4/27/09
5.2 If a product or component requiring a technical inspection is received, a two part yellow tag is
placed on the item identifying the need for inspection. One part of the yellow tag will be torn off
and sent to the inspector as notification of inspection need.

5.3 Authorized personnel inspect the product or component.

5.3.1 If the product or component conforms to the requirements the authorized inspector signs
the yellow tag and the item is made available for production.

5.3.2 If the product or component does not conform to the requirements the inspector will notify
the Project Manager who will make an evaluation whether a true non-conformance exists.

5.3.3 If a non-conformance does not exist, the Project Manager signs the yellow tag and the item
is made available for production.

5.4 If a non-conformance does exist, then the Project Manager will place a Red Tag on the item. The
Project Manager will enter the red tag onto a red tag log. The Project Manager will inspect all simi-
lar components for the job and other jobs if appropriate. Feedback will be given to the authorized
inspector of the yellow tag as to the determination of whether there is a non-conformance.

5.4.1 The red tag log will contain all pertinent information pertaining to the non-conformance,
such as tag number, job number if applicable, and initiator of red tag, brief description of
non-conformance, type of non-conformance (category), how the non-conformance was cor-
rected, who corrected it and what date the correction was complete. If the non-
conformance is recurring, a major problem, or the system possibly needs to be changed,
then the non-conformance shall be recorded on a corrective/preventive action report. When
completed, the original report should be filed with the assistant ISO Coordinator and copies
distributed to any departments affected.

5.5 The Material Manager will confer with appropriate personnel to determine the disposition of the
non-conforming product

5.6 The disposition has been made to return the component to the vendor for replacement or credit.

5.6.1 Purchasing shall complete a Returned Goods Authorization (RGA) form to effectively return
the goods to the vendor.

5.7 The disposition has been made to rework or repair the item to meet the customer's specifications.

5.7.1 Purchasing, Engineering, and Manufacturing will determine whether to return the part to
the vendor or rework/repair the part in house. Go to Step 5.6.1 if the part will be returned
to the vendor, otherwise proceed to 5.7.2.

5.7.2 Manufacturing will rework or repair the part.

5.7.3 An item will be re-inspected by engineering once it has been reworked or repaired. If the
item passes the inspection then proceed to Step 5.7.4. If the item fails the inspection, then
return to Step 5.5.

Turblex, Inc.
Revision: 009
Date: 4/27/09
5.7.4 The Red Tag will be removed and the part made available for production.

5.8 Once the customer's concession or waiver is obtained in writing, the Red Tag will be removed by En-
gineering and the part made available for production.

5.9 A re-graded item will be identified as such and used appropriately.

5.10 The item will be scrapped in the appropriate manner under the direction of the Manufacturing Man-
ager.

5.11 The Project Manager is responsible for clearing Yellow and Red Tags before shipment.


6.1 Yellow Tag
6.2 Red Tag
6.3 Corrective/Preventative Action Report, No. 95050901.QAS
6.4 Red Tag Log, No. 95111001.QAS

Corrective and Preventative Action Procedure
Turblex, Inc.
Corrective and Preventative Action Procedure (QAP# 4.14-01)
Revision: 010
Date: 4/27/09
1.0 Purpose

1.1 To establish and maintain documented procedures for corrective and preventive
action.

2.0 Scope
2.1 This procedure covers the analysis to determine the root cause of a non-
conformance and the corrective action to prevent future similar non-
conformances. The procedure also covers the analysis of new or modified proc-
esses or procedures before being implemented to prevent potential non-
conformances.

3.0 Key Words

3.1 Non-conformance - The non-fulfillment of a specified requirement.


4.0 Reference

4.1 Please reference Procedure 4.13-01 Control of Nonconforming Product.
4.2 Please reference Procedure 4.19-01 Servicing Procedure.
4.3 Please reference Flow Chart 4.14-01 Corrective and Preventive Action Procedure.

5.0 Procedure

5.1 A Corrective/Preventive Action can be initiated by:

A. Internal or External Quality Audits
B. Contact Notes / Customer Complaints
C. Field Reports / Service Reports
D. Vendor Analysis Log
E. Red Tag Log
F. A major problem, a recurring problem, or the system possibly needs to be
changed.
Corrective and Preventative Action
Procedure

Corrective and Preventative Action Procedure
Turblex, Inc.
Corrective and Preventative Action Procedure (QAP# 4.14-01)
Revision: 010
Date: 4/27/09
The Corrective/Preventive Action will be logged. The corrective/preventive actions will be identified
by a consecutive numbering system. A Corrective/Preventive Action Report will be completed, which
clearly describes in detail the verified non-conformance or problem being corrected.

5.2 The ISO department, and/or any other necessary personnel, will perform an analysis to determine
the root cause of the non-conformance. This analysis will examine the applicable processes, proce-
dures, work instructions, quality records, customer complaints, service reports, work operations,
and/or any other related items to the non-conformance.

Any new or modified process or procedure will be reviewed by the ISO department and any other
necessary personnel, to detect, analyze and eliminate potential causes of nonconformities before
implementation.

5.3 The ISO department, and/or any other necessary personnel, will evaluate the Corrective/Preventive
Action Report documenting a summary of the analysis performed, root cause, review of the poten-
tial impact on past product, action assigned to, action completed by and the date corrective action is
required. The ISO department will file the original report and distribute copies to the appropriate
areas listed in the distribution box.

5.4 Initiate measures to correct the root cause of the non-conformance.

5.5 Monitor the situation to determine if the actions taken have corrected the non-conformance and
that no other non-conformances were created. If actions taken were effective, then close the Cor-
rective/ Preventive Action Report; otherwise, return to Step 5.2.

5.6 Supplier non-conformances will be handled internally utilizing a Corrective/Preventive Action Report;
however, completion of the report detailing root cause and corrective action to prevent reoccurrence
is beyond our control and may not be attainable in some situations.


6.1 Corrective/Preventative Action Report, Form 95050901.QAS
6.2 Corrective/Preventative Action Report Log, Form 95110901.QAS

Statistical Techniques Procedure
Turblex, Inc.
Statistical Techniques Procedure (QAP# 4.20-01)
Revision: 006
Date: 4/27/09
1.0 Purpose

1.1 To establish and maintain documented procedures to identify the need for sta-
tistical techniques required for establishing, controlling, and verifying process
capability and product characteristics.

2.0 Scope
2.1 This procedure outlines statistical techniques criteria that Turblex must identify
and address in order to comply with ISO 9001.

3.0 Key Words

3.1 None.

4.0 Reference

4.1 Please reference Procedure 4.10-01 Inspection and Testing Procedure.

5.0 Procedure

5.1 Turblex Field Service Surveys retuned from the customer are kept in a binder;
the administrative assistant does a summary of the reports each quarter.

5.2 Turblex Engineering/Start up Surveys returned from the customer are kept in a
binder, the administrative assistant does a summary of the reports each quarter.

5.3 Customer Complaints are documented on Contact Notes and kept in a file to be
reviewed by the Operations Manager who determines if the Customer Complaint
should be recorded on a Corrective/Preventive Action Report. (See 5.6)

5.4 Field Reports and Service Reports are given to the Operations Manager who de-
termines if any issues encountered should be recorded on a Correc-
tive/Preventive Action Report. (See 5.6)


Turblex, Inc.
Statistical Techniques Procedure (QAP# 4.20-01)
Revision: 006
Date: 4/27/09
5.5 Contact Notes used in the area of Field Service and/or Customer Service are kept in a file to be re-
viewed by the Operations Manager who determines if any issues documented should be recorded on
a Corrective/Preventive Action Report. (See 5.6)

5.6 Corrective/Preventive Action Reports are summarized and reviewed in the Management Review
Board Meetings.

5.7 Job Costs - Assembly labor and engineering hours, material costs, and start-up costs are collected
and monitored to measure product cost trends and quality trends (i.e., warranty).

5.8 Warranty - Warranty costs are tracked and compared to budget and previous years. Information is
reviewed in Management Review Board Meeting.

5.9 Red Tag Log - The red tag log is summarized by category and results are reviewed in the Manage-
ment Review Board Meeting.

5.10 Engineering Change Orders - ECO's are grouped into categories and summarized, results are re-
viewed in the Management Review Board Meeting.

5.11 Vendor problem log - Vendor problems are grouped into categories and summarized, results are re-
viewed in the Management Review Board Meeting.

5.12 The following are guidelines for sampling and inspecting incoming fabricated items:

1. 10 pieces or less: Inspect all items.

2. 11 to 100 pieces: A sample of ten percent of the items shall be randomly chosen for inspection.
If two of the pieces are rejected, then an additional ten percent of the items shall be inspected.
If more than a total of 2 rejections are made, then 100% of the delivery shall be inspected.

3. 101 to 1000 pieces or more: A sample of five percent of the items shall be randomly chosen for
inspection. If two of the pieces are rejected, then an additional five percent of the items shall be
inspected. If more than a total of 2 rejections are made, then 100% of the delivery shall be in-
spected.


6.1 Turblex Field Service Surveys
6.2 Turblex Engineering/Start up Surveys
6.3 Field Reports and Service Reports
6.4 Contact Notes
6.5 Corrective/Preventive Actions Reports
6.6 Red Tag Log
6.7 Engineering Change Orders
6.8 Vendor Problem Log

Requirements
Quote/Proposal
Contract
Review
Acceptance
Letter to
Customer
Job File to
Engineering
Design
Type
Project
Design
Control
Design
Change
Control
Submittal
to
Customer
Shop Package to
Materials &
Manufacturing
Purchasing
Purchase Order
to Vendor
C
U
S
T
O
M
E
R
C
U
S
T
O
M
E
R
Approved
Submittal
Incoming
Product
Customer
Supplied
Product
Inspection
& Testing Control of
Inspection
& Test
Equipment
Control of
Non-
Conforming
Product
Product
Shipment
Servicing
Purchase
Order
Submittal
Changes
QUALITY MANAGEMENT PROCESS

Servicing Procedure
Turblex, Inc.
Servicing Procedure (QAP# 4.19-01)
Revision: 009
Date: 4/27/09
1.0 Purpose

1.1 To establish and maintain documented procedures for equipment commission-
ing (start-up including customer training), satisfying warranty needs, and after
sales servicing activities.

2.0 Scope
2.1 This procedure covers all equipment commissioning, warranty needs, after sales
servicing activities, as specified in the contract and customer complaints.

3.0 Key Words

3.1 Job file - A file made up of several books containing information concerning the
job at various stages of completion.

3.2 Jobsite file - A file made up of several books containing information, correspon-
dence, records, reports and various other documents concerning the job after,
but not limited to, start-up.

4.0 Reference

4.1 Please reference Procedure 4.3-01 Contract Review.
4.2 Please reference Procedure 4.14-01 Corrective and Preventive Action.
4.3 Please reference Procedure 4.18-01 Training.

5.0 Procedure

General Statement:

Only qualified individuals will perform start-up, service, and warranty work. The goal of
Turblex is to meet or exceed customer requirements and achieve a high level of cus-
tomer satisfaction at a reasonable cost.

5.1 If this is a service or warranty activity, then proceed to Step 5.2. If this is a start-
up activity, then proceed to Step 5.3.

Servicing Procedure

Servicing Procedure
Turblex, Inc.
Servicing Procedure (QAP# 4.19-01)
Revision: 009
Date: 4/27/09
5.2 Determine the needs of the customer. Determine if it is a warranty issue, a billable service, or parts
job. Discuss the billable or warranty determination with the customer. If a billable job, then give
quote to the customer. The terms of the purchase order from the customer will be reviewed by the
Service or Parts Manager, and the other information contained in the purchase order will be com-
pared to the quote. Once purchase order details have been finalized with the customer, then pro-
ceed to Step 5.4.

5.3 The customer should complete a Compressor (Blower) Pre-Startup Inspection Checklist and send to
Turblex before Turblex personnel or representatives travel to the jobsite.

5.4 The start-up, warranty, billable service, or spare parts work is completed by qualified individuals.
The person performing the work shall fill out the appropriate documentation applicable to the situa-
tion. The documentation and instructions on use and application shall be found in the department
work instruction books. Documentation such as Field Reports serve, not only as final product valida-
tion, but will also determine billable service work; which if billable, the customer should sign-off on
billable hours.

5.5 When the service, warranty, or start-up work is complete, the customer should sign a field ser-
vice/start-up form and/or any other appropriate forms. These forms should signify the beginning
date of the warranty period.

5.6 The field reports and service reports will be given to the Vice-President who will review the reports
to determine if a Corrective/Preventive Action Report is required. (See Procedure 4.19-02 Sec. 5.2)
Copies will be distributed to the appropriate individuals if necessary.

5.6.1 The signed original is then filed in the job file until warranty is up, and the jobsite file after
that.

5.7 The customer will be invoiced for billable service or parts jobs.


6.1 Compressor (Blower) Pre-Startup Inspection Checklist Form, No. 98012802.QAS
6.2 Field Report Form, No. 98011601.QAS
6.3 Field Service/Start-up Sign-off Sheet Form, No. 98011602.QAS
6.4 Contact Notes Form, No. 96040301.QAS

Item E
Production Traveler Quality Assurance
www.turblex.com
QUALITY ASSURANCE PRODUCTION TRAVELER PAGE: 1 OF 26 FORM: 95063001.QAS
JOB NAME: Vallourec & Sumitomo Tubos Do Brasil LTDA REV.: 17
JOB NUMBER: 4607T REV. DATE: 08/15/07
MODEL NUMBER: KA10S-GL400 APPRV. BY: _________
INSPECTION FORMS COMPLETED BY DATE COMPLETED INITIAL
COMPRESSOR INSPECTION FORM PROJ. MGR.
MOTOR INSPECTION FORM PROJ. MGR.
ENGINE INSPECTION FORM PROJ. MGR.
BASE INSPECTION FORM INSPECTOR
CONE AND BLOW-OFF SILENCER INSPECTION FORM INSPECTOR
INLET FILTER SILENCER ASSEMBLY INSPECTION FORM INSPECTOR
BLOW-OFF VALVE INSPECTION FORM PROJ. MGR.
DISCHARGE VALVE INSPECTION FORM PROJ. MGR.
HEADER BLOW-OFF VALVE INSPECTION FORM PROJ. MGR.
FLOW CONTROL VALVE INSPECTION FORM PROJ. MGR.
SHOP COUPLING ALIGNMENT RECORD FORM MFG. MGR.
LUBE OIL PIPING SYSTEM INSPECITON FORM MFG. & PROJ. MGR.
SKID ASSEMBLY SUFACE FINISH INSPECTION FORM MFG. MGR.
LOCAL CONTROL PANEL SYSTEM TEST FORM E. ENG. & PROJ. MGR.
MASTER CONTROL PANEL SYSTEM TEST FORM E. ENG. & PROJ. MGR.
LABELS INSTALLATION RECORD FORM MFG. or PROJ. MGR.
FINAL INSPECTION FORM MFG. & PROJ. MGR.

ELECTRICAL PANEL LAYOUT/CT LOCATION
LOCAL CONTROL PANEL BACK PANEL LAYOUT APPROVAL E. ENG
LOCAL CONTROL PANEL SIDE PANEL LAYOUT APPROVAL E. ENG
LOCAL CONTROL PANEL DOOR LAYOUT APPR0VAL E. ENG
MASTER CONTROL PANEL BACK PANEL LAYOUT APPROVAL E. ENG
MASTER CONTROL PANEL SIDE PANEL LAYOUT APPROVAL E. ENG
MASTER CONTROL PANEL DOOR LAYOUT APPROVAL E. ENG
CT LOCATION APPROVAL PROJ. MGR.
REMARKS:
RED TAGS:

G:\LIB\ISO9000\WI-FORMS\ENGR-SVC\95063001
COMPRESSOR INSPECTION FORM PAGE: 2 OF 26 FORM: 95063001.QAS
RECORD AND VERIFY THE FOLLOWING DATA:
SERIAL NO.
MECHANICAL OIL PUMP MODEL NO.
IGV ACTUATOR MODEL NO.
IGV ACTUATOR SERIAL NO.
IGV ACTUATOR VOLT., FREQ. & PHASE V, Hz, ph V, Hz, ph V, Hz, ph V, Hz, ph
IGV ACTUATOR SPEED & STROKE LENGTH mm/s, mm mm/s, mm mm/s, mm mm/s, mm
IGV ACTUATOR FORCE & AMP. N, Amp N, Amp N, Amp N, Amp
IGV ACTUATOR CAPACITOR IS OK / SIZE / mfd / mfd / mfd / mfd
VD ACTUATOR MODEL NO.
VD ACTUATOR SERIAL NO.
VD ACTUATOR VOLT., FREQ. & PHASE V, Hz, ph V, Hz, ph V, Hz, ph V, Hz, ph
VD ACTUATOR SPEED & STROKE LENGTH mm/s, mm mm/s, mm mm/s, mm mm/s, mm
VD ACTUATOR FORCE & AMP. N, Amp N, Amp N, Amp N, Amp
VD ACTUATOR CAPACITOR IS OK / SIZE / mfd / mfd / mfd / mfd
VERIFY/INSPECT THE FOLLOWING: 100% INSPECTION OF ALL MACHINES REQUIRED BEFORE CHECKED OFF
UNIT IS CONSISTENT WITH HVT PO EXCEPTIONS & RED TAG NOS:
UNIT IS CONSISTENT WITH P&ID AND GA
IGV ACTUATOR
IGV LIMIT SWITCHES
VD ACTUATOR
VD LIMIT SWITCHES
SHAFT & KEY
MECHANICAL OIL PUMP
BEARING RTDS
BEARING RTD FITTINGS
D&T HOLES FOR PROX. PROBES
D&T HOLE FOR ACCELEROMETER
BLOWER DISCHARGE ORIENTATION
DISCHARGE FLANGE ADAPTER
DISCHARGE FLANGE BOLT PATTERN
SPECIAL TOOLS AS RECEIVED
SPARE PARTS AS RECEIVED
NO OIL LEAKAGE AT THE LABYRINTH SEAL VENT COVERS
REMARKS:
DATE INSPECTED
INSPECTOR INITIAL
MOTOR INSPECTION FORM PAGE: 3 OF 26 FORM: 95063001.QAS
SERIAL NO.
HORSE POWER HP HP HP HP
SERVICE FACTOR SF SF SF SF
RPM rpm rpm rpm rpm
VOLTAGE, FREQUENCY & PHASE V, Hz, ph V, Hz, ph V, Hz, ph V, Hz, ph
ENCLOSURE
FRAME
INSULATION CLASS
MAXIMUM AMBIENT TEMPERATURE C C C C
TEMPERATURE RISE C C C C
NEMA DESIGN
NEMA CODE
EFFICIENCY % % % %
POWER FACTOR % % % %
FULL LOAD AMPS Amp Amp Amp Amp
ROTATION @ ODE
SPACE HEATER VOLTAGE & WATTS V, W V, W V, W V, W
VERIFY/INSPECT THE FOLLOWING: 100% INSPECTION OF ALL MACHINES REQUIRED BEFORE CHECKED OFF
UNIT IS CONSISTENT WITH DATA SHEET & PRINT EXCEPTIONS & RED TAG NOS:
UNIT IS CONSISTENT WITH P&ID
SHAFT AND KEY
BEARING RTDS
WINDING RTDS
TEMPERATURE SWITCH
VIBRATION SWITCH
D&T HOLES FOR VIBRATION SENSORS
SUPPLIED VIBRATION SENSORS
OVERSIZED CONDUIT BOX
SURGE CAPACITORS
LIGHTNING ARRESTORS
PF CORRECTION CAPACITORS
DIFFERENTIAL CT'S
SPARE BEARINGS
REMARKS:
DATE INSPECTED
INSPECTOR INITIAL
ENGINE INSPECTION FORM PAGE: 4 OF 26 FORM: 95063001.QAS
SERIAL NO.
NAMEPLATE DATA: RECORD ALL DATA SHOWN ON THE NAMEPLATE IN THE SPACE BELOW. THERE MAY BE MORE THAN ONE NAMEPLATE.
VERIFY NAMEPLATE DATA IS CONSITENT WITH EXCEPTIONS & RED TAG NOS:
DESIGN SPECIFICATION
VERIFY THE FOLLOWING USING THE ENGINE INSTALLATION DRAWINGS:
ENGINE ROTATION EXCEPTIONS & RED TAG NOS:
ENGINE MOUNTING HOLE SIZES & LOCATIONS
GENARAL LOCATIONS OF ENGINE COMPONENTS
SIZES AND LOCATIONS OF ALL ENGINE
CONNECTIONS
VERIFY ALL SHIP LOOSE COMPONENTS AND ASSEMBLIES. RECORD THE DESCRIPTION OF EACH ITEM IN THE SPACE BELOW.
EXCEPTIONS & RED TAG NOS:
REMARKS:
DATE INSPECTED
INSPECTOR INITIAL
BASE INSPECTION FORM PAGE: 5 OF 26 FORM: 95063001.QAS
NOTE: VERIFY ALL DIMENSIONS TO TAPE MEASURE ACCURACY OF +/- 1/8".
UNIT NO. EXCEPTIONS & RED TAG NOS.
VERIFY/INSPECT THE FOLLOWING:
OVERALL HxLxW
VIBRATION ISOLATOR ANCHOR HOLES
LIFTING LUB STAMPED WITH THE JOB NO.
OIL DRAIN COUPLING IS 1 1/2" NPT
SIGHT GLASS COUPLING IS VERTICAL
LCP & COOLER BRACKETS ARE LEVEL & SQUARE
MOTOR MOUNTS ARE WELDED INSIDE & OUT
ALL WELDS ARE CLEAN & UNIFORM
DATE INSPECTED:
INSPECTOR INITIALS:
NOTE: VERIFY THE OIL RESERVOIRS ARE WATER TIGHT
NO LEAKS AFTER 12 HRS
DATE INSPECTED:
MFG MANAGER INITIALS:
MACHINED DIMENSIONS MATCH THE PRINT
MATING SURFACES FREE OF DEFECTS/RUST
FLANGE GASKETS & PLUGS INSTALLED
DATE INSPECTED:
INSPECTOR INITIALS:
ALL BURRS, TACK WELDS, & JAGGED EDGES ARE
GROUND SMOOTH
PHYSICALLY & DIMENSIONALLY CORRECT PER
PRINT
NOTE: VERIFY ALL MACHINING DIMENSIONS TO TAPE MEASURE ACCURACY OF +/- 1/16"
RESERVOIR COATING (FREE OF HOLIDAY RUNS &
UNIFORM IN COLOR)
THREADED HOLES (FREE OF DEBRIS & THREADS
APPEAR UNIFORM)
EXTERNAL PRIMER (FREE OF HOLIDAY RUNS &
UNIFORM IN COLOR
CONE AND BLOW-OFF SILENCER INSPECTION FORM PAGE: 6 OF 26 FORM: 95063001.QAS
CONE INSPECTION:
UNIT NO.
OVERALL LENGTH EXCEPTIONS & RED TAG NOS:
BLOW-OFF PIPE LOCATION
INLET FLANGE
DISCHARGE FLANGE
BLOW-OFF FLANGE
PITOT TUBE HOLES ORIENTATION
INLET FLANGE ORIENTATION
DISCHARGE FLANGE ORIENTATION
BLOW-OFF FLANGE ORIENTATION
MATING SURFACES (FREE OF DEFECTS/RUST)
FLANGE TO FLANGE SQUARENESS
WELDS (CONFORM TO DRAWING
SPECIFICATION, CLEAN AND UNIFORM)
CONE INTERIOR (CLEAN & FREE OF DEFECT)
COUPLINGS & PLUGS INSTALLED
THREADED HOLES (FREE OF DEBRIS AND
THREADS APPEAR UNIFORM)
PRESSURE TEST COMPLETED BY VENDOR
REMARKS:
DATE INSPECTED
INSPECTOR INITIAL
BLOW-OFF SILENCER INSPECTION:
UNIT NO.
OVERALL HEIGHT EXCEPTIONS & RED TAG NOS:
SILENCER DIAMETER
CONNECTING FLANGE
MATING SURFACES (FREE OF DEFECTS/RUST)
INTERIOR (CLEAN & FREE OF DEFECT)
WELDS (CONFORM TO DRAWING
SPECIFICATION, CLEAN AND UNIFORM)
REMARKS:
DATE INSPECTED
INSPECTOR INITIAL
INLET FILTER SILENCER ASSEMBLY INSPECTION FORM PAGE: 7 OF 26 FORM: 95063001.QAS
UNIT NO.
OVERALL HxLxW EXCEPTIONS & RED TAG NOS:
VERTICAL CENTERLINE
HORIZONTAL CENTERLINE
INLET CONNECTING FLANGE
OUTLET CONNECTING PIPE
INLET FLANGE (FREE OF DEFECTS)
OUTLET PIPE (FREE OF DEFECTS)
FILTER HOUSING (FREE OF DEFECTS)
FILTER/SILENCER INTERFACE (PROPERLY
SEALED AND ALL FASTENERS TIGHTENED)
SILENCER WALL PANELS (PROPERLY SEALED
AND ALL FASTENERS TIGHTENED)
SILENCER/SHROUD INTERFACE (PROPERLY
SEALED AND ALL FASTENERS TIGHTENED)
LIFTING LUGS AND FEET INSTALLED
PRESSURE SENSING PORT (COUPLING AND
PIPE INSTALLED)
ALL EXPOSED SURFACES (FREE DEFECT AND
PROPERLY GALVANIZED)
INTERIOR (CLEAN AND FREE OF FOREIGN
OBJECTS
LAMELLAS (CLEAN AND FREE OF TEARS)
ANY FOAM DAMAGED MUST BE REPAIRED.
REMARKS:
DATE INSPECTED
INSPECTOR INITIAL
BLOW-OFF VALVE INSPECTION FORM PAGE: 8 OF 26 FORM: 95063001.QAS
RECORD AND VERIFY THE FOLLOWING:
VALVE SERIAL NO. ('S)
VALVE SIZE
VALVE TYPE
VALVE MODEL
ACTUATOR SERIAL NO. ('S)
ACTUATOR TYPE
ACTUATOR MODEL
ACTUATOR VOLTAGE
ACTUATOR MOTOR CURRENT
ACTUATOR TRAVEL TIME
VALVE BODY EXCEPTIONS & RED TAG NOS:
VALVE SEAT
VALVE DISC
ACTUATOR HOUSING
LOCAL CONTROL STATION
PAINT
ACTUATOR ORIENTATION
MATCHES PIPING
CONFIGURATION
WON'T INTERFERE WITH
NEARBY PIPING COMPONENTS
REMARKS:
DATE INSPECTED
INSPECTOR INITIAL
DISCHARGE VALVE INSPECTION FORM PAGE: 9 OF 26 FORM: 95063001.QAS
VALVE SIZE
VALVE TYPE
VALVE MODEL
ACTUATOR TYPE
ACTUATOR MODEL
ACTUATOR VOLTAGE
VALVE SEAT
VALVE DISC
ACTUATOR HOUSING
PAINT
MATCHES PIPING
CONFIGURATION
REMARKS:
DATE INSPECTED
INSPECTOR INITIAL
HEADER BLOW-OFF VALVE INSPECTION FORM PAGE: 10 OF 26 FORM: 95063001.QAS
VALVE SIZE
VALVE TYPE
VALVE MODEL
ACTUATOR TYPE
ACTUATOR MODEL
ACTUATOR VOLTAGE
VALVE SEAT
VALVE DISC
ACTUATOR HOUSING
PAINT
MATCHES PIPING
CONFIGURATION
REMARKS:
DATE INSPECTED
INSPECTOR INITIAL
FLOW CONTROL VALVE INSPECTION FORM PAGE: 11 OF 26 FORM: 95063001.QAS
VALVE SIZE
VALVE TYPE
VALVE MODEL
ACTUATOR TYPE
ACTUATOR MODEL
ACTUATOR VOLTAGE
VALVE SEAT
VALVE DISC
ACTUATOR HOUSING
PAINT
MATCHES PIPING
CONFIGURATION
REMARKS:
DATE INSPECTED
INSPECTOR INITIAL
SHOP COUPLING ALIGNMENT RECORD FORM PAGE: 12 OF 26 FORM: 95063001.QAS
ALIGNMENT RECORD (BY SHOP PERSONNEL):
COMPRESSOR SERIAL NO.
MOTOR SERIAL NO.
DATE ALIGNED
NOTES:
SPACER TOLERANCE: 9 IN +1/32" - 0" 0 DEG.
MAX. ALLOWABLE MISALIGNMENT: 0.002 IN
MAX. ALLOWABLE SOFT FOOT: 0.002 IN
270 DEG.
90 DEG.
180 DEG.
LOOKING AT THE COMPRESSOR SHAFT.
ALIGNMENT READINGS:
SPACER DISTANCE
0 DEG. RADIAL
0 DEG. AXIAL
90 DEG. RADIAL
90 DEG. AXIAL
180 DEG. RADIAL
180 DEG. AXIAL
270 DEG. RADIAL
270 DEG. AXIAL
SOFT FOOT READINGS: (LOOKING AT NDE OF MOTOR) @ 0 DEG RADIAL
LEFT NDE
LEFT DE
RIGHT NDE
RIGHT DE
REMARKS:
ALIGNED BY
APPROVED BY (MFG MGR OR PROJ. MGR)
LUBE OIL PIPING SYSTEM INSPECTION FORM PAGE: 13 OF 26 FORM: 95063001.QAS
WATER PIPING ASSEMBLY INSPECTION AND TESTING (BY MFG MGR):
VERIFY THE FOLLOWING
UNIT ASSEMBLED PER DRAWINGS AND ECOS EXCEPTIONS & RED TAG NOS:
COMPONENT FLOW DIRECTION CORRECT
UNIT PASSED PRESSURE TEST (CERTIFIED THAT
ALL PIPE CONNECTIONS ARE LEAK FREE)
REMARKS:
DATE INSPECTED / TESTED
INSPECTOR INITIAL
OIL PIPING ASSEMBLY INSPECTION (BY MFG MGR):
VERIFY THE FOLLOWING
UNIT ASSEMBLED PER DRAWINGS AND ECOS EXCEPTIONS & RED TAG NOS:
FILTER DIFFERENTIAL SWITCHES ARE INSTALLED
CORRECTLY (Per manufacture instructions)
DIPSTICK IS CORRECTLY MARKED
UNIT PASSED 225 PSI DRY NITROGEN PRESSURE
TEST
IF AIR COOLED, AMOT VALVE CONNECTIONS
ARE CORRECT FOR MIXING APPLICATION
REMARKS:
DATE INSPECTED
INSPECTOR INITIAL
OIL PIPING ASSEMBLY TESTING (BY PROJ. MGR):
VERIFY THE FOLLOWING:
UNIT PASSED 24 HOURS TEST (CERTIFIED THAT EXCEPTIONS & RED TAG NOS:
ALL FLANGE & PIPE CONNECTIONS, ALL RTDS &
PROX PROBES, MOTOR BEARING HOUSINGS &
& BLOWER GEARBOX, AND ALL PLUGS ARE LEAK
FREE)
NO OIL LEAKAGE AT THE LABYRINTH SEAL VENT
COVERS
REMARKS:
DATE TESTED
INSPECTOR INITIAL
COUPLING GUARD (BY PROJ. MGR):
COUPLING GUARD DRAWING HAS BEEN ISSUED EXCEPTIONS & RED TAG NOS:
AND RELEASED TO PURCHASING.
REMARKS:
DATE COMPLETED
INSPECTOR INITIAL
SURFACE FINISH INSPECTION FORM PAGE: 14 OF 26 FORM: 95063001.QAS
SERIAL NO.
BEFORE PAINTING:
VERIFY ALL SURFACES ARE PREPARED PER EXCEPTIONS & RED TAG NOS:
TURBLEX COATING SYSTEM SPECIFICATION
RECORD THE THICKNESSES (MILS DFT) OF THE ORIGINAL COATINGS ON THE COMPRESSOR, MOTOR, BASE, CONE & BLOW-OFF SILENCER IN THE SPACE BELOW.
RECORD THREE DIFFERENT POINTS ON EACH COMPONENT.
COMPRESSOR / / / / / / / /
MOTOR / / / / / / / /
BASE / / / / / / / /
CONE / / / / / / / /
BLOW-OFF SILENCER / / / / / / / /
AFTER APPLICATION OF PRIMER COAT:
RECORD THE COMBINED THICKNESSES (MILS DFT) OF THE ORIGINAL AND PRIMER COATINGS ON THE COMPRESSOR, MOTOR, BASE, CONE & BLOW-OFF SILENCER IN
THE SPACE BELOW. RECORD THREE DIFFERENT POINTS ON EACH COMPONENT.
COMPRESSOR / / / / / / / /
MOTOR / / / / / / / /
BASE / / / / / / / /
CONE / / / / / / / /
VERIFY PRIMER THICKNESS CONFORMS TO EXCEPTIONS & RED TAG NOS:
TURBLEX COATING SYSTEM SPECIFICATION
AFTER APPLICATION OF FINISH COAT:
RECORD THE COMBINED THICKNESSES (MILS DFT) OF THE ORIGINAL, PRIMER AND FIHISH COATINGS ON THE COMPRESSOR, MOTOR,
BASE, CONE & BLOW-OFF SILENCER IN THE SPACE BELOW. RECORD THREE DIFFERENT POINTS ON EACH COMPONENT.
COMPRESSOR / / / / / / / /
MOTOR / / / / / / / /
BASE / / / / / / / /
CONE / / / / / / / /
VERIFY FINISH COAT THICKNESS CONFORMS EXCEPTIONS & RED TAG NOS:
TO TURBLEX COATING SYSTEM SPECIFICATION
VERIFY SURFACE FINISH IS FREE OF HOLIDAYS
AND RUNS
VERIFY COLOR AND TEXTURE ARE UNIFORM
REMARKS:
DATE INSPECTED
INSPECTOR INITIAL
LOCAL CONTROL PANEL SYSTEM TEST FORM PAGE: 15 OF 26 FORM: 95063001.QAS
SYSTEM INSTALLATION CHECK (BY ELEC. ENG.):
UNIT NO.
VERIFY / PERFORM THE FOLLOWING:
CONTROL PANEL IS WIRED PER SCHEMATICS REMARKS:
J-BOXES ARE WIRED PER SCHEMATICS
SKID COMPONENTS ARE WIRED TO J-BOXES
AND LCP PER SCHEMATICS
VALVES ARE WIRED TO LCP PER SCHEMATICS
VOLTAGE CHECK AC AND DC POWERS
SET OVERLOADS ON MOTOR STARTERS PER
SCHEMATICS (VERIFY ACTUAL DEVICE RATING)
TRIP TEST AND RESET GFCI
LOAD SOFTWARES
CONFIRM ALL DIGITAL & ANALOG SIGNALS
ARE ACTIVE AND CORRECT PER SCHEMATICS
VERIFY BLOWER AND MOTOR BEARING RTDS
BY DISCONNECTING WIRE AT TRANSMITTER
SET BOV OPEN/CLOSE LIMIT SWITCHES
SET DV OPEN/CLOSE LIMIT SWITCHES
SET IGV / VD LIMIT SWITCHES PER PRC-4
VERIFY AUTO CALIBRATION FOR IGV AND VD
(RANGE OF R/I UNIT IS 100 OHMS TO 900 OHMS)
AUTOMATIC VANE EXERCISE - EVERY 12HRS
COMPLETE PRC-4 TABLE AND ATTACH TO
THIS DOCUMENT WHEN COMPLETED
DATE COMPLETED ABOVE CHECKS
CHECKED BY (ELEC. ENG.)
ECO CLOSE OUT (BY PROJ MGR)
REMARKS
ECO LOG COMPLETED
PROJECT MGR INITIAL/DATE
AS BUILT CLOSE OUT (BY PROJ MGR)
REMARKS
PROJECT MGR INTIAL/DATE
RED TAG CLOSE OUT (BY PROJ MGR)
VERIFY ALL RED TAGS ARE REMOVED REMARKS
VERIFY ALL CORRECTIONS ARE RECORDED ON
RED TAG LOG
PROJECT MGR INTIAL/DATE
GA, LUBE OIL PIPING, AND BASE DRAWINGS
UPDATED TO REFLECT FINISHED SKID ASSEMBLY
ALL ECO'S RELEASED TO PRODUCTION ARE
COMPLETED, SIGNED-OFF, AND RETURNED TO
PRODUCTION TRAVELER
ALL SIGNED-OFF ECO'S TRANSFERRED TO JOB
FILE
ALL RED LINED SHOP DRAWINGS COLLECTED AND
CHANGES TRANSFERRED TO AS BUILT DRAWINGS
SYSTEM FUNCTIONAL CHECK (BY ELEC. ENG. & VERIFIED BY PROJ. MGR)
NORMAL/SERVICE/TEST MODES: SWITCH BETWEEN NORMAL/SERVICE/TEST/ MODES SEVERAL TIMES AND VERIFY THE FOLLOWING.
PAY CLOSE ATTENTION TO THE STATUS MESSAGES, CHECK FOR CORRECT DESCRIPTION AND SPELLING.
VERIFY THE MODE SELECTION REMARKS:
BUTTONS FUNCTION PROPERLY AND
DISPLAY CORRECT TEXT
EACH MODE STATUS IS CORRECTLY
DISPLAYED ON MAIN OPERATING SCREEN
ALARM IS ACTIVATED AND STAYS ACTIVATED
WHEN IN SERVICE MODE
START IS INHIBITED WHEN IN SERVICE MODE
SERVICE MODE OPERATIONS CHECK: PLACE LCP IN THE SERVICE MODE, VERIFY THE FOLLOWING DEVICES OPERATE AS DECRIBED IN THE LCP
PROCEDURE AND CONFIRM ALL STATUS INFORMATION IS CORRECTLY DISPLAYED ON THE SCREEN(S).
AUX. OIL PUMP AND ON/OFF BUTTONS REMARKS:
FUNCTION PROPERLY AND DISPLAY
CORRECT TEXT AND COLOR CHANGE
IGV AND OPEN/CLOSE BUTTONS
IGV GRAPHIC AND/OR NUMERIC VALUE ARE
DISPLAYED CORRECTLY
VD AND OPEN/CLOSE BUTTONS
VD GRAPHIC AND/OR NUMERIC VALUE ARE
DISPLAYED CORRECTLY
BOV AND OPEN/CLOSE BUTTONS
DV AND OPEN/CLOSE BUTTONS
OIL COOLER FAN AND ON/OFF BUTTONS
COOLING WATER SOL. VALVE AND ON/OFF
DISPLAY CORRECT TEXT AND COLOR
CHANGE
SOUND ENCLOSURE FAN AND ON/OFF
BUTTON FUNCTION PROPERLY AND
DISPLAY CORRECT TEXT AND COLOR
CHANGE
OIL HEATER AND ON/OFF BUTTONS
AUTO CALIBRATE IGV & VD BUTTON TO FUNCTION
PROPERLY AND DISPLAY CORRECT TEST &
COLOR CHANGE. BUTTON IS DISABLED WHEN
ON-LINE OR DURING START-UP SEQUENCE
START SEQUENCE CHECK: PLACE LCP IN THE TEST MODE, VERIFY THE START SEQUENCE OPERATES AS DESCRIBED IN THE LCP PROCEDURE
AND CONFIRM ALL STATUS INFORMATION IS CORRECTLY DISPLAYED ON THE SCREEN.
PAY CLOSE ATTENTION TO THE SEQUENCE MESSAGES, CHECK FOR CORRECT DESCRIPTION AND SPELLING.
BLOWER START BUTTON AND START REMARKS:
SEQUENCE FUNCTION PROPERLY AND
STATUS MESSAGES ARE CORRECTLY
DISPLAYED ON THE MESSAGE CENTER
VD AND OPEN/CLOSE BUTTONS
VD/AMPS GRAPHICS AND NUMERIC
VALUES ARE DISPLAYED CORRECTLY
IGV AUTOMATICALLY RESPONSE TO PRC-4
CONTROL AS BLOWER CAPACITY VARIES
LOCAL/REMOTE SELECTION SWITCH
VERIFY CR1 DOES NOT ENERGIZE IN TEST MODE
STOP SEQUENCE CHECK: PLACE LCP IN THE TEST MODE, VERIFY THE STOP SEQUENCE OPERATES AS DESCRIBED IN THE LCP PROCECURE
AND CONFIRM ALL STATUS INFORMATION IS PROPERLY DISPLAYED ON THE SCREEN.
PAY CLOSE ATTENTION TO THE SEQUENCE MESSAGES, CHECK FOR CORRECT DESCRIPTION AND SPELLING.
BLOWER STOP BUTTON AND NORMAL STOP REMARKS:
DISPLAYED ON THE MESSAGE CENTER
E-STOP BUTTON AND E-STOP
DISPLAYED ON THE MESSAGE CENTER,
AND THE ALARM WINDOW
SIMULATE A SOFT STOP - SOFT STOP
DISPLAYED ON THE MESSAGE CENTER,
AND THE ALARM WINDOW
ALARM / TRIP FUNCTIONAL CHECK: PLACE LCP IN THE TEST OR NORMAL MODE, SIMULATE THE FOLLOWING ABNORMAL CONDITIONS AND
VERIFY THEIR ALARM / TRIP FUNCTIONS OPERATE AS DESCRIBED IN THE LCP PROCEDURE, CONFIRM ALL
ALARM MESSAGES ARE CORRECTLY DISPLAYED ON THE ALARM WINDOWAND HORN/BEACON ARE ENERGIZED.
PAY CLOSE ATTENTION TO THE ALARM MESSAGES, CHECK FOR CORRECT DESCRIPTION AND SPELLING.
SOFT STOP IS INITIATED BY:
HIGH OIL TEMPERATURE REMARKS:
HIGH INLET AIR TEMERATURE
HIGH BLOWER BEARING TEMPERATURE
HIGH MOTOR BEARING TEMPERATURE
HIGH MOTOR WINDING TEMPERATURE
SURGE
HIGH MOTOR AMPERAGE
E-STOP IS INITIATED BY:
LOW OIL PRESSURE REMARKS:
LOW/LOW OIL PRESSURE REMARKS:
HIGH BLOWER VIBRATION
HIGH MOTOR VIBRATION
BOV NOT CLOSED AT START SEQUENCE
BOV NOT OPEN AT STOP SEQUENCE
CHECK THE NEXT THREE IN NORMAL MODE
NO MOTOR FEEDBACK AT START SEQUENCE
LOSS OF MOTOR FEEDBACK
MOTOR NOT STOPPED AT STOP SEQUENCE
CONFIRM ALARM ACKNOWLEDGE
BUTTON FUNCTIONS PROPERLY
AUTOMATIC PLC SAFETY OPERATIONS CHECK: PLACE LCP IN THE TEST MODE, VERIFY THE FOLLOWING PLC OPERATIONS AS DESCRIBED IN THE
LCP PROCEDURE AND CONFIRM ALL ALARM MESSAGES ARE CORRECTLY DISPLAYED ON
ON THE ALARM WINDOW, AND HORN/BEACON ARE ENERGIZED.
PAY CLOSE ATTENTION TO THE ALARM MESSAGES, CHECK FOR CORRECT DESCRIPTION AND SPELLING.
LOW OIL TEMPERATURE ALARM - AUX. REMARKS:
OIL PUMP ENERGIZED UNTIL 2 MINUTES
AFTER ALARM IS CLEARED
LOW-LOW OIL TEMPERATURE ALARM -
START INHIBIT UNTIL ALARM IS CLEARED
HIGH MOTOR AMPS ALARMS - VD LIMIT @
98% FLA, REDUCE VD @ 102% FLA AND TRIP
@ 105% FLA AFTER 45 SECS WATCH DOG
REVERSE ROTATION ALARM - AUX.
OIL PUMP ENERGIZED UNTIL 2 MINUTES
AFTER ALARM IS CLEARED
DIRTY OIL FILTER ALARM - ALARM ONLY
DIRTY INLET FILTER ALARM - ALARM ONLY
LOW OIL LEVEL ALARM - ALARM ONLY
RESTART BLOCKING - START INHIBIT
UNTIL ALARM IS CLEARED

AUTO/REMOTE MODE OPERATIONS CHECK: PLACE LCP IN AUTO/REMOTE MODE, VERIFY THE FOLLOWING OPERATIONS AS DESCRIBED IN THE LCP
PROCEDURE AND CONFIRM ALL STATUS INFORMATION IS CORRECTLY DISPLAYED ON SCREEN.
REMOTE START/STOP REMARKS:
(IF MCP IS NOT PROVIDED)
REMOTE INCREASE/DECREASE
ALL SPECIAL REMOTE SIGNALS AND CONTROLS
OPERATOR INTERFACE SCREENS CHECK: GO THROUGH EACH SCREEN AND VERIFY THE FOLLOWING.
MAIN OPERATOINS SCREEN: VERIFY ALL
TOUCH COMMANDS FUNCTION PROPERLY,
ALL TEXT LABELS, SPELLING, COLOR
CODE AND ANALOG SCALES ARE CORRECT
SERVICE SCREEN: VERIFY ALL TOUCH
COMMANDS FUNCTION PROPERLY, ALL TEXT
LABELS, SPELLING, COLOR CODE, AND
ANALOG SCALES ARE CORRECT
AIR MONITOR SCREEN: VERIFY ALL
OIL SYSTEM MONITOR SCREEN: VERIFY ALL
BLOWER BRG TEMP SCREEN: VERIFY ALL
BLWR VIBRATION SCREEN: VERIFY ALL
MTR TEMP/AMP SCREEN: VERIFY ALL
MTR VIBRATION SCREEN: VERIFY ALL
TRANS MONITOR SCREENS: VERIFY ALL
ALL TEXT LABELS, SPELLING, AND
ALARM/TRIP COUNTER SCREENS: VERIFY ALL
ALL TEXT LABELS, SPELLING AND COLOR
CODE ARE CORRECT
ALARM/TRIP DISPLAY SCREEN: VERIFY ALL
ALL TEXT LABELS, SPELLING AND COLOR
CODE ARE CORRECT
TRANS SCALE SETUP SCREENS: VERIFY ALL
ALARM AND TRIP SETPOINT SCREENS: VERIFY ALL REMARKS:
ALL TEXT LABELS, SPELLING, AND COLORS
ARE CORRECT
PASSWORD ENTRY SCREEN: VERIFY ALL REMARKS:
ARE CORRECT
PASSWORD CHANGE SCREEN: VERIFY ALL REMARKS:
ARE CORRECT
SET POINTS AND DEFAULT MODES FINAL CHECK: COMPLETE THE FOLLOWING CHECKS PRIOR TO SHIPPING.
ALL ALARM/TRIP SETPOINTS ARE CORRECTLY REMARKS:
SET PER THE STANDARD SETTINGS
ALL ANALOG UPPER/LOWER RANGES ARE
CORRECTLY SET PER EACH INSTRUMENTS
ACTUAL CALIBRATED RANGE
ALL TIMERS AND DEFAULTS ARE PROPERLY
SET PER STANDARD DEFAULTS
CHECKED BY (EE) / SIGN-OFF BY (PM)
MASTER CONTROL PANEL SYSTEM TEST FORM PAGE: 21 OF 26 FORM: 95063001.QAS
SYSTEM INSTALLATION CHECK (BY ELEC. ENG.):
CONTROL PANEL IS WIRED PER SCHEMATICS REMARKS:
INTERCONNECT CABLES TO/FROM LCPS AND
FIELD DEVICES ARE CONNECTED
CONNECT ONE OF EACH DEVICE (DO, FLOW, TEMP)
TO VERIFY WIRING SCHEMATICS ARE CORRECT
ALL VALVES ARE WIRED PER SCHEMATICS
PERFORM THE FOLLOWING:
VOLTAGE CHECK AC AND DC POWERS
SET OVERLOADS ON MOTOR STARTERS PER
SCHEMATICS (VERIFY ACTUAL DEVICE RATING)
TRIP TEST AND RESET GFCI
LOAD SOFTWARES
CONFIRM ALL DIGITAL & ANALOG SIGNALS
ARE ACTIVE AND CORRECT PER SCHEMATICS
ZERO / SPAN R/I TRANSMITTERS
CONFIRM ALL COMMUNICATIONS WITH LCPS
AND FIELD DEVICES ARE ACTIVE AND CORRECT
SET BASIN VALVE OPEN/CLOSE
LIMIT SWITCHES
CALIBRATE BASIN VALVE POSITIONING AND
POSITION FEEDBACK
SET HBOV OPEN/CLOSE LIMIT SWITCHES
CALIBRATE HBOV POSITIONING AND POSITION
FEEDBACK
CHECKED BY (ELEC. ENG.)
SYSTEM FUNCTIONAL CHECK (BY ELEC. ENG. & VERIFIED BY PROJ. MGR)
SERVICE MODE OPERATIONS CHECK: PLACE FOLLOWING DEVICES IN THE SERVICE MODE, VERIFY THEIR OPERATIONS AS DECRIBED IN THE MCP
PROCEDURE AND CONFIRM ALL STATUS INFORMATION ARE CORRECTLY DISPLAYED ON THE SCREEN(S).
HBOV, MODE SELECTION AND OPEN/CLOSE REMARKS:
DISPLAY CORRECT POSITION, TEXT AND
COLOR CHANGE
CONTROL VALVE, MODE SELECTION AND
OPEN/CLOSE BUTTONS FUNCTION PROPERLY
AND DISPLAY CORRECT POSITION, TEXT
AND COLOR CHANGE

MCP CONTROL LOOPS CHECK: VERIFY THE FOLLOWING MCP OPERATIONS AS DESCRIBE IN THE MCP PROCECURE AND CONFIRM ALL STATUS
INFORMATION ARE PROPERLY DISPLAYED ON THE SCREENS.
BLOWER LEAD/LAG OPERATION, LEAD/LAG REMARKS:
SELECTION AND BLOWER MODE SELECTION
DISPLAY CORRECT BLOWER STATUS,
TEXT AND COLOR CHANGE
PRESSURE CONTROL SELECTION AND
SETPOINT BUTTONS FUNCTION PROPERLY
AND DISPLAY CORRECT STATUS, TEXT
AND COLOR CHANGE
CASCADE (PARALLEL) CONTROL ON
INCREASING DEMAND FUNCTION PROPERLY
AND DISPLAY CORRECT BLOWER STATUS
CASCADE (PARALLEL) CONTROL ON
DCREASING DEMAND FUNCTION PROPERLY
AND DISPLAY CORRECT BLOWER STATUS
FLOW CONTROL SETPOINT BUTTONS
CORRECT STATUS AND TEXT
DO CONTROL SETPOINT BUTTONS
CORRECT STATUS AND TEXT

OPERATOR INTERFACE SCREENS CHECK: GO THROUGH EACH SCREEN AND VERIFY THE FOLLOWING.
MENU SCREEN: VERIFY ALL TOUCH REMARKS:
COMMANDS FUNCTION PROPERLY, ALL
TEXT LABELS AND SPELLING ARE CORRECT
BLWR CONTROL & SEQUENCE SCREEN:
VERIFY ALL TOUCH COMMANDS FUNCTION
PROPERLY, ALL TEXT LABELS, SPELLING,
COLOR CODE AND ANALOG SCALES ARE
CORRECT
BASIN/TANK CONTROL SCREENS:
VERIFY ALL TOUCH COMMANDS FUNCTION
PROPERLY, ALL TEXT LABELS, SPELLING,
COLOR CODE AND ANALOG SCALES ARE
CORRECT
TRANS MONITOR SCREENS: VERIFY ALL REMARKS:
TIMING/SCALING SET UP SCREENS: VERIFY
ALL TOUCH COMMANDS FUNCTION
PROPERLY ALL TEXT LABELS, SPELLING,
AND ANALOG SCALES ARE CORRECT
MOV CALIBRATION SCREEN: VERIFY ALL
ALL TEXT LABELS AND SPELLING ARE
CORRECT

DEFAULT MODES FINAL CHECK: COMPLETE THE FOLLOWING CHECKS PRIOR TO SHIPPING.
ALL ANALOG UPPER/LOWER RANGES ARE REMARKS:
CORRECTLY SET PER EACH INSTRUMENT'S
ACTUAL CALIBRATED RANGE
ALL TIMERS AND DEFAULTS ARE PROPERLY
SET PER STANDARD DEFAULTS
CHECKED BY (EE) / SIGN-OFF BY (PM)
LABELS INSTALLATION RECORD FORM PAGE: 24 OF 26 FORM: 95063001.QAS
LABELS INSTALLATION RECORD (BY MFG MGR OR PROJ. MGR):
SERIAL NO.
CAUTION: DO NOT OPERATE WITHOUT GUARDS. REMARKS:
THIS MACHINE MAY START AND STOP AUTOMATICALLY
(ON COUPLING GUARD)
CAUTION: THIS EQUIPMENT STARTS
AND STOPS AUTOMATICALLY
(ON COUPLING GUARD)
CAUTION: DO NOT OPERATE WITHOUT GUARDS.
THIS MACHINE MAY START AND STOP AUTOMATICALLY
(ON CONTROL PANEL DOOR)
DANGER: ELECTRICAL HAZARD
AUTHORIZED PERSONNEL ONLY
DIECAST TURBLEX LOGO, 13" X 3"
(ON COUPLING GUARD -KA44 &UP)
DIECAST TURBLEX LOGO, 7" X 2"
(ON CONTROL PANEL FRONT AND
COUPLING GUARD - KA22 & DOWN)
SS COMPRESSOR NAMEPLATE
(ON COMPRESSOR GEARBOX)
SET @ 15 PSIG LABEL
(ON LLPS BRACKET)
SET @ 29 PSIG LABEL
(ON LPS BRACKET
SET @ 5.5 " W.C. LABEL TOTAL IF PDS
SHOWS 0.2 PSI DROP (LOCATE LABEL ON DPISH BRACKET)
SET @ 4.125 " W.C. LABEL TOTAL IF PDS
SHOWS 0.15 PSI DROP(LOCATE LABEL ON DPISH BRACKET)
SET @ 1 " W.C. LABEL ON PRE-FILTER,
(LOCATE LABEL ON DPISH BRACKET)
SET @ 4" W.C. LABEL ON THE FINAL FILTER
(ON DPISH BRACKET)
SCALE
__________ TO ___________
(MECAHNICAL LIMIT SWITCH LABELS ON IGV BRACKET)
SCALE
__________ TO ___________
(MECAHNICAL LIMIT SWITCH LABELS ON VD BRACKET)
UL CONTACTOR RATINGS LABEL
UL APPROVED LABEL
(INSIDE CONTROL PANEL DOOR)
UL FUSE LIST
(BEHIND CONTROL PANEL DOOR)
LABELS INSTALLATION RECORD FORM PAGE: 25 OF 26 FORM: 95063001.QAS
LABELS INSTALLATION RECORD (CONTINUE)
TEST GFCI MONTHLY LABEL REMARKS:
(ON GFCI)
TERMINAL TIGHTENING TORQUES LABELS
(NEXT TO TERMINAL BLOCKS)
EMERGENCY STOP LABEL
(E-STOP BUTTON)
HOUR METER LABEL
(ABOVE HOUR METER)
UNIT NUMBER LABEL
(ON CONTROL PANEL)
BUILT BY LABEL
(INSIDE CONTROL PANEL)
TESTED BY LABEL
ACCEPTED BY LABEL
DATE COMPLETED
INSPECTED BY
FINAL INSPECTION FORM PAGE: 26 OF 26 FORM: 95063001.QAS
FINAL INSPECTION RECORD (BY MFG MGR & PROJ. MGR):
NOTE: EQUIPMENT CANNOT BE DISPATCHED BEFORE THIS FORM IS COMPLETED.
DATED COMPLETED COMPLETED BY REMARKS:
ELECTRICAL "AS BUILT" DRAWINGS FINISHED
AND INSERTED IN CONTROL PANELS
SHIP LOOSE ITEMS INSPECTED
ALL INSPECTION FORMS COMPLETED
FINAL VISUAL INSPECTION OF ALL EQUIPMENT
COMPLETED
EQUIPMENT APPROPRIATELY PACKAGED
FOR SHIPMENT
DIAGRAM OF LOAD LOCATIONS ON TRUCK
COMPLETED
PICTURES OF LOADED TRUCK TAKEN
SHIPPING LIST RECORD COMPLETED

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VSB VALLOUREC & SUMITOMO TUBOS DO BRASIL LTDA

BLAST FURNACES 1 & 2

TYPICAL INSTALLATION DETAILS

has set the standard for

Camfil Farr - clean air solutions

A Crane Co. Company

Electric multi-turn actuators

625 ASTM A494, Gr. CW-6MC

-18 to 204 0 to 400

Viton is a registered name of DuPont.

316 S.S. Inconel 600 316 S.S. 316 S.S.

316 S.S. Inconel 600 316 S.S. Steel

TYPE 91 SERIES ADAPTER KIT

BIMETAL DIAL THERMOMETERS

industrial bimetal ther-

The hermetic seal prevents entry

industrial bimetal ther-

The hermetic seal prevents entry

Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Pressure Limiting Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

is a registered trademark of J.A. Campbell Co.

is a registered trademark of Chemiquip Products Co. Inc.

gauges or Halocarbon filled

gauges will tend to yellow. Silicone fill will

instrument for every ten (or fraction thereof)

instrument for every ten

) require that the

PRESSURE GAUGE CALIBRATION

Pressure Limiting Valves

9.3.13 Type 1230 throttle plug insertion (

9.3.14 Type 1231 throttle plug insertion (

XT, basic unit BXT BAS

XT, Module BXT ML2 B 180

XT, basic unit BXT BAS

XT, Module BXT ML2 B 180

XT, basic unit BXT BAS

XT, Module BXT ML4 B 180

XT, basic unit BXT BAS

XT, Module BXT ML4 B 180

XT can be remotely monitored with the appropriate accessories. For further

VT, BVT AD 24 918 402

XT, basic unit BXT BAS

XT, Module BXT ML2 BD HFS 5

XT, basic unit BXT BAS

XT, Module BXT ML2 BE S 12

XT can be remotely monitored with the appropriate accessories. For further

VT, BVT AD 24 918 402

XT, basic unit BXT BAS

XT, Module BXT ML2 BD HFS 5

XT, basic unit BXT BAS

XT, Module BXT ML2 BE S 12

XT can be remotely monitored with the appropriate accessories. For further

VT, BVT AD 24 918 402

XT, basic unit BXT BAS

XT, Module BXT ML2 BD HFS 5

XT, basic unit BXT BAS

XT, Module BXT ML2 BE S 12

XT can be remotely monitored with the appropriate accessories. For further

VT, BVT AD 24, 24 VDC

XT Basic unit BXT BAS,

XT Module BXT ML2 BD HFS 5,

XT Basic unit BXT BAS,

XT, Module BXT ML2 B 180,

XT can be remotely monitored with the appropriate accessories. For further